Bernel's new electric motorcycle build

General Discussion about large electric scooters and motorcycles and other things with no pedals.
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Bernel
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Bernel's new electric motorcycle build

Post by Bernel » Sun Aug 20, 2017 1:12 pm

Hi everyone, I will shortly be embarking on a new project to build a road legal electric motorcycle from the ground up. For those who don't know I have already converted a YZF600R and from the lessons learned from my mistakes on that conversion I hope to create an impressive road bike.

I have already ordered a Gen4 Size 6 matched with a ME1507 and I will be sourcing a Nissan Leaf pack as funds allow. I will be starting with a blank canvas but I do have some prerequisites, I want the bike to have a trellis frame, chain drive and full fairing.
So please chip in with any suggestions you may have.

I look forward to all comments and suggestions.


Bernel

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Re: Bernel's new electric motorcycle build

Post by Bernel » Tue Aug 29, 2017 12:50 pm

Just received the Gen4 Size5 and ME1507.
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Bernel
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Re: Bernel's new electric motorcycle build

Post by Bernel » Tue Aug 29, 2017 3:36 pm

My first attempt at designing the frame.
frame rev001.jpg
Frame Rev001
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jonescg
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Re: Bernel's new electric motorcycle build

Post by jonescg » Tue Aug 29, 2017 7:54 pm

Subscribed! :D

Looks good mate! I would advise that you make the seat subframe separate to the main frame. It's one of the first things to bend when you have a crash, even a minor one, so being able to replace it is a good idea.

Also, put the motor a bit lower - you'll want some of that antisquat action for mod-corner stability.

Chris

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Re: Bernel's new electric motorcycle build

Post by Bernel » Wed Aug 30, 2017 12:23 pm

Here is frame rev002 following Chris Jones' comments. I must add I am not a motorcycle frame builder and I am taking my cues from existing bikes of all types. This bike is not going to be for racing it will be a commuter/weekend warrior bike.
frame rev002.jpg
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Re: Bernel's new electric motorcycle build

Post by jonescg » Wed Aug 30, 2017 9:09 pm

I was thinking keeping the swingarm as it was before, but simply lowering the motor about 20 mm relative to the pivot point. You don't want a flat swing arm - only at full compression.

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Re: Bernel's new electric motorcycle build

Post by Mike Edwards » Thu Aug 31, 2017 3:42 pm

Agree with Chris, higher motor mount and swing arm pivot will definitely work better.

Another vote also for rear subframe that can be unbolted. Having it part of the main frame will cause you problems in the long run.

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Re: Bernel's new electric motorcycle build

Post by Bernel » Sat Sep 02, 2017 10:05 am

Here is the third iteration, I think I am getting closer now.
frame rev003.jpg
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I am thinking of using the front and rear sections of a Sprint ST 1050 with the trellis frame sandwiched in the middle. There are plenty of these parts on ebay. What do you think?

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Re: Bernel's new electric motorcycle build

Post by Duck-Stew » Wed Sep 06, 2017 8:41 am

My two cents:

Try to find good used motorcycle parts from as similar a bike as possible to what you're trying to finish up with. Think about final bike weight, bike type (sport, standard, cruiser, etc), rough power output, etc. Then go further and try to find something with a good aftermarket following (as an example: buy used CBR parts ilo: Hyosung 650R parts). Try to measure (as much as possible) what you're after so you really *know* as much as you can about these prior to purchasing. Always try to buy entire assemblies from the same bike (differences arise even between model years).

After all that, go for it.

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Re: Bernel's new electric motorcycle build

Post by Bernel » Fri Sep 08, 2017 6:51 am

Thanks Duck Stew, all points duly noted. I was thinking along those same lines as well. Now also considering a Yamaha FZ1S.

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Re: Bernel's new electric motorcycle build

Post by Mattbastard » Wed Sep 13, 2017 10:06 pm

I'm going to be watching this closely as I just purchased the same exact motor and controller for my build. I'm retrofitting them into a 2011 Zero XU.

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Re: Bernel's new electric motorcycle build

Post by maydaverave » Fri Sep 15, 2017 12:32 am

If you wanted to covert an ice bike with a trellis frame there are a bunch of ktm rc390 and duke 390s out there for cheap.
e-bikekit 50v 9.2ah cellman pack

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Re: Bernel's new electric motorcycle build

Post by maydaverave » Fri Sep 15, 2017 12:36 am

Rc390 trellis frame check, full fairing check, rad looking cheap bike check.
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