Electric motorcycle check list?

Snowmnason

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Hi. I am not engineer but my buddies who are and I want to start the huge project of making a custom street legal motorcycle from the ground up.
So I am the designer and the test subject (I have a license and they have the desire to build) what would be a check list to all the parts i would need? And of it isn't to much to ask the order I should consider when we start working.

I.e. I need a battery, a motor, breaking system....

And

I would need to build the frame. Then attach the battery then the motor/wheels, then wire the thing.

I will be reading every topic on this fantastic website for tips and parts but I want to make sure I hit all the stops
Thank you so much. For the help. I live in NY if that makes any difference
 
First, you must decide exactly what it is you want this MC to do for you, and how you want it to do it.

Then you would look at other MCs (of any propulsion type) that do those jobs well, and design yours based on the parts of those that do those jobs, and all of the principles of how things work to do those things.


Then you can look at electric builds like those here on these forums that do the same jobs you want to do, and do them well, and use systems like they used. If there aren't any that do what you want, then you can still read them for all the questions you must answer for yourself that will allow you to figure out the systems you will need.


But if you don't have a clear idea of what you want, and a specific set of requirements the design must meet, you don't have anything to guide you in making it, and so you don't have any way to determine what to use to build it with, or what it needs to be built like.

So that is your very first step....

...Right after you check with your local DMV or whatever to find out what it takes to register a custom MC. Some places don't have a way to issue a VIN to individuals, and/or not allow modifications to a frame, or other restrictions, so you may have to build your bike on an existing chassis...which means defining what you want in a way that lets you do that.
 
This would be helpful for someone who understands the lingo. I know I want a bike similar to (an automatic) cruiser/sport touring. I don't plan on reaching 100mps just to get to Point A to B. So when you say propulsion type I would need to read through the form to find the right type of course.

But I guess the first step is contact the DMV
And find a model bike I would want to base my build on? Or get a frame and go from there.

I do appreciate the help! I guess I have a lot more reading to do then I thought lol
 
Snowmnason said:
This would be helpful for someone who understands the lingo. I know I want a bike similar to (an automatic) cruiser/sport touring. I don't plan on reaching 100mps just to get to Point A to B.
THen there's a start.

Do you want a big touring bike like a Goldwing or a Voyager with a long range and lots of storage? Or do you want something lightweight but shorter range that can't carry anything?

You must decide what you want it to do for you before you can start.

If you do not sit down and make a *complete list* of exactly all the things it must do, then you can't design it to do those things. You might end up making a bike that happens to be able to do some of them, but there will be things it cannot do so you will be unhappy, especially if they end up being major parts of what you want to do.

So make a list--here's a few things to start with, though there's a lot more you'll have to come up with depending on your needs:

Some electrical design things:

Max range you will need, ever, without recharging.

How quickly it has to recharge--what is the maximum time you can wait before going out on another maximum range ride?

Max speed you will need, under any condition you might ride in (high winds, up steep hills, etc)

Do you need quick acceleration, or do you mind if it takes a mile to get to 30mph? And does it need to do that under all conditions, or just under perfect ones?

Some mechanical design things:

Do you need it to be nimble, or is it ok if it's sluggish and have to slow way down for corners and such?

Do you need to be able to pick it up yourself when you crash it or knock it over, or do you mind having to get at least one ohter person to help you?

Do you want a "cool" looking bike, or just functional?

Do you want pure aerodynamic, or practical?

Do you have a weight or size (length, width, height) limit?

How much weight does it have to carry? (you, and what or who else?)


You also need to think about conditions you'll ride in.

What kind of roads will it be used on?

What kind of weather will it be used in?

What kind of terrain do you have to ride on?




So when you say propulsion type I would need to read through the form to find the right type of course.
No. Propulsion type just means gasoline, diesel, steam, electric, hamster wheel, whatever.


But I guess the first step is contact the DMV
Yes.


And find a model bike I would want to base my build on? Or get a frame and go from there.
No. You must answer for yourself all the questions above and list for yourself all the other things you might want it to do. If you just randomly start with something, you are stuck with it's limitations, and they may prevent you from doing what you want.

If you just want to convert a gas motorcycle to electric, it's fairly easy--there's a lot of threads here on doing it with hubmotors. But whatever you start with limits you to what it can do.

If you are starting from scratch, designing something, you should do it to your needs, your purposes, but it's a lot harder than a simple conversion, because you have to know how motorcycles work, and why everything on one is setup the way it is for a particular type (wheel size, wheelbase, steering angles / rake / trail, suspension or not, type of suspension, amount of travel, weight, weight balance, etc.).

You can approximate this by finding a bike that does the things you want it to do, and copying that basic design in your own. But knowing what each thing actually does, how it changes handling, etc, will let you make exactly what you want. ;)


I suspect you're going to end up doing an interative approach, where you just convert a gas bike the first time, then find all the things you don't like about it, and change them for the next version. That at least gets you on the road soonish, but it costs more to do this wya (just not all at once).

You'll still need to answer all the questions and define your needs, but for this purpose it is to establish a baseline for the battery, motor, controller minimum, and then figure out which bike to start with for a conversion, so it will do the things you want *and* have enough space for the battery to give you the range you need.
 
Given that you are new to this, you don't want to build a frame. As noted it may also be necessary to use an existing bike for ease of registration. So after you compile that list of What The Bike Must Do you should then look for input as to what commonly available gas bike frames would support a drivetrain that meets those wants and needs. It sounds to me like you want either a small or mid-sized chain-driven street bike frame, but that's only a guess.
 
I really REALLY appreciate your time for helping a dingus like me. and this project means a lot more to me now, for the fact I can't get a motorcycle on the road because of the pandemic so it will be a fun little project while I wait for a gas one to be street legal to practice more.
To answer those question (mostly for me to see easily)

Max range- probably like 100 miles, I live on Long island so nothing is too far, I don't expect to go cross country any time soon!
Max recharge time-probably min of an hour because I wanted to use this to go to school (where they have electric charges and saves on gas)
Max speed- 60 is the min, but the ability to go to 100 or so would be a cool pissing contest ya feel
Quick Acceleration- Doesn't matter, I am not looking for a speedster, I am just looking to make someone awesome looking to make people look at me with awe
Does it need to be nimble- Nah, not really I am still a relatively new ride so it would be a good habit to start of with it this somehow becomes my first bike. Plus the design (Chassis) is probably on the fatter size
Do I need to pick it up myself- yes definitely
"cool" looking bike-HELL yes, I want to be able to take this to car meets and as I said before to make people look at me with aw, but the more functionality the better if this could be MY bike I would love that
Aerodynamic or practical- Practical
Weight/size- I haven't put much thought into it, the lighter the better because if I could throw this in the back of my pick up would be helpful but that is something I need to consider when I answer all these questions and do more in-depth research.
Carry weight- I weight 240, so it needs to hold at least 400 if I EVER have a passenger.
What kind of roads-Primailry high ways (as I said most a way to get to school if this would be my normal bike)
Weather- Sunny days, no rain, no snow, no high winds, I ain't riding within the next 5 years in bad weather unless I need to
Terrain- Mostly flat.

Went to the DMV found out I can start from strach, but I need to double check

If you are starting from scratch, designing something, you should do it to your needs, your purposes, but it's a lot harder than a simple conversion, because you have to know how motorcycles work, and why everything on one is setup the way it is for a particular type (wheel size, wheelbase, steering angles / rake / trail, suspension or not, type of suspension, amount of travel, weight, weight balance, etc.).
The issue I am having with designing, or starting the designing is I am not sure what parts are needed. i.e. Battery, motor, breaks, horn, etc.

Thank you so much again amberwolf I now am a lot further then I was 2 weeks ago!
 
Max range- probably like 100 miles, I live on Long island so nothing is too far, I don't expect to go cross country any time soon!

Max speed- 60 is the min, but the ability to go to 100 or so would be a cool pissing contest ya feel

I hope that you realize that these are either/or parameters, unless you can spend $10k on batteries. As in: you can go 100 miles OR 70+ MPH, but not both at once.
 
Snowmnason said:
for the fact I can't get a motorcycle on the road because of the pandemic so it will be a fun little project while I wait for a gas one to be street legal to practice more.
Not quite sure what you mean by this part. If you mean you want to build this to ride around, you'll need it to be street legal and registered, licensed, and insured, by whatever rules you have up there, or LEOs will probably notice you don't have a plate and take away your new toy. ;)

If you want to ride something that doesn't need a plate, etc., you'd need to verify that ebikes are legal where you are (NYC had made them illegal, and I don't know that any of the efforts to change that have gone thru yet, because LEOs keep confiscating people's ebikes and ticketing/fining them for owning/riding them). If they *are* legal, then you'd need to find out what the limitations in speed, power, and weight are, and any other limitations, then build a *bicycle* that matches those, that you can pedal around and be assisted by the motor...or risk having the LEOs take it away and charge you money for it too. :(

Max range- probably like 100 miles, I live on Long island so nothing is too far, I don't expect to go cross country any time soon!
Max speed- 60 is the min, but the ability to go to 100 or so would be a cool pissing contest ya feel
If you need to go 60mph for 100 miles, that's going to be a huge and heavy and very expensive battery. If you need to go 100mph for 100miles, I think you will need a trailer. ;)

60mph is, on an average-aero motorcycle, probably going to take around 150wh/mile or more if you are just going with no stops. If there's a lot of starts and stops, it'll take more, and a lot more the higher the weight of everything is, because you're wasting power re-acclerating all that mass over and over.

So to do that for 100 miles, it would take 100 * 150 = 15kwh of battery. That is a HUGE battery, I have a 2kwh battery that weighs around 35lbs, bare, no casing, and is the size of a stakc of hardback books. Yours would be seven times that, so battery alone would be, without a casing to protect it from weather and crashes and stuff, about 250lbs. It will be bigger than a human torso, perhaps closer to two. Gonna need a big bike to hold it, like a Voyager or Goldwing, etc. Not gonna fit on a little bitty sport bike. ;)

Just to give you a real world reference, this electric motorcycle claims 112miles highway use, which I would presume is estimating around 60mph but doesn't say:
With an aerodynamic riding posture that helps deliver up to 223 miles in the city and 112 miles on the highway, the Zero SR offers the highest range in the Zero lineup.
But when you actually look at the specs page, it then gives some more realistic numbers:
https://www.zeromotorcycles.com/model/zero-s
City 89 miles (143 km)
Highway, 55 mph (89 km/h) 54 miles (87 km)
Combined 68 miles (109 km)
Highway, 70 mph (113 km/h) 45 miles (72 km)
Combined 60 miles (97 km)
So realistically you get about half of what it claims. It has a "7.2kwh" max capacity battery, which is about half of what you'd need for your range, and it gets about half of the range you want at the speed you want, so it has about the same 150wh/mile "efficiency" (kinda like MPG in a gas bike) at that speed as yours might.


Max recharge time-probably min of an hour because I wanted to use this to go to school (where they have electric charges and saves on gas)
FWIW, the standard charger on the bike above is a 1.3 kW, integrated charger, and takes about 5 hours to charge it up from about empty. For yours, it would take twice as long becuase your doulbe-size battery would take twice as long to fill up, unless you use a bigger, heavier charger (assuming the charge stations they have can output more power than that--some go up to 3kw or more, which would halve or less your charge time).


Quick Acceleration- Doesn't matter, I am not looking for a speedster, I am just looking to make someone awesome looking to make people look at me with awe
<snip>
"cool" looking bike-HELL yes, I want to be able to take this to car meets and as I said before to make people look at me with aw, but the more functionality the better if this could be MY bike I I'would love that
Well, if you mean look at you with awe as you ride down a street, you'd probably have to be riding something that looks like the TRON bike for that, as the average motorcycle probably doesn't draw much attention, much less awe, and no one will have any idea you have an electric motorcycle even if they think those are awesome (most people don't care). You'd need something that looks radically different from anything you see on the road...which probably means something that is not necessarily built to actually do a job well (other than the job of looking awesome), or be safe or maneuverable under various conditions you may encounter, or be efficient, etc., and is likely to be an engineering nightmare to work out the design for. And might not be allowed on the roads, if your local rules say anything about that sort of thing (probably not...but you'd have to check your DMV about that sort of thing, once you've worked out sketches and guesstimates of size/weight/etc.) ;)

Draw up what you think people would find awesome. Show it to them. See if they do. When you have something they think is awesome (regardless of what *you* think of it, since if your goal is to have them look at you in awe, your bike's job is to satisfy them, not you), then you have a design to work with.


Do I need to pick it up myself- yes definitely
I'd recommend finding people that will lay their bike down for you and let you see if you can put it upright again a few times. Find as many differnet sizes of bikes to see where the limit is for you, then go down a size from there so you can still do it after you've been hurt in the crashes you're going to have. (everybody crashes, and if they're new they'll crash a lot).


Weight/size- I haven't put much thought into it, the lighter the better because if I could throw this in the back of my pick up would be helpful
How much can you dead-lift? I doubt you can lift your own weight, and just the battery could weight that much, and the bike even more (even if you have a much smaller battery), so you will need a ramp on the truck that you can walk or ride the bike up, or a lift built into the truck to do it. With a lift, it has to handle the bike's weight, and the bike can't be very long or it wont' be able to roll onto the bed from the lift, and the weight can't be too much unless it's a big truck, or the front end of the truck may lift off the ground with the lift's weight and the bike's weight both cantilevered off the tailgate end. (unless you have jacks back there to hold the back end off the ground).

Carry weight- I weight 240, so it needs to hold at least 400 if I EVER have a passenger.
You'll also have to design it to carry a passenger--it may be illegal where you are to carry one without a saddle/seat specifically for them, and footpegs for them, etc. You may have to make the bike longer than you want to ensure they are forward of the rear axle, or else you may have wheelie and control/handling problems with them on there.


The issue I am having with designing, or starting the designing is I am not sure what parts are needed. i.e. Battery, motor, breaks, horn, etc.
It doesn't matter about any of that yet.

First you must design the bike itself. What do you need it to do, what do you want it to look like, how do you want it to handle, etc. Then find out how to design a frame that does those things, and suspension that works like you need it to, etc. Or find an existing bike that does that and looks like you want or can be modified to do so without changing the other characteristics.

Designing and building a motorcycle from scratch is not a trivial task. I recommend just looking around the web for people that have done this, and see what they had to say about the process, and how much they knew before they started, and how long it took. If you literally know nothing about it, you could spend years learning enough to start from scratch.

So...what *exactly* do you want? Make some drawings that layout the bike you want, how you want it to be "cool", what you think will make people look at it in awe.

Look at bikes that do what you want to do. See what they're like. What is their steering angle? Rake? Weight distribution? Wheel sizes? Brakes types? Suspension type and travel? Etc.

If you don't know anything about any of those and why they make different bikes for different purposes, go to a motorcycle club and start talking to the members with different bikes to see what they can tell you. You'll learn some of it, see some of it. Then you have a basis to look other stuff up.


I used to design all sorts of vehicles (and other things) when I was much younger. They did look awesome...but none of them were actually practical to build or ride/drive/fly. Some of the stuff that exists now would've looked awesome back then...but today it's just stuff--it's everywhere so noone even notices it. :( Nowadays I just do practical, and let looks work themselves out around that. Maybe if I had a lot of money I'd be able to do both, but there's no time without that.
 
-on moblie so excuse stupidity. And lack of quotes-

My bad. When I said max range I didn't expect my random number to be so outlandish. Highways speed here is about 55 so max speed of 70 at least. And I definitely over estimated the max range WOW max range would probably be like 20-50 (the school I had it mind is 8 miles away, so there back with out a recharge would be important incase there is no charging ports open)...I live on long island, so traveling anywhere is a 3 mile radius lol

When I said "I can't get a bike on the road" is because of the pandemic; I can't make a reservation for registration for vehicles till September or later. So this is just a project to keep me busy since I can't ride legally.

I can actually pick up my body weight lol, but with my new knowledge (and your tid bit on how batteries work helps a ton) I don't think thats necessary lol

Lol I was thinking of a tron like bike. Ever cyberpunk inspired, have some designs in mind for chassis and design, but I need to consider all the things you wounderful people have been saying.

Picking up a bike, my father has this full cruiser that needs work (so no plates :x ) i had trouble with that, but I was able to.

Design first? Okay. I haven't had to sit down to start drawing. I have just been reading lol
 
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