The idea is to take an old bike hat still has all systems (Engine excluded) functioning and turn it into an electric motorcycle.
Why?

• 1. Why not?
  
• 2. It's cheap and easy to maintain: No gas, no oils. Regular running cost is about a tenth,
  
• 3. Green is good: No air polution, no noise polution
• 4. Effordable: Should cost around the $3000 (bike included) , hopefully even less/
• 5. Motorcycles are cool
  

Planning

• Research: Find converted motorcycles, parts, prices etc
  
• Find a bike for the project: It needs to be cheap, in good condition and with enough room for the batteries
  
• Free the bike from un-nessesary part and liquids: Engine, carburators, air box, radiator, gas, oils, transmition..
  
• Decide which components will be used and order (anything that can be found second hand or locally is prefferd)
  
• Till all the parts arrive, cosmetic modifications and preparations can be made
  
• Once the motor is available the arrangement of the batteries should be tested and decided
  

Putting it all together

Details, details - We'll figure it out

May 1st, 2008 Found a bike on Craigslist. The guy was even nice enough to transport it to me and threw in the bike's manual. Here it is in its original state: It's an an old 3 cylinder motor (~90kg/ 200lb) so there should be enough wiggle room for batteries. I am going to go for a 72V motor so 6 car size batteries will have to find room in there...

 

MAY 9, 2008 After some resistance the motor came out along with a bunch of other un-nessesary parts (carburators, Exhaust Set system, air box, radiator and some nasty fluids. Total weight removed: 117kg/ 258lb

MAY 27, 2008

Managed to sell all the ICE (Internal Combustion Engine) parts. Now the work area is cleaner, plus, I got some cash back wich will probably pay for a battry or two.

I ordered "Secrets of El Ninja"

Started narrowing down my options/ prefrences for motor, controler, batteries and charger/s.

I will be ordering within the next couple of weeks, till then I will start work on the gas tank and replacing the handlebar with a more comfortable one.

June 16, 2008

Finally, the main order has been made. After checking multiple sources and options I have ordered from "electricmotorsport.com"

Shipping costs to Canada dictate that I order as much as possible from one source. Could have found better prices/ cheaper components but if I split the order to 3-4 places I end up paying pretty much the same.

I went with the "E-tek-RT 72 Volt Motor Drive Kit "

Power: 8 continuous -- 19 peak hp
Voltage: 72 Volt rated
Speed: 3700 rpm @ 72V unloaded
Size: 8" OD, 6.5" long (with out shaft)
Shaft: 7/8"x 1-3/4", 3/16" key
Weight: 38 lbs.

The kit includes: E-tek-RT Motor, Alltrax AXE 7234, Magura twist grip throttle, Contactor, Wire kit, Fuse and holder. I added a DC-DC convertor

I have also purchased one of six chargers. I will be using one charger per battery. Main reason is to cut on cost but there are other advantages as well (and dis-advantages)

June 17, 2008 Finished stripping the old layers of paint from the gas tank. . Started creating carton models of the motor and batteries to test how they fit.

June 27, 2008

A big box arrived today (darn that motor is heavy)… Nobody asked for customs and such, Happy :-)
Had to hook it up to a 12V battery just to see it working, that is one angry motor..

For some reason the wire kit wasn't included... They sent it over later.

Update on the customs: They charged it to my employer Fedex account (that was my delivery address) and I had to pay...

Went out and bought 6 Discover D12350D 12V 35Ah batteries with matching 2Amp chargers.
These batteries are not the strongest in the market but have the best size/ price/ comfort ratio:

• They are 19.5 X13X 18h including terminals
  
• I found them locally, so no shipping handling and customs
  
• Only 10.2kg/ 22.5lbs
  
• Price that wouldn’t break thee bank

The chargers ended up costing less then half then the fancy 72V (Zivan, NG1..). They will take longer to charge, but most of my charging will be overnight anyway.

Made a cardboard “model” of the motor mounting, with all the measurements, so I can take it to welding and machining. Would have loved to do it myself but don’t have the time, tools and place to do it properly.

Aug 6 , 2008 Finally got the motor mount with all the chain sprockets etc. Took some final adjustment but should fit perfectly. I had to add another little shaft to support the final drive shaft, so the whole mount + engine ended up taking a bit more room then I wanted .

Aug 7 , 2008 Mounted the motor, connected it to the final drive shaft. Started connecting the Battery Trays (With the carton stand-ins for now .

Stats'

Project photo Album