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Thread: Nic's Kawasaki Ninja 250 EV conversion

              
   
   
  1. #1
    Junior Member Nicman's Avatar
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    Nic's Kawasaki Ninja 250 EV conversion

    Here goes.

    I've never been one to post/write on forums, this will be my first newbie experience. Every thread I have read so far has been filled with great information, people helping people and thoughts and concerns that are well thought out and written. I hope to continue that trend without making a complete @$$ of myself in the process. Thank you for your patience with my lack of know-how, both electric and forum related.

    On to the meat.

    I bought a 2009 Kawasaki Ninja 250 as the title of this thread hints at
    I have completely disassembled the bike of the IC parts and have purchased the below from EVdrives .com

    Motenergy ME1003 Motor, 11.5KW continuous, 23KW Peak for 1 minute @ 72Volts
    AXE7245 at 450amps - with fuse
    SW200 solenoid
    3 amp Diode & 470 ohm Pre-charge Resistor
    Throttle - Magura Twist Grip

    I have yet to purchase batteries, or a charger as I am currently working on a custom motor mount. I have seen many people use 1/4" and 1/2" 6061 aluminum and I plan on doing the same. I am looking for ME1003 blueprints I can print to scale and follow others lead by printing and then milling out the aluminum at a fabrication shop.

    I know have a long way to go and I hope to have a complete bike within the year.
    Any suggestions or advice on resources to help me decide based on my needs ( 75MPH highway, 50 mile range daily) would be appreciated.

    Thanks for reading!IMG_1145.jpgIMG_1146.jpgIMG_1148.jpg

  2. #2
    Member Lunchbag's Avatar
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    The drawing of the motor can be downloaded from this page.

    It says "do not scale drawing" but it does provide exact dimensions for the mounting holes and a few other dimensions. Welcome, you'll find a lot of Ninja 250 ideas on this site.

  3. #3
    Senior Member DRZ400's Avatar
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    Nice....I love the look of the 2nd gen 250's!
    2003 Ninja 250EX, Agni #95R, 6:1 Gearing, 11 Leaf Modules.
    Alltrax SPM72400, 400 amp Controller, all LED lighting
    2014 CRF450X Supermoto
    http://www.evalbum.com/1955
    http://www.evalbum.com/3337

  4. #4
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    Welcome. Great project you have going. I'm planning to use the exact same motor/controller kit for my bike from evdrives.

    What batteries & bms do you plan to use?

    That range & speed sounds doable. Probably going to need a 6kwhr pack to achieve it.

  5. #5
    Junior Member Nicman's Avatar
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    That is exactly what I am researching now. I started a new job last month and have been playing catch-up ever since. I did manage to cut out my motor bracket and get it attached to the frame.
    I really want to try out CALB 100AH's and I am trying to find out how many I'll need. At 3.2V each I would need 23 to get to 73.6V (to make sure I am getting 72V to the controller and subsequently the motor).

    I thought I read about people getting close to 90V to the controller which I think it can handle, but I'm not sure why they would since the controller should only allow 72 to the motor.
    Also, BMS is really challenging me. I see people just add in their circuit board and BAM! problem solved. But I'm the type of person who needs to understand it before I buy and attempt it.

    Anyone out there have experience with CALB's/BMS or any of these expensive goodies? I want to stay away from AGM's.

  6. #6
    Senior Member DRZ400's Avatar
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    I had 25 CALBs with Mini BMS before switching to the LEAF cells. The Mini BMS works great. I did mine in 2008, First was 6 35ah AGMS, then 25 40ah CALBS and now 11 Leaf Modules. Fitting 24 100 AH into a Ninja will be tight but it has been done.
    2003 Ninja 250EX, Agni #95R, 6:1 Gearing, 11 Leaf Modules.
    Alltrax SPM72400, 400 amp Controller, all LED lighting
    2014 CRF450X Supermoto
    http://www.evalbum.com/1955
    http://www.evalbum.com/3337

  7. #7
    Junior Member Nicman's Avatar
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    I think I might just go Leaf Modules right away. I found 8 modules on hybrid auto center . com and I'm trying to find out if I can get 3 more modules individually to make my 11 modules and obtain over 72V. Awaiting a response.

    Lets talk chargers! DRZ GO!

  8. #8
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    You have 2 options for chargers:

    Meanwell HLG LED Poweder Supplies - make sure you get the model with the adjustable voltage and current output (has 2 rubber caps to cover trim pots, the model number will end with an A). You can get 2 of these in 320W or 600W at 48V and wire them in series to get your final pack voltage. Easy to work with and adjustable.

    The other option would be a Delta-Q Quiq charger, but you'll have to get somebody to program it for you. I think Travis (frodus) sells them and programs them. They also have a built in DC/DC converter and have a switched and unswitched output (meaning you can have certain things always powered and certain things powered only when a switch is used)

  9. #9
    Senior Member DRZ400's Avatar
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    I'm using the BMSBattery 600 watt alloy charger. Cost about $75.00 Very easy to adjust output V or I with internal pots. Since I don't use a BMS I slightly undercharge to 90 volts (11 modules) @6 amps. The charger has worked flawlessly for 5 years. I think they have a 900 watt version now as well. The Guys over at endlessphere have fully documented these chargers to component level.
    2003 Ninja 250EX, Agni #95R, 6:1 Gearing, 11 Leaf Modules.
    Alltrax SPM72400, 400 amp Controller, all LED lighting
    2014 CRF450X Supermoto
    http://www.evalbum.com/1955
    http://www.evalbum.com/3337

  10. #10
    Junior Member Nicman's Avatar
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    No BMS? This is the first I've read about being okay without them. Meanwell has an awesome reputation and that was my first thought. Jonny Panic, I'll look at the Delta-Q Quiq charger, if it's the yellow one I'm thinking of, it was crazy expensive, like $500. A little out of budget for something that still requires overnight to fully charge.
    Thanks for all the help everyone. I think will be buying my Leaf Modules from Hybrid Auto Center. 1,419 including rods and end brackets. Before I pull the trigger, is that an okay price? (Best I've found so far)

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