10/21/14
OwnerRich
LocationAustin, Texas US map
Vehicle1994 Kawasaki KE100
My first motorcycle conversion after doing
over 15 ebike conversions. Still a work in
progress. It hauls my wife and I pretty
well, though it's a small bike.
MotorPerm Motor 132 Permanent Magnet DC
This came off an old Zero motorcycle I
believe. Works well. Very quiet and smooth (I guess that's the benefits of brushed motors).
Drivetrain420 chain 16:56 ratio
ControllerKelly
600 amp older model. It works, but has
it's quirks. Such as when I roll back on
the throttle I get a touch of regen. And of course how Kelly controllers ramp up current with speed. You can't get full power until at least
>70% of max speed. So takeoffs are weak,
relatively. I now have it set to 60%, which would be 360a peak, and I'm pretty happy with my takeoffs now. I still haven't seen more than 263a peak yet because I don't ride much above 50mph.
Batteries18, 68.00 Volt, Lithium-Ion
2p18s Nissan Leaf cells. 3.7kwh. Total weight with battery rack is 82lbs. I am quite happy with this pack, they are staying very well balanced.
System Voltage68 Volts
Charger
I just bought some Mean power supplies to put in series 3 x 25v for 75v and they output 14amps.
I almost always solar charge with my homebuilt panels which are 110v .8amp. When it's sunny I get about 500wh/day.
DC/DC Converter
Generic Chinese cheapie. 90v max, 10a max.
InstrumentationCycle Analyst v 2.1 upgraded to high
current
Top Speed58 MPH (93 KPH)
limited by my current gearing of 16-56. It has no problem getting there quickly. I rarely go that fast though, since I avoid such higher speed roads. It's just so windy and load.
AccelerationPretty good now that I have the amps set to 60% or 300. In reality I hit 242a, but only at high speed. Thanks Kelly
controller for your restricted amps at low speed. It's no slouch now. Quite fun. I won't gear it higher as I avoid highways due to high power consumption.
Range70 Miles (112 Kilometers)
Watt Hours/Mile50 Wh/Mile
It seems 50wh/mile is the most common figure I see. It was 65-70wh/mile before my new homebuilt fairing which has clearly made a big improvement.
EV Miles
Current:1,250 Miles (2,011 Kilometers)
Seating Capacity2 adults
Curb Weight230 Pounds (104 Kilograms)
About 40lbs more than stock, but has loads more power now with the Leaf modules.
TiresFront is 17x2.75 Shinko street tire. Rear is a a Shinko 80/90-17. I will move up a size when it comes time for a new one.
Conversion TimeA lot of hours. Over a year. So much time
spent reconfiguring, setting up drivetrain,
battery placement. Still not done, but chipping away slowly.
Conversion CostAbout $2000. 1200 being the battery
Additional FeaturesI built a rear bike rack for it - such as "2x2" has done. Works great, installs in a minute with 3 wing nuts. Solid. Now I can go mtb'ing without using a car. I've used it to haul odd things too, such as bicycle kid trailers, a large window, large tools. Utility is important to me. I don't own a car myself, and believe in more than one use for a vehicle.
I would like to make a dustbin fairing for it. I think there is a lot of improvement in efficiency to be had with fairings. I feel like I'm a parachute when above 40mph.
4/20/15 update - I tore the whole thing down and reconfigured the battery, motor and controller placement. More pics and update to follow soon.
5/17/15 - Added pics of the new motor and battery configuration, and shabby front fairing. Replaced the turn signals to cheap incandescent bulb instead of cheap LED (much brighter now). Swing-arm motor works good, less noise, slightly less good over bumps, but not a problem since I don't off road. The space I gained was HUGE.
7/27/15 update: I swapped the fork tubes for a TTR125 set, with a YZ85 front wheel and disc brake. This has made a huge improvement to the bike. I can stop quickly now, and the shocks act much better (though still soft). Currently no fairing. I will rebuild a better one soon.
6/12/16 Update: new front fairing made from coroplast built around a new front rack made of plywood and bike handlebars/rims. I used a GSXR headlight. I need to redo the top to make it enclose me more, it has a lot of room for improvement. I get a lot of comments, mostly positive. I didn't build it for looks. I built it for efficiency and almost 0 cost. It easily saves me 1000watts at 50mph. That's a lot of waste due to no fairing. Lately I'm doing food deliveries with it, so range is important when working all day.

code by jerry