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Functional Artist replied to the thread 1980 Kawasaki 440 LTD 8kW conversion.
"
Quote Originally Posted by Electro Flyers View Post
It seems to me you're going to a lot of work,expense, and an extra 5# of weight, when there is an easier, cheaper, and lighter solution. An idler on the slack side of a chain or belt drive is typically lightly loaded when compared to the other bearings and sprockets in the system. Regenerative braking would put an intermittent somewhat heavier load on the idler- but probably well within its load capacity.

The location for the idler sprocket I'm referring to is far away from the motor location, close to the rear sprocket, on top of the swing arm.
I'm not following you.

On top of the swing arm, between the motor (drive sprocket) & wheel (driven sprocket) is the "heavy load" drive side & not where an idler is needed

I needed an "idler" sprocket down below the motor, on the "slack" side, to help route the chain around the swing arm


The motor rotating clockwise pulls on the sprocket of the rear wheel, via the chain, making it turn clockwise too

...on the "slack" side, the chain comes down off of the motor sprocket to the jack shaft sprocket "idler"

...then, wraps around the "idler" sprocket, clearing the swing arm & goes back to the sprocket on the rear wheel completing "the circuit" "

30 Minutes Ago

Stevo replied to the thread Looks promising....
" I guess I'm a glass half full kinda guy "

44 Minutes Ago

Electro Flyers replied to the thread 1980 Kawasaki 440 LTD 8kW conversion.
"
Quote Originally Posted by Functional Artist View Post
Ya, I know. I've done a lot of work on go karts & jack shafts are used a lot.
I just working with technology & terms that I was used to & also parts that I already had, to work with.

I was thinkin' strength. Most idlers, that I knew of were for light duty situations like routing belts on car engines.
I figured this big motor, motivating a full size motorcycle, would apply much more pressure/force.
I guess you could call it a DIY super HD idler/(1) sprocket jackshaft.

I can't put anything above the swing arm, that where the motor is going to be mounted (it fills the whole space)
It looks like this set up will but, I appreciate the input, stay tuned

Here is a video with more info

https://www.youtube.com/watch?v=P0ReyyFYkKk&t=190s
It seems to me you're going to a lot of work,expense, and an extra 5# of weight, when there is an easier, cheaper, and lighter solution. An idler on the slack side of a chain or belt drive is typically lightly loaded when compared to the other bearings and sprockets in the system. Regenerative braking would put an intermittent somewhat heavier load on the idler- but probably well within its load capacity.

The location for the idler sprocket I'm referring to is far away from the motor location, close to the rear sprocket, on top of the swing arm. "

2 Hours Ago

Functional Artist replied to the thread 1980 Kawasaki 440 LTD 8kW conversion.
" Ya, I know. I've done a lot of work on go karts & jack shafts are used a lot.
I just working with technology & terms that I was used to & also parts that I already had, to work with.

I was thinkin' strength. Most idlers, that I knew of were for light duty situations like routing belts on car engines.
I figured this big motor, motivating a full size motorcycle, would apply much more pressure/force.
I guess you could call it a DIY super HD idler/(1) sprocket jackshaft.

I can't put anything above the swing arm, that where the motor is going to be mounted (it fills the whole space)
It looks like this set up will but, I appreciate the input, stay tuned

Here is a video with more info

https://www.youtube.com/watch?v=P0ReyyFYkKk&t=190s "

4 Hours Ago

Atrastin replied to the thread Parting out old Project - Motors-Charger-Motor Controller-Batteries : Make Offer!!.
" Hi!

I'm also interested in the motor, if it is still available. I'm planing to convert my Suzuki GSF 600 Bandit to electric
I sent you an email with few questions. "

10 Hours Ago

Electro Flyers replied to the thread 1980 Kawasaki 440 LTD 8kW conversion.
" Technically speaking, what you call a jack shaft is actually an idler shaft or just an idler. A better placement for the idler would be above the swing arm to get the maximum chain wrap on the sprockets. This decreasing wear, chain noise, and reduces the possibility of the chain slipping.

Chain idler sprockets are available. They are compact, easy to mount, and cheap: https://www.amazon.com/Idler-Sprocke.../dp/B00O57YAL4 They can be mounted with a single shear bolt on a heavy bracket or with a double shear bolt between 2 lighter brackets for more strength. The idler sprocket would have to be mounted well back on the swing arm to allow the chain to clear the inside of the swing arm. Some bikes may not have enough clearance in this area. The front and rear sprockets may have to be moved in to create more clearance. Or, the swing arm flattened slightly on the inside near the rear sprocket teeth. "

16 Hours Ago

Richard230 clicked Likes for this post: Chang Jiang 750 Sidecar Conversion by bob_piper

20 Hours Ago

Richard230 replied to the thread Looks promising....
"
Quote Originally Posted by Stevo View Post
I'm shocked I beat Richard to this one...
https://news.umich.edu/battery-break...nt-catch-fire/
That is because I get my news from my local newspaper in California and not from the MU. Sounds promising, but we all know that there have been a lot of great sounding battery ideas that are developed in University labs which never seem to see the light of day in the consumer market. Let me know when and where I can buy one and then I will believe it. "

20 Hours Ago

Functional Artist replied to the thread 1980 Kawasaki 440 LTD 8kW conversion.
" We kinda have a plan
...now, let's see if we can make it work

Going to have to
...build a motor mount extension shelf
...then, get the motor aligned & mounted
…& add a couple of bearings & an "idler pulley/gear" to help route the chain

https://www.youtube.com/watch?v=QvE4Ir8pxPk&t=5s "

21 Hours Ago

flo replied to the thread Sachs xtc 125 conversion.
" hi
fabricated those centering devices - necessary? well not really but it will impress the MOT engineer when making the bike road legal weights next to nothing and will transform a little of that load from the cantilevered motor-mount. Of course it needs counter/lock-nuts with it.
Attachment 7856Attachment 7857

Also played a little with future power cables. some cut offs from an unused garden house serving well for this purpose.
The shown layout will only the most foreward line to be longer than the others by about 1 cm
Attachment 7858

and will just fit into the frame and fairing by the amount of "just"
Attachment 7859

fairing will need some notching to make the sides meet without bulging... but only a tiny bit it already closes with some slight pressure...
Attachment 7860


greets

flo "

1 Day Ago

bob_piper created the thread Ural 650 custom EV.
" This project is only in the dream phase right now. I'm new to EV conversions and while enthusiastic, quite down in the pocket. I ride a 1995 Ural 650 tourist (one-wheel drive) and I'm waiting for the ICE or transmission to crap out which could happen soon or never with these bikes. For my ideal project I'd create a new sidecar frame out of aluminum with a more streamlined, fiberglass body. The aluminum frame would act as a battery tray so that the weight is evenly distributed and provides a low center of gravity. The 12V acc. battery could stay under the seat where it is and the tank could be cut open to serve as a home for the controller and/or charger. (Would this cause over-heating problems? Is it better to have the controller out in the airflow?) One of the issues with older Urals is that it has mechanical drum brakes which don't work well to begin with. I'd want to convert the front brake to disc at the very least, but if I have an AC motor and regeneration, are the brakes a problem?

As I said, I'm new to this, so I need to figure out what size motor and battery pack I need for decent performance and work from there. "

1 Day Ago

bob_piper replied to the thread Chang Jiang 750 Sidecar Conversion.
" I'm new to EV conversion, but I've always wanted to do one. I ride a Ural 650 tourist (one wheel drive.) I was thinking of making a battery box under the sidecar frame that would distribute the weight more evenly and provide a good center of balance for the bike. This would leave more room for the motor and the controller/charging unit could be incorporated into the tank. The nice thing about the older Urals is that they are relatively cheap, shaft driven, and the sidecar frames are fairly beefy. "

1 Day Ago

Stevo created the thread Looks promising....
" I'm shocked I beat Richard to this one...
https://news.umich.edu/battery-break...nt-catch-fire/ "

1 Day Ago

EVcycle replied to the thread The Juiced Drag bike progress post.
" Muther Nature got us again!

We loaded the "new" van with the bike, and all the race gear, drove two hours to the "good" track,
unloaded, setup the generator and chargers, took the bike to the inspector, (all he wanted to do was
ask questions about the electric bike) returned to top off the charge and got out the rest of the racing gear.

We sat around in the heat for another 1 1/2 hours.
5 minutes before the track opened the staging lanes a rumble in the background paused the track prep.

One of the officials stopped by to let us know it was going to rain within the next 20 min. We scrambled
and got everything back just in time to beat the storm.

A hour later they shut down for the evening. It was a 20% chance of rain today....

We will try again on Sunday and the "OK" track. "

1 Day Ago

Functional Artist replied to the thread 1980 Kawasaki 440 LTD 8kW conversion.
" Decision time

The motorcycle (Kawasaki) uses "big 'ol" #50 chain (5/8" pin to pin) & sprockets

My 8kW motor has a 10 tooth sprocket for #40 chain (1/2" pin to pin)
...I have a 54 tooth driven sprocket (that I can use on the rear wheel)
...& I have ~10' of #40 chain too

#40 chain is also a bit lighter

So, we'll go with that, #40 is the winner

Then, I removed the rear wheel assembly, to switch the sprocket from a 45 tooth for a #50 chain to a 54 tooth for a #40 chain

Before instillation, I had to do some DIY machine work, on the driven sprocket to make it "fit" onto the Kawasaki rear wheel

Here is a video with more info

https://www.youtube.com/watch?v=boTUgLzOe00 "

1 Day Ago

flo replied to the thread Sachs xtc 125 conversion.
" Hi
working 18 days in a row somehow dampens sparetime or social life somewhat.
at least i managed to fabricate 4 small holders for the controller.
Small steps... well i guess its important to carry on.
Took the craddle out of the bike again , like this its easy to work on it..
Pics show how these holders keep controller in place...
last pic is taken from top down, it shows how the controller plate extends fore and aft of the cutout so basically the controller now can go nowhere.
greets

Flo
Attachment 7853Attachment 7854Attachment 7855 "

1 Day Ago

Stevo replied to the thread 1980 Kawasaki 440 LTD 8kW conversion.
" Hmmm... Are you using "the Gallery" to upload your pics into? From there, you can copy the link to your pics and they will show up large on your thread. The Gallery is cool too because you can copy a link and post pics on other forums without having to upload the pic again on that forum. "

2 Days Ago

Spoonman clicked Likes for this post: Is Enertrac Corp. legit? by markcycle

3 Days Ago

Spoonman clicked Likes for this post: 1980 Kawasaki 440 LTD 8kW conversion by Functional Artist

3 Days Ago

Functional Artist replied to the thread 1980 Kawasaki 440 LTD 8kW conversion.
" I think, I can stuff the motor "up in the pocket"
...mounted right onto the trailing arm

This way the motor & the rear wheel will move as one
& there will be a heck of a lot more room, inside of the frame, for batteries & electrical components

So, now the motor will go where the battery used to be
& the batteries will go where the engine used to be

https://www.youtube.com/watch?v=zUfhil1jfqE "

3 Days Ago