Factory Tour: Askoll Ultra – Alex builds a 1200w motor by himself
Ascoli, Northern Italy—In a blend of precision engineering and Italian craftsmanship, Askoll Ultra reveals how they interpret a cutting-edge e-bike motor. From raw components, it will overall take only 10 minutes to build.
Join Alex Boyce on his behind-the-scenes factory tour, where torque, tech, and tradition converge … Head with him on the trails to find out what this motor is able to do in an e-bike and how software affects your riding experience.
Video: Watch the full factory tour
The Heart of the Machine: Motor Specs
Askoll Ultra invited us to their factory to build an ultra-powerful eMTB motor, the ASKOLL ULTRA C90A, with 1200W of peak power from the battery with a nominal 250W according to the EPAC standards. It has 110 Nm of torque in boost mode and 90 Nm in standard mode. The Ultra C90A system gives different types of torque control and motor power at the wheel with different motor firmware versions.
We try a few and describe how they feel. We get to see inside the motor and learn about its features and design, plus the fact it can be repaired makes it real competition for the market.
Askolls flagship 250W motor packs a punch:
110 Nm torque in boost mode (90 Nm standard)
Ultra-lightweight at 2.9 kg
Shimano frame-compatible design for universal integration. Fits most e-bike frames—no custom parts needed.
Heat Management: Larger housing dissipates heat better than compact rivals.
Repairability: Modular design simplifies maintenance
Step-by-Step Assembly: Where Human Hands Meet Robotic Precision
Stator Prep: Insulation wraps the stator – the motor’s stationary core. Alignment is critical.
Coil Winding: Copper wire spins into force-generating coils (20-minute process). Workers add contacts during downtime.
Quality Control: Resistance tests (Ohms) ensure electrical integrity. Green light = go.
Rotor & Magnets: In-house designed rotor slots into coils. Powerful magnets drive efficiency – precision avoids magnetic interference.
Diamond-Coated Axle & Gears: Transfer pedal power seamlessly. "Everything must align perfectly," notes Emio Figatti, Askoll’s guide.
Brains of the Operation: The inverter board – loaded with MOSFETs, capacitors, and proprietary software – is secured with torque-calibrated screws.
Sealing & Firmware: The motor is sealed, firmware uploaded, and a final green light signals readiness.
Key Insight: Parallel production allows multiple motors on the line simultaneously – each taking just 10 minutes from start to finish.
Rigorous Testing: Compliance Meets Real-World Simulation
In Askoll’s test lab, motors face EU-mandated trials:
250W Continuous Power: Validated via simulated hill climbs (5%-15% gradients).
Peak Power Management: Motors draw up to 1,200W temporarily but revert to 250W to comply with regulations.
Speed Cut-Offs: Software enforces regional speed limits (e.g., 25 km/h in Europe).
Marcus Sa, Testing Lead, demonstrates: "On a 15% incline, power surges to 600W–700W – then drops to legal limits post-climb."
Field Test: Firmware Makes the Difference
On rocky Italian trails, four firmware versions reveal stark contrasts:
V1 (Original): Erratic power delivery, "dead spots," and wheel slip.
V2 (Production): Smooth, responsive assist. "I felt connected to the bike," Alex.
V3/V4: Balanced power-to-pedal input; excels on 30% slopes in boost mode.
Efficiency Reality Check: Despite peak battery draws of 1,300W, drivetrain losses mean just 750–800W reaches the wheel.
Final Ride: Beyond Spec Sheets
Askoll’s Ultra C90 motor conquers loose rock and 30% grades with ease. As the host summits a technical climb, the verdict is clear: "It’s got a lot of power, a lot of torque... very dependable."
Conclusion: The market will become more diverse
The offerings for e-bike motors are constantly growing. As customers, we can absolutely benefit from this movement. Technology will evolve, and (maybe) prices will come down through the competition between these companies. The question is how the race of power will continue and if this will affect the riding style and trail access. You may want to dive deeper into this topic by listening to this podcast.
Credits & Supporters
Presenter: Alex Boyce
Video Maker: Pier Francesco Macchi
Video Tape Editor: Alex Boyce
Askoll Motor Builder: Imerio Figatti
Chief Askoll Engineer: Ilario Angonese
Test bench tech: Marco Xotta
