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Thread: 2004 Kawasaki ex500

              
   
   
  1. #1
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    2004 Kawasaki ex500

    I recently acquired a rolling chassis ex500 and I plan on following JoeReal's build quite closely. Right now all I have is the chassis, but I will update this thread with planned components and pictures.

  2. #2
    Senior Member EV_Scoot's Avatar
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    Nice work. Good to have another Kwacka being converted.

  3. #3
    Senior Member DRZ400's Avatar
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    Great chassis, plenty of used ex500 parts available on ebay.
    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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    Ok so I have been doing quite a bit of research over the past few days and I have compiled a build list:

    EV drives conversion kit - $1275.85
    Includes ME1003, Alltrax SR72400, SW180 contactor (I will opt for 12V version), Domino throttle, Flyback diode, and pre-charge resistor
    Transmission items -$146.73
    14 tooth front sprocket from electric motorsport, 50 tooth rear sprocket from sprocket specialists and 520 chain form electric motorsport
    Delta-Q QuiQ-Icon 72v charger w/ dc-dc (used old stock from ev-drives) $275
    11 Nissan Leaf modules @ $129 each = $1419
    Bike cost $328 at auction (bid was $125, but copart charges outrageous fees)

    Total conversion cost: $3,444.58

    I don't plan on using a BMS at first, but will manually balance cells during install and undercharge during routine use

    So now some questions before I pull the trigger on purchasing everything:
    1. Can I potentially have a reverse gear with this setup? If not, how difficult would that be to accomplish? I would like to reverse into my garage which is at the top of my steep driveway.
    2. Has anyone had any experience with the "new old stock" chargers from ev-drives. Are they reliable? How do I go about getting it programmed for Lithium?
    3. What do you think of my 3.57 gear ratio? I am hoping to get up to at least 65mph if necessary, but I doubt I will ride on the highway due to the extreme negligence of other drivers in my area.

    I am trying to get this elmoto excel file to work, but I must admit it is rather confusing.

  5. #5
    Senior Member DRZ400's Avatar
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    I would go with a 14:60 and a 420 chain. Should give you ~65 mph. I've been using the $90 BMS Alloy charger for 4 years...no issues. Forget the reverse!
    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

  6. #6
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    I based the 520 chain off of the stock chain on the ex500. Would 420 chain be strong enough for this application?

    I have been reading around some more and I agree that 14:60 would likely be a better gear ratio. I secretly want to be able to do a wheelie on this thing, so acceleration is pretty important.

    Is reverse too technically challenging to implement?

  7. #7
    Senior Member DRZ400's Avatar
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    I've been using 420 for 8 years. Over 5k miles. You would have to find a reversing controller or make a DPDT switch with contactors
    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

  8. #8
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    Finally managed to take some pictures. Here is my build so far. Hopefully this link works...


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  10. #9
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    I have a very similar setup as your plan also with a very large and heavy 530 chain as that was stock on my fazer fz6-E but with the less effective Kelly controller I've clocked 68mph from 10 leaf cells with a 1:3.3 gear ratio but the chain 520 or 530 are over kill even for the petrol engine drz400 knows his stuff and I don't want to contradict him but for ease and cost I would keep the stock chain and sprockets untill they need replacing then consider down sizing a little

  11. #10
    Member Duck-Stew's Avatar
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    As a suggestion: try if possible to opt for sprockets with odd number of teeth. They last longer as the inside plate of the chain will hit every spot between the teeth instead of every other one. They also run a little quieter.

    Also: industrial #40 sprockets are dimensionally identical to motorcycle 428 chain. But: ALWAYS, ALWAYS use motorcycle chain and not industrial chain (sprockets are OK)...
    '10 Zero S project

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