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Thread: Juiced Cafe Racer Battery Swap

              
   
   
  1. #1
    Old EV Racer EVcycle's Avatar
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    Juiced Cafe Racer Battery Swap

    Phase one of the battery swap has commenced!!!

    After some research and good advice from my friends here the swap is on!

    The Volt battery packs have been ordered (2 - 48V 45AH packs) and will be here Thursday.

    The old battery boxes and cables have been pulled and weighed. A whopping 148 lbs! The original
    ICE to EV conversion still made the bike 160 lbs less than the original ICE setup. Now we are
    looking at another 50+ loss. The rest of the this weekend will be spent inspection the bike and
    touching up any paint issues etc.

    Photos as I go will be posted.

    _DSC0413 800.jpg

    Later!
    Last edited by EVcycle; 15 August 2015 at 0449.
    EV Ed
    Never let being a responsible adult get in the way of passion and curiosity.
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  2. #2
    Moderator Nuts & Volts's Avatar
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    Excited to see this. I know must guys are using Leaf cells, but I have seen volt packs used in an el moto yet. I think they offer some interesting advantages if you can utilize the packaging size/configuration. So you will be using two 12s modules?
    Whats under my tank may shock you!!! R6 Build, Blog/, [/URL] OSU Current webpage

  3. #3
    Old EV Racer EVcycle's Avatar
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    Quote Originally Posted by Nuts & Volts View Post
    So you will be using two 12s modules?
    Yes, 2 - 12s. I think the weight loss on the bike should make up for the smaller amount of AH compared to the LEAF cells. (Still more than I currently have)
    We will see. This is a older 79 frame so fitting the leaf cells would have been a chore.

    I work 9 miles from the house so either way I should be able to ride hard and still have plenty when I get home.
    EV Ed
    Never let being a responsible adult get in the way of passion and curiosity.
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    Ev album 2456, 2458, 2457, 2681, 3456, 3630, 5511, 5512

  4. #4
    Old EV Racer EVcycle's Avatar
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    The Cafe bike is up and running in a Beta test mode. I took it around the block this morning and the 52lb weight loss
    made a big difference in acceleration and handling. The acceleration was better, as expected, but the CG
    difference was more pronounced than I expected. It was good, but when you lose that much from the bike it is
    MUCH easier to lean into the turn..

    The voltage drop was minimal, but I have not "twisted it up" just yet.

    More later!!

    Ed
    (Note: The cable ties are not holding the controller on, they are holding the cables up
    underneath from rubbing the battery pack.)

    New battery packs.jpg
    Last edited by EVcycle; 22 August 2015 at 1239.
    EV Ed
    Never let being a responsible adult get in the way of passion and curiosity.
    Motenergy.com
    Ev album 2456, 2458, 2457, 2681, 3456, 3630, 5511, 5512

  5. #5
    Senior Member DRZ400's Avatar
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    If they're anything like the Leaf cells, just bulk charge to 4.1 per cell and only pull ~80% of the AH's out'a them (avoid the cliffs). They STAY within .025 volts of each other. *This data based on ~25 cycles.
    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
    Old EV Racer EVcycle's Avatar
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    Charged the batteries to 4V and took the Cafe racer out again today. It accelerated quickly and was only at a max of 128 amps thoughout the ride.

    Did 4.3 miles at 4.8 AH. A little higher than I normally see, but I was running at 60 MPH.

    I did check the weight of the Bike without me on it. 154 lb on the front and 178lb on the back. 332lbs on a bike that was 564 pounds when it was an ICE ride. This is a net loss of 48lb from the old battery pack.
    I had to add some brackets, but still have about 2 pounds of cabling and other brackets to remove (Never cut anything off until you are done testing!).

    More later!
    Last edited by EVcycle; 23 August 2015 at 1147.
    EV Ed
    Never let being a responsible adult get in the way of passion and curiosity.
    Motenergy.com
    Ev album 2456, 2458, 2457, 2681, 3456, 3630, 5511, 5512

  7. #7
    Senior Member Stevo's Avatar
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    Cool... so have you decided to call it a Hondvy or a Chevda?
    Current rides: '96 Honda Ohlins VFR, '03 Cannondale C440R, '03 Cannondale Cannibal, '06 Yamaha 450 Wolverine 4x4
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  8. #8
    Senior Member DRZ400's Avatar
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    Quote Originally Posted by EVcycle View Post
    Did 4.3 miles at 4.8 AH. A little higher than I normally see, but I was running at 60 MPH.
    Makes sense, you have a higher pack voltage before correct? Same WH with less V you're going to use more I !

    How did it feel? Stiffer than the headways (less sag)?
    Last edited by DRZ400; 23 August 2015 at 1413.
    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

  9. #9
    Old EV Racer EVcycle's Avatar
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    Less sag, but I would expect that with the lighter bike.

    I will know more when I get a longer ride on it. (lots of thunder storms lately.)
    EV Ed
    Never let being a responsible adult get in the way of passion and curiosity.
    Motenergy.com
    Ev album 2456, 2458, 2457, 2681, 3456, 3630, 5511, 5512

  10. #10
    Senior Member DRZ400's Avatar
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    Mine is like 8 volts less sag between the Leafs and Calbs. The Calb's were only 40ah however....Leafs 62ah.
    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

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