ICE BikeD&D MotorNo Exhaust PipeCAD ModelTear down beginsThrottle assemblynew chargerbottom battery racksAll Batteries In!
OwnerMike Kugler
Owner's Other EVs1987 Kawasaki KLF110
1971 General Electric Elec-Trak
LocationHope Valley, Rhode Island US map
Email email image
Vehicle1997 Honda CBR 600 F3
CBR 600 was complete and running ICE before conversion. Sold all ICE parts and paid for original purchase price.
MotorD&D Motor Systems, Inc. ES-15-A Series Wound DC
72 Volt 40 HP peak 6.8" DIA X 16.8" long
65 lbs
Crisp, smooth and powerful!
DrivetrainD&D ES15-A 72 Volt motor, direct drive 13/56 sprockets
ControllerKelly KDH09500 OPTO Isolated
96 Volt 500 AMP OPTO Isolated. Very nice controller.
Batteries6 C & D Technologies 75 AH High Rate Series, 12.00 Volt, Lead-Acid, AGM
56 Lbs each, VERY difficult making these fit in a 600CC bike!
System Voltage72 Volts
ChargerBlack & Decker 2/4/6 Amp x 6
I used 6 B&D 2/4/6 Amp chargers for bank charging. Eliminates the need for battery equalizers or BMS. Nice chargers for the money ($29ea). I would recommend stepping up to the 2/6/10 amp ones. 10 Amps would quicken the charge time without hurting the batteries.
HeaterHA! I have been riding on 40 degree F mornings. BRRRRRR!
DC/DC ConverterKelly 72V - 12V 300 Watt
Very nice DC-DC converter. Never a problem with lights dimming etc. One of the least expensive available. A little on the large side. Takes up a fair amount of space.
InstrumentationPak-TraKer 600 amp model. A MUST HAVE!
Panoram v-12 Bicycle wired computer:
MPH/ODO/clock with max speed and distance memory.
Top Speed60 MPH (96 KPH)
Top speed at 72Volts is 64 MPH on the flats so far.
easily cruises at 55 MPH
AccelerationI can pull away from stop lights quicker than most ICE cars. Pulls hard to 45 MPH, then tapers off up to 55 MPH.
Range25 Miles (40 Kilometers)
Max range is 25 miles cruising between 45-55 MPH, with medium sized hills.
20 Miles with me and my wife. 45-50 MPH.
Watt Hours/Milenever calculated
EV Miles
Current:1,200 Miles (1,930 Kilometers)
 
    As of 6/19/2009
Seating Capacity2 adults
Curb Weight600 Pounds (272 Kilograms)
empty bike frame 200 lbs
motor 65 lbs
(6)X 56 lb batteries = 336
TiresNew Stock
Conversion Time200 hours:
100 research (40 hours on EV ALBUM alone)
100 conversion.
Conversion Cost$3500 After selling off ICE parts.
Additional FeaturesUtilized factory throttle assembly so I could maintain the factory panic thumb switch. I used a 0-5V automotive type throttle position sensor hooked to a wheel that the factory throttle cable hooks to.
Removed the tank bottom to house the controller and (2) 36 volt powerstream 3 amp on-board chargers. Extension cord comes out the gas cap. (copied that from this EV album).
I since have upgraded the onboard charger to a Kelly 8 amp 72 Volt charger.
So far I have 650 miles on it. I ride when ever possible. You may think the 75 AH batteries are too heavy, but I like the range, acceleration and the average speed I can maintain. I tried my best to make the bike look factory stock. I am enjoying this project and I am extremely happy with it. This was a huge learning curve. I made some errors in component selection, about $200 in money spent incorrectly. Could have been much worse! This bike is great fun and the torque and acceleration is a blast on the twisty back roads. I can enjoy riding with my wife to church or to the ice cream parlor and taking my son to the Scout meetings. No scooter can compare to the range and performance for the money. Things will only get better when LiFePo batteries become affordable.
Advice: BUILD ONE NOW! don't wait until LiFePO batts are available. If you want to cruise at 50 MPH, size your components for 70MPH. I would suggest a 900 CC frame for a bike with more than 48 Volts. Do the research and call the suppliers of the products before you order. I have found that EVERY EV supplier has been willing to ensure you have the correct components rather than getting your money. Buy your donor bike from Craig's list in the middle of winter! Sell the ICE parts on E-bay! Before you buy the bike, search E-bay to see what the parts are selling for in the same condition. You should be able to calculate your potential return on your investment. Don't buy a bike that is in need of restoration. Buy a good quality running bike so after the conversion it will have maximum value and long life.

THANKS TO ALL WHO POSTED THEIR PROJECTS HERE TO HELP ME DESIGN AND BUILD MINE!!!!

1200 miles and counting!

code by jerry