Fazer Conversion Completed

Folks - just thought I'd share my project that I just completed this weekend - UK MOT test this weekend and if it passes I'm street legal

Cheers,

Mike.

Very nice! Tell us all about it!

Thanks!
A few more details

Yamaha Fazer FZS600 2000 Year
Enertrac 602 Liquid Cooled Hub Motor
Kelly KLS8080 400 Amp Controller
Kelly HWZ 325w DCDC
Kelly Charger
13 Leaf modules, Bulk Charging to 107.9v

I bought the Donor bike back in June last year as I just needed a project to keep my brain ticking over! I commute on an NC750X DCT into London everyday, if I can sort out some charging here I'll start using it instead.
It's been an interesting build and I've learned loads, which was the point really.
Hopefully start getting some miles on it next week and see how it performs - so far it's only been about 100 yards up the road, but feels super smooth...

Cheers,

Mike.

I'll be interested to hear how you get on with insurance. I suspect anything home-made (no matter how well done) will be difficult and expensive to insure.

It's insured already.... Yes it was challenging to find insurers, but not impossible and not prohibitive.

Great conversion!
If you have any more photo's of the progress please post them here. Or a link to a build site? Would love to hear how it performs if you start to use it more.

Nice job, great feeling isn't it. Good luck for the MOT, next steps are video footage and performance data.

Bernel

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A few more pics of the build as requested!

Nice, where did you get the Leaf batteries from?

Bernel

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MOT passed, Taxed (free!) Now street legal...... And it goes rather well....

Except at the moment, it doesn't. First ride out, and 40 miles in (with about 20 remaining) and I start getting a clicking noise from the motor, although it continued to run normally. Spoke with the manufacturer and he thought it was a bearing. Stripped it today and sure enough a sealed bearing was dry inside. Not their fault, they don't make the bearings, just one of those things, it'll be up and running again in a few days. Love it!

Hi Mike,

Glad to hear it passed the MOT and you are on the road. Looks like a lovely conversion.
Do you mind telling us who you got insured with?
Most of us guys in the UK with modified gas bikes seem to be with MCE and I just wondered if you found someone else who would cover us.

- Spata

Hi Spata - yep - MCE, I rang at least a dozen 'Specialists' but MCE were the only ones that would insure it.

Cheers!

Mike.

So - major problem this weekend.

My Kelly KLS 80801 controller released the magic smoke. Just pulled away from a junction, and at about 20mph there was a series of loud pops followed by much smoke. I hit the emergency cutoff, but the controller is toast.

I have an email in to Fany at Kelly to see what we do now - only had 4 rides out since I finished the bike. Confidence not high in the Kelly controllers right now.

I'm hoping nothing has been damaged in my Enertrac hub motor, need to find out how to test the windings / halls if anyone has any info?

Cheers,

Mike.

the easiest way to test the windings is with an LCR meter (or just an LC meter) as the reading from an ohm meter will be too low to interpret.
check the inductance (l) of all the windings to see if they are approximately the same
for halls, power them with 5v, put a dmm between the hall signal and gnd and turn the wheel, you should see the signal rise and fall between around 0 and 3.5v , check all 3 signal lines that they give similar results, albeit in different wheel positions.

Gutted to hear such a small shelf life to your kelly. What about MOBIPUS or APT controllers? One day id like to do a conversion like this from scratch but i have taken the easy option of putting lifepo4 an already electric moped.

Yikes, that's some bum luck man. I wonder what controller you're using exactly (e.g. KLS14401...). Did you overvolt the controller, e.g. run 108V on a 96V controller? I could see overcurrent being an issue too, as that happened to me before. I think it's good to dial a Kelly back down a bit, or else invest in a beefier one. My 500A controller drew a measured 620A once, at 70-75V. I used to not worry, thinking it would kill the motor before anything (just an 8kW QS hub), but one day the Kelly failed catastrophically after taking off with WOT. Might've blown a cap from too much power. I try not to go past 450A now bursts now. Just safer for it, though they should be hardware protected from nuking themselves (overvolt, overcurrent, overthermal hardware self-protection in the description... however their, translations aren't always the greatest, so what I'm taking to be built-in hardware self-protection might actually be referring to the programmable features one can enable optionally in the controller app, I see now in retrospect). Either way, I hope Fany sorts you like he did me. I really like your bike BTW.

You can also test the windings by using an oscilloscope on them and manually spin the wheel to see the waveform. Put the scope ground on one phase, and the scope signal on another phase.

You should get the same waveform (though phase shifted) regardless of which pair of windings you put the scope leads on. It will probably be a sine wave, or close to one.

Voltage expected would be determined by the motor's kV, and the RPM you spin it at.