1993 Suzuki Katana EV Conversion1993 Suzuki Katana EV Conversion1993 Suzuki Katana EV Conversion1993 Suzuki Katana EV Conversion
OwnerFrank Weyer
LocationHollywood, California US map
Vehicle1993 Suzuki Katana 750
1993 Suzuki Katana converted to EV using 15KW DC motor mounted on extended swing arm.
MotorMars ME1004 Permanent Magnet DC
I originally used an Etek pancake motor. The stator failed after 1500 miles. Same thing happened to a second motor after another 1500 miles. Possible cause of failures is the mounting location on the swingarm, which subjects the motor to a lot of movement. Changed to the MARS ME0909 brushed motor, which failed after 1000 miles. Next tried a MARS/ETEK brushless DC motor, which failed after slightly more than 450 miles, with a lot of smoke. I now think overheating is the problem. Have changed to a Mars ME1004 with an external 48V fan that is keeping the motor much cooler. 600 miles so far on the ME1004 motor without any problems.
DrivetrainUpdated to Mars ME1004 brush motor with added external 48V cooling fan.
ControllerCurtis 1204
Batteries12 20AH Li FE PO4, 12.80 Volt, Lithium-Ion
Upgraded to Li Fe PO4 batteries at 1250 miles (original lead acid batteries had lost nearly 50% capacity by then). Added additional 4 batteries in Oct. 2010 for total of 12 (twelve) 12.8V 20AH batteries, approx. 3KwH total.
System Voltage48 Volts
Top Speed55 MPH (88 KPH)
Range35 Miles (56 Kilometers)
Haven't run the batteries down, so max. range is unknown.
Watt Hours/Mile110 Wh/Mile
This is what I am averaging in my real world daily commute through stop and go city driving with speeds up to 55 mph.
EV Miles
Current:5,108 Miles (8,218 Kilometers)
Seating Capacity2 adults
Conversion Time40 hours
Conversion Cost$1500 (+$1200 for Lithium battery upgrade)(+$600 for add'l Lithium batteries)+$1500 for replacement motors

code by jerry