Mac 1000W rattling noise

So after a few rides I noticed slight rattling sound coming out of somewhere. At first I thought it might be something on the outside, maybe cabling or a gearbox somehow touching the hub. The sound has become exponentially worse with each mile I rode the bike. One could probably hear me a block or even two away - something I got fed up with quickly. Read the forums - most suggested checking the spokes, but I still cannot understand how a sealed hub can get a spoke (or a piece of spoke) inside it. Anyway, today I had some time to devote to this issue, so after some serious torque, I finally got the hub open to check things out. Turns out one of the gears is violently grinding the stator when I turn the axle backwards.

In the attached two pics, the green one is attached so that you can see the white paper underneath the hub (well, maybe you can't, but trust me on this, I can). The red one you cannot see through, because its thing (I don't know what you call that part) is touching the stator and is making that noise when it does - at least it's the most plausible explanation I can come up with.

So, if anybody has a suggestion or experience with this sort of thing, I'd appreciate any advice.

Have you talked to the person/company you bought the motor from yet?
I don't see how the gear is doing that, but the outer gear ring could very well be doing it. Is there play in the assembly? i'm thinking maybe a circlip is not in the right place..

neptronix said:

Have you talked to the person/company you bought the motor from yet?
I don't see how the gear is doing that, but the outer gear ring could very well be doing it. Is there play in the assembly? i'm thinking maybe a circlip is not in the right place..

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This is from Cellman's kit, I have not contacted him yet.

Okay, maybe put it back together and see if there is play or not though.

This motor has a lot of resistance when spinning backwards. This is normal for the motor because the clutch is not engaged when spinning backwards. Now if it is clicking when you spin it backwards, then that's something else.

neptronix said:

Okay, maybe put it back together and see if there is play or not though.

This motor has a lot of resistance when spinning backwards. This is normal for the motor because the clutch is not engaged when spinning backwards. Now if it is clicking when you spin it backwards, then that's something else.

Click to expand...

Okay, I've just put that thingy back into its place with the help of light hammering, and it isn't making that noise anymore; I've put some Energy Release grease on some ridges and will take it for a spin shortly.

What's energy release grease?
Hope it's not petroleum based, as that can eat away at the plastic.

Lemme know how it goes.

neptronix said:

What's energy release grease?
Hope it's not petroleum based, as that can eat away at the plastic.

Lemme know how it goes.

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I've got a G100 grease.

Ok, worked beautifully for a few hundred meters (not even a kilometer), then back to grinding.

Yep, back out again.