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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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