sans batteries & cowlingswith batteriesbatteries & wiringinstrument clusterEV Fest 2012
LocationBurlington, Ontario Canada map
Email email image
Vehicle1991 Suzuki GSX600F
Road worthy motorcycle intended for in-town travel and capable on secondary highway use.
MotorPerm Motor PMG 132 Permanent Magnet DC
The smallest PM DC motor for its power rating at the time.
Drivetrain14t drive and 60t driven sprockets, #40 chain, more efficient for speeds <110km/h
ControllerCurtis 1205M
72V, 400A PWM controller
Batteries96 Headway 38120S, 3.20 Volt, Lithium Iron Phosphate
Three 24V battery banks series-parallel configured for 40Ahr.
System Voltage72 Volts
One 800W charger under the gas tank. One 2kW charger (custom design by ElectroCraft EV Systems) at home.
DC/DC Converter PST-DC4812
Powerstream 48 to 12V @12A (accepts 80V input)
Instrumentationstock speedo & Cycle Analyst
Top Speed60 MPH (96 KPH)
About 110km/h (68 mph) on slight downhill grade.
AccelerationWith current set to 300A, pulls very well off the line.
Range25 Miles (40 Kilometers)
Farthest trip so far -- 45km (28 miles) at an average speed of 60km/h
Watt Hours/Mile130 Wh/Mile
Determined by time it takes to recharge the motorcycle x charger power draw from AC supply / distance traveled. This method includes losses.
EV Miles
Start:41,573 Miles (66,890 Kilometers)
Current:47,497 Miles (76,422 Kilometers)
Total:5,924 Miles (9,531 Kilometers)
    As of 3/17/2017
Seating Capacity2 adults
Curb Weight400 Pounds (181 Kilograms)
Just a guess but no heavier than stock.
Tiresnothing special
Conversion TimeAt least 140 hours research and buying parts, 150 hours building on and off... I really have no idea!
Conversion CostStopped counting but at least $10000CA, most of the cost was for lithium batteries, motor, motor controller and chargers.
Additional FeaturesLED tail lights and signal lights. AC cord on retractor stolen from a vacuum cleaner. Custom control breakout box for vehicle control and future upgrades. Removed one front rotor/caliper to reduce weight. 72V battery common connected to chassis via 10k resistor for safety. Stash box under the seat where the old battery compartment was.
Advice: Educate yourself about batteries, especially lithium. Had I taken the time to study up, I would have saved a lot of cash.

Thanks to EV Album for ideas gleaned off other conversions. Thanks to my father for all the welding work, beer, conceptual ideas and allowing me to make a mess of his garage. Thanks to Ian for cutting the rear sprocket; looks stock.

code by jerry