Started with the motor1996 Sportster ConversionAlternative Energy FairCharging stationTank DecalClimate Action DayGreat Commuter!
OwnerMike Workman
Owner's Other EV1995 Nissan Altima
LocationTumwater, Washington US map
Vehicle1996 Harley Davidson Sportster
Conversion completed Feb. '07
MotorPerm Motor PMG-132 Series Wound DC
24 to 72 volt, 19 Hp peak,
8 Hp continuous
Drivetrain11 tooth sprocket direct mounted to motor shaft. Chain drive to rear 51 tooth sprocket. (4.64 to 1 ratio)
ControllerAlltrax Axe 7234
300 Amp Programmable (Currently set at 85% power)
Batteries6 ea. Werker WKA 12-55C/FR, 12.00 Volt, Lead-Acid, AGM
60 Ah at 20 hrs. / 55 Ah at 10 hrs. / 33 Ah at 1 hour
System Voltage72 Volts
ChargerGuest 3 ea 2611 dual
3 stage, smart marine chargers. Potted for vibration and water resistance. Mounted in the left rear saddle bag.
HeaterDetachable windshield for winter driving.
DC/DC Converter N/A
Rather than a DC/DC converter, the bike retains the original 12 volt 19 Ah battery (used for lighting). It's charged with a seperate 750 mA Battery Tender.
Instrumentation2 Digital multimeters, one for battery voltage and one connected to a 500A/50mA shunt for battery current.
Bicycle spoke magnet speedometer
Top Speed52 MPH (83 KPH)
52 mph with present 11 tooth gearing, 85% controller setting and 72 volt battery pack. (11 tooth, 60 volt = 45 mph.)
(12 tooth, 72 volt = 54 mph. and 12 tooth, 60 volt = 48 mph.)
AccelerationEven though it's like starting in second gear, performance flows well in traffic. 0 to 30 mph in < 8 seconds. 0 to 40 mph in < 12 seconds. 1/4 mile in < 19 seconds. Good power band at 25 to 40 mph.
Range10 Miles (16 Kilometers)
9.5 mile commute (one way) draws depth of charge down to 70%. Longest run was 22 miles, drawing the depth of charge down to 30%.
Watt Hours/Mile125 Wh/Mile
"Kill a Watt" recharging measurements (1.19 kwh/9.5 miles = 125 Whr/mile for smart chargers) and (1.79 kwh/9.5 miles = 189 Whr/mile for core and coil chargers.)
EV Miles
Current:5,343 Miles (8,596 Kilometers)
 
    As of 7/20/2009
Seating Capacity1 adult
Curb Weight630 Pounds (286 Kilograms)
Original vehicle weight 525 lbs.
Batteries are 43 lbs. each
Chargers are 18 lbs. total
TiresDunlop D401 hard compound
Conversion TimeOn and off for 3 months. Maybe 80 hours total compressed production time for original 60 volt layout.
Conversion Cost$2,720 present running condition. Add $260 for new "smart" chargers. Plus lots of mistakes!
Additional FeaturesCarry along smart chargers to charge each battery seperately thus improving battery balance. LED lamps used for turn, tail and stop lamps. Last winter I had installed an experimental battery heating system. It was an 18 foot 120volt AC water pipe heat wrap. It drew about .6 amps (at 60 volts DC) and heated the batteries about 20 degrees above ambient. Could warm them even more when the batteries were wrapped in a rubber floor mat. Ugly but effective! It did show improved performance and less depth of discharge.
This conversion has grown to be 105 pounds more that the original vehicle weight, but still handles great. Balance and the center of gravity are close to original. At 25 mph it draws approx. 25 amps on the flat and steady.
Special thanks to BATTERIES PLUS of Olympia WA.

code by jerry