Suzuki Mighty Boy as purchasedNew flywheel/clutchNew motor fittedHigh voltage components in placeNew EVMS MonitorNew engine mountBattery rack with BMS and polycarbonate Engine bay completeNew EVMS
OwnerRobert Doig
LocationGeelong, Victoria Australia map
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Vehicle1986 Suzuki Mighty Boy
Very small utility. These cars were made in Japan for kei class registration. They were only exported to Australia and Cyprus.
MotorMars Motenergy ME0913 Brushless DC
Axial flux, brushless DC.

NB Motenergy formerly Mars Electric
DrivetrainFront wheel drive, 4 speed manual, Clutch
originally removed but now (2016) replaced.
ControllerSevcon GEN 4 size 4
Batteries30 Winston TS-LFP100AHA, 3.20 Volt, Lithium Iron Phosphate
Located as two rows of 15 cells behind the seats in the cabin.

To be upgraded to 32 cells.
System Voltage96 Volts
Charger TCCH-32C-10A 102V
HeaterElectric heater core from EVSource
DC/DC Converter Chennic JCDI35
InstrumentationZEVA monitor, this displays the State of
Charge, current discharge/charge in amps and
kW. Also voltage of every cell and balancing

This management system also drives the
original fuel and temperature guages
Top Speed55 MPH (88 KPH)
Will not exceed 30 MPH going uphill in 3rd gear but can do up to 45 mph uphill in 4th gear.

Does 55 (90km/h) on the flat.
AccelerationIn town I normally drive in third gear and this gives acceptable acceleration.

Taking off in 4th is possible but slow.
Range50 Miles (80 Kilometers)
Watt Hours/Mile234 Wh/Mile
Cost to run is about 3.5 cents / Kilometre
EV Miles
Start:89,809 Miles (144,502 Kilometers)
Current:93,205 Miles (149,966 Kilometers)
Total:3,396 Miles (5,464 Kilometers)
Seating Capacity2 adults
Curb Weight1,344 Pounds (610 Kilograms)
Original car was 550 kg (1212 lb) curb weight.
It now weighs about 610 kg (1344 lb)

Weight distribution was 66/34 Front/Rear.

It is now 52/48 - much better.
Tires12 inch
Conversion TimeComplete and road registered in just under 3
March 2015 road registered.
Conversion CostBudget for car purchase, panel beating,
trimming and conversion was $20,000.

Have spent $18,000 to complete including
engineer's certificate and roadworthy

Additional $6-700 spent on clutch in 2016.
Car is intended for town use only. Range or top speed are not critical.

Controller appears to limit motor revs to about 4000 limiting top speed. If anyone can suggest a cheap way into the programming I would be very grateful.

I have been driving this car for about 18 months now (July 2016)

March 2016 to July 2016. The car has been off the road getting a new clutch installed. The original rubber coupling failed and I have found it useful to be able to use 3rd and 4th gear so a clutch is preferred. I have built a new "flywheel" as the original
was missing. Finding a replacement was hard as most have cracks and are discarded by wreckers. Also, they are cast iron which could not be welded to motor hub.

The clutch is now installed and working(28/7/2016).

February 2017. Installed ZEVA EV Management System.

June 2017. New leather seats installed.

August 2017. I have temporarily added two cells (making 32) so that the battery charger slows down to allow the new BMS to balance the cells. This has added a little speed and range and, most usefully, allows speeds of up to 60 km/h in third gear. This allows me to do most city driving in third gear only. Bliss!

August 2017. Replaced front springs with softer springs (from rear of Toyota Starlet) to reduce harsh ride and ride height. Necessary due to much lighter engine. Weight distribution is now 52/48 Front/Rear. Standard is 66/34.

code by jerry