Voltage LimiterBeforeAdapter PlateMotor mountStereo SystemBattery Box BaseNov 08
OwnerCorry Peterson
LocationLehi, Utah US map
Email email image
Vehicle2000 Kawasaki EX250 Ninja
MotorAdvanced DC K91-4003 Series Wound DC
The motor mount plate was made from a 9 1/2" tall x 7" wide x 3/8" thick aluminum from www.metalexpress.com.
See the picture with the specs.
DrivetrainThe front sprocket is currently a 16 tooth, #50 ANSI chain size, 7/8 inch ID from www.grainger.com. The rear sprocket is a 56 tooth, #530 chain size from www.sprocketspecialists.com.
ControllerCurtis 1209B-6402
The Curtis controller is mounted under the front of the seat on a 1/4" aluminum plate heatsink. It never gets warm to the touch. The heat sink and controller and batteries are all electrically isolated from the chassis for safety!
Batteries24 Thunder Sky LFP90, 3.30 Volt, Lithium-Ion
I have installed a very simple "voltage clamp" circuit on each battery to limit the voltage to 3.8 during charging.
The battery frame / holder was made from 1/4 inch aluminium plates and "L" brackets sprayed with truck bed liner.
System Voltage80 Volts
ChargerZivan NG1
I use the Zivan as my main charger. I have opened it up and turned the "I" potentiometer all the way down. It charges at less than 10 Amps now, so I have to wait 8 or so hours for a full charge. That's OK. I like to charge slowly and carefully.
HeaterAfter a ride in Utah weather I reach down and rub my hands all over the motor!
DC/DC ConverterSevcon 622/11086
72/80 volt input
300 Watt 13.5 Volt output Mounted under the seat.
InstrumentationPakTrakr 600EV with hall effect current sensor.
Top Speed70 MPH (112 KPH)
Wind really becomes a factor at 70 MPH.
I'm looking for ways to make the bike more aerodynamically slippery.
Acceleration0 to 60 in about 6 seconds with the current limit turned all the way up. Big EV grin! 0 to 60 in 10 seconds with the current limit turned all the way down.
Range55 Miles (88 Kilometers)
55 mile range at 55 MPH. I commute to work 22 miles each way with several hills and sometimes high winds. The average speed of my commute is about 60 to 65 MPH.
EV Miles
Start:5,746 Miles (9,245 Kilometers)
Current:14,803 Miles (23,818 Kilometers)
Total:9,057 Miles (14,572 Kilometers)
Seating Capacity2 adults
Curb Weight305 Pounds (138 Kilograms)
Have not weighed it.
The ICE bike weighed 305 lbs. dry
TiresPirelli MT75
Conversion TimeI completed most of the conversion between June and Dec 2007 just working on weekends. The modifications are on-going.
Conversion CostAbout $6,000.00. when considering the Utah state tax incentives. I rode around on my Valence batteries for a year and decided I wanted more range, so I'm on my second set of batteries.
In April '08 I qualified for the clean air tax credit. $2500.00 bucks right off the top of of my 2007 Utah state taxes! YAHOO! I took another $1250 off of my 2008 Utah State Taxes! I sold my old gas engine for $80.00. People tell me there is no way I will ever recover all of the conversion costs with gas savings because I will eventually have to buy new batteries and that I could have just rode my 100cc scooter and saved more money.
I say, "so what, that's not the point". Then I ask "So when will your Mercedes start to pay for itself? Instead of buying & driving a Mercedes you could have bought a forty dollar bus pass each month and saved more money!" I glide to work everyday ( except in Winter ) jamin' to my favorite tunes. It's a joy to ride. I really look forward to my commute. Was it was worth the money? Hell yeah! At least a little bit less of my hard earned cash is going to the oily bastards.
Additional FeaturesStereo system!
Ipod shuffle mounted on top of the front brake fluid reservoir.
PolyPlanar 4 channel 25 watt marine amplifier mounted under the gas tank.
2 Boss 1 3/4" tweeters
1 Boss Marine 5 1/4" woofer
( fits perfectly where the gas cap used to be! )
( Bridged the two sub-outs on the amp )

Painted it Blue ( 2011 ) more pictures soon.
I would recommend the Kawasaki EX250 when doing a conversion, because they are lighter than a lot of other bikes you could use and you can get parts ANYWHERE!

code by jerry