|Location||Rondeau, Ontario Canada map|
|Vehicle||2004 Polaris Sportsman 500 HO |
Purchased this as a running ATV. Good market
for used parts, so selling all removed parts.
|Motor||HPEVS AC-20 3-Phase AC|
With the motor controller I am using this motor
has a peak output of 60 HP and 80 ft-lbs of
torque. This is approximately twice the peak HP
and torque of the original engine.
|Drivetrain||I used the stock transmission in the ATV. The |
transmission is in a separate housing from the
engine, which is one of the reasons I used
this ATV for conversion. The transmission has
a high and low range plus reverse. I used a
synchronous belt drive system to drive the
input shaft of the transmission from the
traction motor. Works well and is quiet. I
have added a cover for the belt drive since
the photos were taken.
It has a nominal input voltage range of 72-96V,
a 2 minute current rating of 650A, and a 2
minute power rating of 74kVA.
|Batteries||32 CALB/Skyenergy SE-100, 3.20 Volt, Lithium Iron Phosphate|
Using miniBMS to monitor batteries. There are
18 cells in an enclosure at the back, 10 cells
in an enclosure within the front of the frame,
and 4 in front of the seat where the fuel tank
|System Voltage||96 Volts|
|Charger||Delta-Q Technologies 96V model 912-9600|
This charger is mounted on ATV
|DC/DC Converter||Meanwell SD-500|
This converter is hooked up in parallel with 12V
vehicle battery. It comes on when either the
ignition switch is turned on or the charger is
|Top Speed||60 MPH (96 KPH)|
Top speed is 35mph in low gear and 55-60mph in
|Acceleration||Very fast. Not typically something you do with |
an ATV, but I am fairly sure that this
conversion would beat any stock ATV in a drag
race. In low gear it gets to top speed (35mph)
in about 2 seconds.
|Range||30 Miles (48 Kilometers)|
30 miles of aggressive off-road driving. Likely
would be much higher if driven only on the road
and did not have knobby tires.
|Curb Weight||900 Pounds (409 Kilograms)|
Stock dry weight was 700lbs, and based on
weight of components removed and added I
estimate I have added 200lbs. GVWR is
1200lbs, so still well within GVWR after
conversion and with rider. I have put
aftermarket heavy duty springs on the ATV that
some guys use for a firmer ride on a regular
|Conversion Time||Spare time over about 6 months|
|Additional Features||I also have a secondary series DC Curtis motor controller|
mounted in the front of the machine to allow me to connect
electric implements (like the electric snowblower I built).
I have the controls (on/off, and speed control pot) for this
controller mounted on the ATV headlight pod within easy reach.
The motor and all the battery cells except the 4 under the
original fuel tank are in steel enclosures that I built and are
sealed well enough to withstand washing and immersion in
water while driving. The battery cells in the enclosures are
surrounded by 1/2" of firm sponge rubber to provide some
insulation and impact protection. Watertight cable grips are
used for all wire/cable entry into enclosures.
Since the motor is enclosed, I am using a boat bilge blower
to force air cool the motor within the enclosure. I mounted
three thermostats to the exterior of the motor, which turns
the blower on and increases the blower speed as the motor
I have set up a push button switch (momentary on-off) on
handlebar to allow electronic reverse of controller, which
is handy for using the ATV for plowing and other jobs.