|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 was located.
|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 plugged in.
|Top Speed||60 MPH (96 KPH)|
Top speed is 35mph in low gear and 55-60mph in high gear.
|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 ATV.
|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 gets warmer.
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.