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Thread: New user, new project. Motorcycle conversion.

  1. #1
    Junior Member
    Join Date
    Mar 2020
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    New user, new project. Motorcycle conversion.

    Hey all!
    I am in the process of my first EV conversion and I thought I'd find a place to get feedback, suggestions, and just generally try to benefit from the wisdom of those who've been through the process. I will be converting a motorcycle for the purposes of a commuter vehicle. Goals are a top speed in the neighborhood of 45 to 50 mph and a range of ~20 to 25 miles on a charge. With the components I already have I think these goals are achievable but as with anything new I am certain there are complications I have not considered. That is where you guys will hopefully come in.

    I have a friend in the EV industry who has been assisting me in selecting and acquiring the drive components (motor, controller, bms, can charger etc) and will be tuning the system for me once it is built, but his expertise does not translate to the conversion of an existing vehicle and since I'm sure he is already sick of my endless questions I am hoping to get y'all involved. Let's start with what I've already got.
    Motor is Motenergy ME0201012801 http://www.motenergy.com/me0201012801.html
    Motor controller is a Sevcon Gen4 and is configured for 48v with 100A continuous. Don't remember peak at the moment.. http://www.sevcon.com/products/low-v...trollers/gen4/
    BMS is a CAN enabled Orion Jr 2 (battery pack is 16s 4p so each parallel chain will be treated as a single cell but the cells are brand new and have been balance tested so I feel comfortable with this configuration) https://www.orionbms.com/products/orion-bms-jr/
    Charging unit is an ElCon HK-H-H66-25 https://www.elconchargers.com/catalo...0/10295151.htm
    The throttle is an inexpensive hall effect unit that I bought Ebay.
    The battery pack is 16s4p and is built from 38120 HP cells that i was able to source brand new. http://www.headway-cn.com/en/showproducts.php?id=1560
    I also have all appropriate fuses, mains contactor, CAN connectors etc.

    What I am left with is deciding on what donor bike will best suit my needs, and the mechanical aspects of the build such as motor mount, sprockets, battery box, mounting bms and controller components, chain guard etc..
    I'm currently looking for a donor bike somewhere in the kz440 to cb750 range. Don't want a bigger bike than necessary so I can keep the weight down, but need enough space for everything and it has to support a big guy (I'm 6'5 and 260 lbs).
    Any and all comments, suggestions and assistance is welcome! If it gets some interest I will update as the build progresses. Thank you all in advance!

  2. #2
    Senior Member
    Join Date
    May 2013
    Kildare, Ireland
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    Given you're tall, I'd go for a dual-sport/trailie type.
    Varadero, V-strom, Tenere... etc...

    On the whole, that spec seems fairly optimal - by which I mean that you'll be using it to its full capacity to achieve that brief, but it does seem achievable.

  3. #3
    Junior Member
    Join Date
    Mar 2020
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    Thanks for the feedback and recommendations! I've honestly never heard of most of the bikes you mentioned but I'm not sure if that's due to my general lack of motorcycle knowledge of if it's due to geographical separation. I will certain look into the ones you've mentioned and if they're not common where I am I will look for a reasonable analog.

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