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Thread: First E-Moto project underway '10 Zero S rebuild

              
   
   
  1. #1
    Member Duck-Stew's Avatar
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    First E-Moto project underway '10 Zero S rebuild

    Although not as amazing a re-working an ICE motorcycle as so many of you have done (and I've just watched), this is my first attempt so I thought I'd start off small (and cheap).

    Rewind a bit here: Back in August an ad appeared on the local Craigslist for a '10 Zero S for $300. Yes. Three Benjamin's got a very neglected, clean titled, 10 Zero S. Couldn't believe my luck really. I know it's not a 2012 or anything, but it IS a start and I'm not financially 'hit' on it.

    Current condition: Battery pack is toast. Some wiring has been cut (for whatever reason, god only knows...). Back tire's flat. Front brakes do nothing. Both fork seals are shot (fork oil EVERYWHERE). Plastics are...well...they weren't great when new so add six years of neglect to that. I'm really considering running it without any plastics.

    Plus side: Bike does have the Corbin seat. Gauges appear in-tact. I doubt this bike has even 1000 miles on it.

    Plan of action: Remove the chain and put 12VDC onto the motor (with the original leads off of it) to verify that the brush holder and brushes haven't gone south. Remove the front end and remove the OE battery pack. Purchase 7 Leaf cells and re-wire into OE battery box. Fix brakes, tires and forks. Test ride!!!

    Couple of questions: First: Are the OE cells recyclable? Second: Am I missing something here in my assessment? More to look into or look at as this goes forward?

    I'll try to get some pics up.

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    '10 Zero S project

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    Last edited by Duck-Stew; 13 November 2016 at 2024.
    '10 Zero S project

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    Attachment 7197

    No fear of harming anything... My 58VDC battery pack registers 4.28VDC.
    '10 Zero S project

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    Ok, so things are evolving... I now have an electrical engineer on board and we're thinking of upping the ante a bit:

    So, here's the list:
    Higher battery voltage
    New bms
    New charger
    New controller
    And most importantly: BLDC motor swap. So, what BLDC would you all recommend in place of the Agni 95R?
    '10 Zero S project

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    Member Duck-Stew's Avatar
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    http://www.thunderstruck-ev.com/96v-brushless-kit.html

    This may just be the ticket! Thoughts?
    '10 Zero S project

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    Quote Originally Posted by Duck-Stew View Post
    http://www.thunderstruck-ev.com/96v-brushless-kit.html

    This may just be the ticket! Thoughts?
    Looking at the specs for the Agni it doesn't seem like you would be getting a whole lot more. You may have more fun getting a higher current DC controller and just working the motor harder. I Personally haven't ridden on that bike though so maybe someone else can weigh in on it. I do think getting the most current out of your controller is the most important factor. I have been underwhelmed with my 600A kelly controller. Find a good controller that allows full torque at startup.

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    Member Duck-Stew's Avatar
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    That could work. Presently the Agni isn't responding to a 12vdc input so I was fearing the worst...

    How would I best determine if the Agni has bit the dust?
    '10 Zero S project

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    Hey cmcnall,

    Any thoughts on a controller and what voltage/amperage that an Agni 95R can take?
    '10 Zero S project

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    To put things in perspective, the ME1003 motor is VERY similar in specs. Here's the most powerful Alltrax controller powering a ~1200 lb car with passenger:
    https://www.youtube.com/watch?v=Gr9pnSeadSY

    First pass is 1st gear, 2nd pass is 2nd gear.

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