I have spent quite some time marveling at the creations of others and heeding the wise advice of many in this post.. quietly accumulating knowledge and
motivation to develop my own electric motorcycle. This is what I was able to create with some research and much wisdom from this forum
I build this electric motorcycle for my mechanical engineering individual final year project with guidance from my lecturers and much assistance from the
faculty technicans. The concept was the design and build a zero emissions vehicle which could be used for Caribbean suburban commuting. Though most
Caribbean islands are small the infrastructure in more rural areas is insufficient for a Zero emission vehicle so the suburbs was the target area.
Using much product n market research via surveys etc the following specs were attained
Geared top speed: 72KPH
Range: A min of 25miles (calculation based)
48V using four 40Ah SLA batteries,
using a MARS ME0708 motor with an Alltrax 4834 controller
Hall Effect throttle used with a 9AH 12V battery to produce signal voltage
Donor frame: Yamaha ZX600E (1993)
Gear ratio 1:5 (done in 2 stages)
The electric drive was designed as an integrated system much like an ICE with a modular construction such that all components (motor, controller etc) could be
easily removed via bolts for repair or upgrade. The drive is mounted utillising the standard mounting points of the donor frame (ZX600) but the mounting
brackets can be changed for mounting on other 600cc motorcycle frames
The subframe of the drive was fabricated using 1" mild steel RHS 1" square tube
The drive uses a pulley - chain and sprocket power transmission with a triple groove pulley belt on the left to give a gear reduction of 1: 1.67 on one side running across a jack shaft to a chain and sprocket system using the original sprockets on the bike to give a total gear reduction of about 1:5 .... a larger rear wheel sprocket would have made this reduction much easier to achieve but funds and availability of such a part in the Caribbean led to the use of the current power transmission.
A hall effect throttle was purchased for the ALLTRAX control because i didnâ€™t know any better
. As a result we ( my elect. technician and I) used a small 9V SLA battery to create a 5v signal for the throttle using an Amplifier circuit i think ( he made it ) The damn throttle unfortunately refuses to read 0v on start up as a result the wheel moves on start up. A cheap fix was a reset switch for the throttle, we used the on off switch from the donor frame since it was right next to the thumb. This switch allowed you to turn on the bike without moving, when u then flick the switch you then get the motion and throttle control.
To reduce the weight and give the bike its own identity I carved a seat and tank from carving foam which was layer with fiberglass and coated with body filler to provide a smooth finish. I was going for more classic Cafe racer look than the naked sport bike feel.
The tail of the bike was made large enough to hold a 48V 6A SLA charger(not yet implemented). Last time I charged the bike from really low it took 4 hours so Iâ€™m guessing 6hrs from dead ?
All in all this project was a challenge, particularly since nobody but me seemed to know what I was doing or even why, many were skeptical and were certain it would barely work if at all ( an electric motorcyle) since the EV concept is still just a fairy tale in the Caribbean, but I think I did a good job of illustrating this talehttp://www.youtube.com/watch?v=t0zzpjFCze8http://www.youtube.com/watch?v=rQFzwURZ76Q http://www.youtube.com/watch?v=ktqgQHG0yZQ
Hope you enjoyed viewing the build as much as I enjoyed making it