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E-tron
18 April 2012, 1052
Hello to all!My Zero Emissions Motorcycle conversion is about to start.I have been watching this forum for about 4 years, and i must admit that i have learned a lot of things from you guys...

Of course i will need your guidance at every step i make.I don't want to spare my time and money.It's a hard time here at Greece:confused:

My Honda Hornet 250cc is about to change!The materials i own till now except the motorcycle, is just the motor(Mars ME0810).I am also waiting for a KD72401 controller to arrive, 4 AGM 12V/55Ah and one 48v battery charger(this will be onboard).

The system will be 48V, plus a small 12v battery for the lights,instruments....Targeting for a top speed of 50mph (i assume a gearing about 4,5:1) and about 12miles range at 50% DOD.

I am also thinking of the possibility to integrate some solar cells onto the motorcycle’s body, to keep charged the small 12v battery.

At the next days i will start stripping the bike.I will share photos with you as the project will go on and on…

Forgive me if my english are not so good, or if my questions are fool!

Here comes the first one…
The ME 0810 runs CCW without problem?I haven’t found much infos about this motor, apart the thing that it was used at Zero motorcycles.

E-tron
21 May 2012, 0753
Here some pics from the bike...naked at the end :o

3203320432053206

thesprocket26
21 May 2012, 0822
Ooooo I like that frame. Looks like you are off to a good start!

E-tron
21 May 2012, 0931
Yes, the frame is just right to fit all the equipment.Anyone knows if the following sprocket is the proper for my ME0810 ?

https://www.surpluscenter.com/item.asp?item=1-2124-13-D&catname=powerTrans

What pitch should the sprocket be?This one is 50.Any suggestions?

podolefsky
21 May 2012, 1308
Hey E-tron. Interesting frame. Lots of room in there. You'll probably need to reinforce it somehow, since it looks like the engine was a stressed member before (meaning the engine was also part of the frame, so without it the frame is significantly weakened).

That sprocket will fit the 0810. Any 7/8" bore sprocket will fit (as long as it has a standard keyway). 13t is probably a good place to start. I suspect with that motor you'll want a fairly low gear ratio, like 4:1 to a top speed of 50mph.

#50 sprockets will fit 530 chain, which is the easiest way to go. Some people have gone with 420 chain since it's plenty strong (for what you're doing) and lighter. You can get 420 front sprockets that will fit from Zero motorcycles. None of the standard size sprockets (#40 or #41) fit exactly right without machining.

Just curious, why the 0810 and not the 0708? With the longer shaft on the 0708 it will be easier to get the chain line right. If you can move the sprocket on the shaft, then you have more flexibility in how you mount the motor (otherwise, you have to design the motor mount to get the chain line right, which might not be ideal).

Keep us up to date!

E-tron
22 May 2012, 0657
Dear podolefsky,

i end up with the 0810, since i found it for just 230Euros.It's a '' not QC passed'' from Zero motorcycle, due to overheating issues.This is what i was told.Anyway it has a temp sensor inside, so i will watch out the temp.I am targeting to a commuter, not to a dragster beast :) Besides it's not easy and cheap to find or get brand new items for such a conversion here at Greece.So i choose this particular motor.With some help from friends, i think that i will mount the motor at the right place, even with this small shaft:)

For the reinforcing issue of the frame that you mentioned, i intend to do this, since i must construct a metal structure for my batteries.So this structure will fiil up and connect the ''gap'' that the engine left behind.

I will order the above sprocket, hoping to fit properly.

Soon i will upload some pictures from the parts...

E-tron
30 June 2012, 0810
Almost one month from my last post.At last i manage to collect most of the items.Here are some pics.....

33113312331333143315

E-tron
30 June 2012, 0811
...and the rest....3316331733183319

E-tron
30 June 2012, 0813
I still miss the rear sprocket and the chain.How to find out if the front sprocket needs 420,500 or 520 chain???Can somebody help me on this?Then i can order the rear sprocket:rolleyes:

Hugues
30 June 2012, 0925
I still miss the rear sprocket and the chain.How to find out if the front sprocket needs 420,500 or 520 chain???Can somebody help me on this?Then i can order the rear sprocket:rolleyes:

i was given this link by Noha, you should be able to measure the distance between 2 teeth on your sprocket and tickness and match it using their table. I think:
http://gizmology.net/sprockets.htm

podolefsky
30 June 2012, 1039
It's either #40, 41, or 50. The link that Hugues posted will help you figure it out.

Just looking at it, assuming it's a 7/8" bore, I'm 90% sure it's a #50 sprocket, which fits a 530 chain. There's no such thing as 500. #50 sprockets can be machined to fit 520.

If it's #40 or 41, it won't exactly fit a 420 chain. #40 can be machined to fit 420. #41 is the right width, but not quite the right roller size, so it might bind or wear quickly.

E-tron
01 July 2012, 0228
Here is the sprocket details https://www.surpluscenter.com/Item.asp?item=1-2124-13-D .If i understand well, i need a 530 chain:)

podolefsky
01 July 2012, 0906
Yup, 530.

E-tron
21 July 2012, 0230
Where can i buy a 60tooth rear sprocket for Honda hornet, for such a 530 chain?Can you suggest me anyone who can manufacture such a thing???:confused:

podolefsky
21 July 2012, 0733
http://www.sprocketspecialists.com/

E-tron
17 October 2012, 0756
Hello to all, after a long time.My project is not finished yet but there is some progress and i ‘d like to share it with you.

I am waiting for the chain to run at last the rear wheel!!!Then i am going to weld and reinforce the batery frame and put all the components on the bike.

If everything works fine, i am thinking of constructing a polyester ‘tank’ and 2 side pieces to ‘hide’ all the components.Maybe i’ ll integrate some solar cells for charging the small 12Ah batery.

37083709371037113712

And some questions now....

1)What gauge wire should i use since the motor can drain up to 300Amps for 1 minute?

2)My motor is a Mars ME-0810.It has a temp sensor on it.Where should i connect this, in order to watch the inside temperature?Can you suggest me a compatible thermometer?:rolleyes:

yankee1919
17 October 2012, 0819
Yahsu!:)

E-Tron,
Your project is on its way, times are tough all around I feel your pain. I am still working on my Vespa!

Tony
Los Angeles.

E-tron
17 October 2012, 0843
Dear Tony,

indeed...times are really tough here at Greece.But the creativity must never be stopped:o

E-tron
21 October 2012, 0053
So, can anybody help me with the following questions?

1)What gauge wire should i use since the motor can drain up to 300Amps for 1 minute?

2)My motor is a Mars ME-0810.It has a temp sensor on it.Where should i connect this, in order to watch the inside temperature?Can you suggest me a compatible thermometer?

Thank you...

podolefsky
21 October 2012, 1050
Alltrax recommends 4 AWG, but I'd go with 2 AWG. It'll be slightly more efficient, not much more expensive. Anything larger would be overkill.

On the temp sensor, you might email motenergy (http://www.motenergy.com/) and ask what they would recommend. John is really good about responding to tech questions.

It's probably just a standard thermistor, but you'd need to know how to calibrate it to get an accurate reading. Most temperature gauges are meant to go with a specific sensor.

E-tron
29 October 2012, 0435
Thanks for the infos!John advised me to get a K thermocouple temperature meter and i already order one.

Searching at ebay i found also this.....

http://www.ebay.com/itm/DC-120V-500A-Volt-Amp-Combo-Meter-Battery-Charge-Discharge-Indicator-With-Shunt-/170901504188?pt=LH_DefaultDomain_0&hash=item27ca8600bc

Is anybody familiar with this?Could this be a cheap alternative to the Cycle analyst?:rolleyes:

E-tron
12 November 2012, 0809
3778Time to upload some photos...A lot of things more to do, but at last the bike is moving:D3774377537763777

E-tron
12 November 2012, 0811
37793780

Allen_okc
12 November 2012, 0926
:cool: lookin awesome E-tron, looks like your about ready to ride...