As some of you know we have been working out of Calfee Design
on a Power Systems Division.
We are about to put together a poll to determine what people want to see as an upgrade to their 2012 to 2017 Zero Motorcycle.
Anything from turn-key install, to a kit, to pieces and parts, to support.
We are also looking at providing power systems to those not on the Zero platform already.
Here are some of the options we have prototypes of:
1) Upgrade an existing Base Model Zero
You remove your motor and Sevcon Gen 4 size 4 controller and ship to us as a core charge.
We return a new programmed Sevcon Gen 4 size 6 controller
We return a professionally machined motor to handle the additional power
We provide mounting provisions, basic install guide, and limited support
As an option we can provide a "reverse switch" pigtail
As an option we can provide a "Variable Regen" pigtail
This modification can turn an S into an SR and an FX into a monster.
All original Zero functionality preserved including the MBB
2) Roll your own power system that is clean
We have a Sevcon harness that eliminates the Zero MBB for those running other applications
Harness is connectorized to expand to any form factor and IP67
We can provide Sevcon Gen 4 size 4 or size 6 controllers programmed for the Zero motor
If you have a Size 4 programmed for a different motor we can move this over to a size 6 for you
We have very early prototype batteries (that is some months out) - think carbon fiber and modular
We can program any aspect of the Sevcon and harness any functionality required or desired
We can support you in tuning and further modification.
We are currently funded through grass roots effort
We may consider Kick-Starting or otherwise attracting investment
We have working prototypes, pictures, videos.
We have a motor dyno running
We have commissioning for Sin/Cos encoders running
We have tooling for the OEM connectors and a pilot production line
We have an OEM arrangement with Sevcon and parts suppliers
We have several customer projects going including a strip-down version of the Zero
* CA on the handlebars
* New harness eliminating the proprietary equipment
* Pin compatible with existing zero gear (like the battery, motor, controller, and accessories)
* Different battery form factor in Carbon Fiber
I come from Aerospace (10 years) so I completely understand the rigor and requirements of harnessing and connectors. We can not only meet but easily exceed existing OEM quality.
Increasing battery voltage and controller current limit will result in a non linear experience