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

              
   
   
  1. #31
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    Huh?
    Richard - Current bikes: 2018 16.6 kWh Zero S, 2016 BMW R1200RS, 2011 Royal Enfield 500, 2009 BMW F650GS, 2005 Triumph T-100 Bonneville, 2002 Yamaha FZ1 (FZS1000N) and a 1978 Honda Kick 'N Go Senior.

  2. #32
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    Quote Originally Posted by lanhoang134902 View Post
    B*i viết của bạn rất hay , chia sẽ thêm nữa nhé , những thông tin thế n*y rất hữu *ch
    Time for you to move on to another forum.
    Richard - Current bikes: 2018 16.6 kWh Zero S, 2016 BMW R1200RS, 2011 Royal Enfield 500, 2009 BMW F650GS, 2005 Triumph T-100 Bonneville, 2002 Yamaha FZ1 (FZS1000N) and a 1978 Honda Kick 'N Go Senior.

  3. #33
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    https://m.youtube.com/watch?v=WB_H6Z4cXJY

    Decided on a 96vdc system (12x Nissan leaf cells) with a Re-Volt RV160-Pro (same as project Blue-Smoke) wound to 56KV. Kelly has a 500A sine-wave controller (KLS96501-8080I) to slightly over compensate for the overrated Kelly specs.

    That yeilds a 6.1kwh battery pack, about 28hp and from what I'm understanding about 56#/ft of torque. ReVolt now offers the motor with a liquid cooling option so I'll be getting that for sure.

    Now to find a charger (set up for 240 & 120 vac input to take advantage of my J1772 Juice-Box charger), a BMS system and a 96-12v DC to DC... Suggestions?
    '10 Zero S project

  4. #34
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    It's been an interesting couple weeks...

    The Motenergy ME1507 motor, although designed for the Sevcon Gen 4 controller, doesn't have to be used with it specifically. I found a reverse trike build using a Kelly KLS96501-8080IPS to run his ME1507. So, clearly more research was in order. With that, more questions arose:

    Anyone ever use or hear of someone using a Roboteq RGDC1896 controller? http://www.roboteq.com/index.php/com...ail?Itemid=970

    Seems like a good fit for my project as the programming of the sin/cos encoders is a simple procedure according to their engineer, it has field weakening capabilities and free programming software and programming help.

    Also, with regard to the Nissan Leaf batteries: I found a company who will build a custom pack of lightly used Tesla cells to your spec. Since I've heard they're the best energy density, I'm considering going that route. Cost will be up a bit from the Leaf modules, but still doable-ish. http://www.edisonmotors.net

    Thoughts?
    Last edited by Duck-Stew; 19 January 2017 at 0220.
    '10 Zero S project

  5. #35
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    I'm leaning towards a 96vdc system again, so I believe that would be 24s configuration. For about the same $$ as the Leaf cells mentioned above (84vdc & ~$1700), I can get 480 Tesla cells (not factoring in their build $ for the pack) and that yeilds 24s20p.

    IF my math is correct, that's: 3.2v * 3.6Ah * 480 = 5.5Kwh at nominal voltage
    Peak: 4.0v * 3.6Ah * 480 = 6.9Kwh at peak voltage

    Is that correct?
    '10 Zero S project

  6. #36
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    Well, I’m dusting off the Zero project. I was breifly seduced by ICE again. I’m a recovering petrol-head...

    More updates as they come in.
    '10 Zero S project

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  8. #37
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    Couple of questions for the more enlightened among us:
    1) If I use 13x Nissan Leaf cells, that would provide a more 80%-to-20% voltage of about 96vdc, yes? I want to make sure my thinking on this is correct.

    2) Rear wheel: I've been looking around and due to the non-adjustable rear axle on the '10 Zero S and the 12.2" length from rear axle centerline to swingarm cross-brace, I'm leaning towards 16" wheels (same size as original, just want the reduced weight of those spokes & tubes gone). 17" tires are hard to come by less than 24.4" OD. The 16" wheels don't leave much in the way of available imported motorcycle wheels to choose from (domestic motorcycles and their parts are just too heavy to consider). So, that leads me to my question: Does anyone see a problem with running a 16" FRONT wheel on the back of my Zero? I'm reasoning that if I got a front wheel where the brake rotor bolts near the axle (instead of out on the spokes), that the hub would provide enough strength to use as the flange which powers the motorcycle.

    To be clear, the FRONT wheel I'm considering for use on the REAR of my Zero is from a mid-90's Honda CBR900RR at 16"x3.5".

    Another update: ME1507 will be the motor for the bike.
    Last edited by Duck-Stew; 12 December 2017 at 0802.
    '10 Zero S project

  9. #38
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    So, if anyone else comes across an early Zero and wants to make it more usable (read as: update everything), I’m hoping this thread can be a resource. I have found (at least) suitable replacements for all the ‘cost-cutting’ bits that Zero needed to use in order to get production up and running. I’ll be detailing these in the next couple months.

    Today’s replacement part is the rear shock: Honda Grom. Only two things which prevent it from being truly a direct swap and they’re minor. Zero uses 8mm mounting bolts & Grom uses 10mm, so suitable shims will need to be sourced. Second thing is that the shock mounting is about ~1mm too wide but has enough material to grind down for fitment. The shock I bought is a used Honda to verify fitment as I intend to replace it with an hlins later on. (I love good suspension!!)

    More later & Happy Holidays one and all!
    '10 Zero S project

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  11. #39
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    6E519522-9FC3-43A4-B16F-ADDFF90B9D1D.jpg

    Confirmation photo of Honda Grom shock mounted on a ‘10 Zero S.
    '10 Zero S project

  12. #40
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    78CA2E83-7CF1-4ED8-B1CF-367217A66D9D.jpg

    ME1507 and Sevcon just showed up!!
    '10 Zero S project

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