It's been discussed a lot about the avinox motor rattle, there have been numerous review videos and users reports that the rattle is real, even Rob chimed in to offer his view when he had a preproduction unit. The conclusions are that some rattle, some don't, but will probably develop rattle down the road as it's inevitable due to the internal gearing structure(gear backlash of metal to metal).
Why some don't rattle at the start? Gear tolerances, thicker grease and tighter seals(a revised motor version by dji supposedly). If you have ever seen an open motor after a few thousand km you know that the grease is everywhere except on the gears. A colder environment where the grease doesn’t break down from heat or spread away from the gears is obviously beneficial, but only delays the inevitable. My opinion was/is that the two main big gears also rattle(probably the motors that have a louder rattle)as the tolerances on straight cut gears tend to be less tight and there is no lateral force to push the gears together. While helical gears due to the shape of teeth inherently push them self's into each other and so create a tighter connection.
Rob mentioned that on his test motor the gears in blue(are slightly helical I think-would need to see it irl) rattled when tested, which is quite understandable as it's really hard to achieve a tight tolerance in a multiple(ring and three planets) gear system. As a matter of fact there actually needs to be some extra space between the gears for material heat expansion and space for grease to stick to the gears surface otherwise the gears would self destroy due to excessive grinding. All this precision is really hard to achieve, and slight errors in material, bearings not pressed in straight, assembly mistakes, grease amount, seal type, etc... create motors that rattle from start and others that probably will develop it later on or if driven lightly in a colder environment maybe never. There maybe be exceptions(unicorns) that were assembled perfectly and the tolerances are to point and so are dead silent.
Those riding them Unicorns consider yourselves lucky bastards as you have been chosen by the emtb universe for it's children and try not to convince others that weren't that the Rattle isn't real.

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