E-Bike XB502 conversion project

General Discussion about large electric scooters and motorcycles and other things with no pedals.
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ElectricGod
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Re: E-Bike XB502 conversion project

Post by ElectricGod » Jan 14, 2018 3:49 am

The chain line is finally done! It shouldn't have been this hard, but it was. I made 3 wood mock-ups and tried different places on the swing arm. All of them had issues. I finally went with a smaller roller and that fit in this location nicely and solved all the issues I was having with running into the swing arm with the roller or the chain. I've spent several days now trying different rollers and tensioner locations. It took a loooong time to get the chain line right, but it's silky smooth, dead straight and doesn't interfere with anything now that it's done.

The final tensioner took several hours to make and tweak, but it's rock solid and works perfectly. The 3 holes need to be elongated so that it will slide up or down the swing arm a little as the chain stretches and it needs to be painted. Otherwise it is finished.

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This location gets the return side of the chain away from the swing arm. Having the chain graze the swing arm was causing me lots of problems.

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ElectricGod...it's a joke...don't take things so seriously folks!

XB-502 Moped:
https://endless-sphere.com/forums/viewt ... 0#p1222730

Currie scooter:
https://endless-sphere.com/forums/viewt ... 7#p1227407

SlowCo
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Re: E-Bike XB502 conversion project

Post by SlowCo » Jan 14, 2018 5:34 am

Why the chain tensioner when you can just slide the rear axle further back?

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ElectricGod
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Re: E-Bike XB502 conversion project

Post by ElectricGod » Jan 14, 2018 6:38 am

There we go...slotted.

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ElectricGod...it's a joke...don't take things so seriously folks!

XB-502 Moped:
https://endless-sphere.com/forums/viewt ... 0#p1222730

Currie scooter:
https://endless-sphere.com/forums/viewt ... 7#p1227407

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ElectricGod
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Re: E-Bike XB502 conversion project

Post by ElectricGod » Jan 14, 2018 6:55 am

SlowCo wrote:
Jan 14, 2018 5:34 am
Why the chain tensioner when you can just slide the rear axle further back?
For several reasons, one reason is because of how the brake caliper mounts. One end of the bracket is trapped on the axle.

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See that 8mm pan head bolt just above the brake caliper? It threads into the swing arm and then threads into the bracket for the brake. Even though the axle has a tensioner on it, the 8mm bolt won't allow the axle to move since it's all locked together.

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And then finally, the chain needed to be lifted up so it doesn't drag on the frame right below the motor. Notice how the return side of the chain just grazes the frame? It makes a good bit of noise and of course wears on the frame. The chain tensioner solves this issue.

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The chain is lifted away from the frame where it grazes the frame as the chain passes over top of it.

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ElectricGod...it's a joke...don't take things so seriously folks!

XB-502 Moped:
https://endless-sphere.com/forums/viewt ... 0#p1222730

Currie scooter:
https://endless-sphere.com/forums/viewt ... 7#p1227407

SlowCo
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Location: The Netherlands

Re: E-Bike XB502 conversion project

Post by SlowCo » Jan 14, 2018 12:53 pm

Ah, now I see!
I've been following some of your threads and like the work you're doing. Good luck finishing this.

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ElectricGod
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Re: E-Bike XB502 conversion project

Post by ElectricGod » Jan 14, 2018 6:50 pm

SlowCo wrote:
Jan 14, 2018 12:53 pm
Ah, now I see!
I've been following some of your threads and like the work you're doing. Good luck finishing this.
Thanks!

Lots of people read my threads and then PM me about their builds. I've gotten requests for help from all over the world. Quite often we stay connected for many months as I help them work through their issues. A few months ago I was working with a guy from your country. Right now I'm working with 3 people from NYC, San Francisco and Romania.
ElectricGod...it's a joke...don't take things so seriously folks!

XB-502 Moped:
https://endless-sphere.com/forums/viewt ... 0#p1222730

Currie scooter:
https://endless-sphere.com/forums/viewt ... 7#p1227407

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ElectricGod
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Re: E-Bike XB502 conversion project

Post by ElectricGod » Feb 12, 2018 4:09 am

I've been busy with LED's and chargers and batteries. I also got the Pantera moped running and sold it off for $400. I had a bunch of SLA's and an old controller that went in it to get it running. Cost me nothing but an hour to get it running again. Anyway, it's been a while since I made any progress on the moped.

I got a new throttle for it and installed it, brake lights are hooked up now and the XHP70.2 headlights are in place. Since I've never had a working throttle on here before, I've never known which way the motor turns. Well it's backwards...go figure! That's pretty easy to straighten out. There's always something I suppose.

The headlights have been done for a good while. They were waiting on free time to get them installed and wired up. I took the lens ring off and used that to figure out where to cut out the headlamp shell for the new LED lights. I also got better reflectors which needed some slight massaging to make them fit the LED shells, but that's all done now. The lights are glued in place by their front lens rings. The backs of the lights sit on some plastic parts inside the moped.

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Dashboard.

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Rear running lights and tail light.

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Brake light.

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Front running lights.

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These handlebar lights are actually 2 sets of LEDs...yellow and white. I really wanted to use the white LEDs for another set of running lights and the yellow ones for flashers, but they wash each other out so they all became directionals instead.

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Low beams...they are cheap Chinese LED headlights, but plenty bright enough.

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Because of the shutter closing down, it's impossible to show how bright the high beams are. Suffice to say, they are plenty bright!

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ElectricGod...it's a joke...don't take things so seriously folks!

XB-502 Moped:
https://endless-sphere.com/forums/viewt ... 0#p1222730

Currie scooter:
https://endless-sphere.com/forums/viewt ... 7#p1227407

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