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Disc Dog

  • Date JoinedJun 24, 2008
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marco19705 years ago
I like the performances of your bike!
Could you help me out here:
I have a 1989 Honda Interceptor 250 VTR that has nothing on it (II took everything away). It has only the frame, rear and front fork, and wheels, I bought a kit from Battery Powered Systems.
They don't make it anymore but there is one very similar at http://www.beepscom.com/product_p/ki-72-p132-k400-r.htm

The one I have is a 72V Perm-Motor (PMG-132-12-72 VDC), Alltrax programmable 450 amp controller (AXE7245), fuse holder for class T with a 400 amp fuse, switch power cutoff (5000amp), PB-5-0-5K lever Throttle (would like to switch to a magura twist grip, though), two 2 gauges cables and all the connectors for the batteries and controller, and 2 starting/deep cycle heavy duty marine/RV batteries of 115 amp 12V each.

Can you tell me how to put all this together or tell me where I could go to have step by step instructions on how to do it?
I already read the "Secrets of El Ninja" book and it only added confusion.
I would like to do it myself, but just in case, do you know of a place that does these conversions?
Disc Dog (author)  marco19705 years ago
Marco, The Instructable does a pretty good job of where to start and gives you a logical progression of what to do and when. But you do need to be somewhat of a 'back-yard' mechanic. You will need to figure out where to put the motor, fabricate the brackets for it all the while making sure you have some easy way to adjust for alignment and [maybe] chain stretch. In other words, you will need a bit of inventiveness to get that kit onto that frame. That being said, if your not mechanically inclined and not a dare devil, then you might go to your local high school and talk to the auto mechanic teacher (most high schools have a shop class that teaches auto mechanics). See if they will put it together for you! I know my local school would do it for me if I asked/needed, and they love that kind of stuff. But you may still have to lend a helping hand, as they may not be that familar with EVs. As for the throttle, just tie that PB-5 to the frame and run a cable from your throttle grip to it. That way it behaves just like a regular bike. That's what I did. You don't neet that fancy grip. Another point, you're gonna need more than those 2 batteries. You only have 24 of the 72 volts that you need. You'll need at least six 12-volt batteries. But get smaller ones! 115 amp/hr batteries are way too big (unless you are going to run a car!) You should be looking for 20 - 30 amp/hr RV batteries (look at wheelchair batteries). If you could use those 24 volts worth of batteries you'll go all day long on just those two, but you'll never get over 20 mph (and besides, I doubt your controller will run on 24 volts). I suspect that your controller is like most 72-volt controllers; it will run on anything from 72 to 120 volts (but not 24).
Thanks for the tips Kentucky! The college where I go to should be able to help me, thanks for the advice. I thought the more amperes the better, that's why I bought two 115 ampere/hours batteries, unfortunately I later realized 6 deep cycle batteries (to get to 72 volts), are really hard to fit in the frame. I was planning of buying other 6 of them at a later time (after testing it), but if I need only 20-30 amperes then now I need to re-plan everything. In all of this, though, I have one other question: The ampere/hours are written on the battery, but how do you find out the amperes? The Ohms? If there is anyone who can answer me, please do... Have a nice day guys!
Love the bike you built. I'm writting the book "how to build your own elcetric motorcycle" and i would like to include your work in the book. i built one of the electric bikes that was used on a TV series on Discovery Science. can you eamil me at cvogel (at) vogelbilt (dot) com. Thanks carl
rabbidgoat5 years ago
Love your bike -I want to build one but I need same approx speeds and a 25 mile range . Would a 2 speed or variable speed belt drive make 25 mile range possible ? Any info at all would help ! Thank You ... James
Disc Dog (author)  rabbidgoat5 years ago
James, Having a 2 speed transmission would definitely help, but it won't double your mileage. Its biggest benefit would come in stop-n-go traffic. Normally it might give you 20% - 40% better range. Most single speed bikes (like mine) are optimized for 45 - 50 mph. Since electrics have so much more torque (than gas) at slow speeds, they don't need that lower gear to get started down the road. But they do use a lot more energy for the same equivalent horsepower before they get up top speed. This is where having a lower, 'start gear' would help. However, the actual cost of incorporating that 2-speed transmission and the additional weight may 'out weigh' the cost of a better battery pack though (which would give your 25 miles range), so you may have to do a little home work and [just maybe] a little experimenting to find the economic break-even point. But remember, the one advantage that an electric vehicle has over ICEs is that their range and performance can usually be upgraded over the life of the vehicle with a simple battery swap and a controller upgrade. Use that to your advantage when building your bike.
Kentucky pride, my friend. Kentucky pride.

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