First E-motorbike build @ Bali

[Wayan]

Hi all,

Ive been a long time motorbike rider, and have owned several IC bikes. I currently own a Kawasaki Z250, and have had several Ninjas prior to this bike.

Several months ago i was fortunate enough to have my mountain bike converted by Ewabi (ebike company here) and ive gotten my first taste of the Electric drive train, and really love it!

Its running a 48V 18659 battery pack with like 15ah. 1000w hub motor and used to to have a generic controller. We have since replaced that with a Sinewave Kelly controller and the bike runs so much better!

After letting a friend use my e-bike, hes also fallen in love with it and asked me to help him to put together the same kit on another frame. However he wanted to go one step further and make the battery and controller box built into the frame.

I was able to find a bike fabricator who could weld aluminium and got to work with prepping all of that...

Donor bike~

bike stripped and sand blasted

Triangle side panels were fabricated:

and checked it over for fitment~

Got some Screws for the side panel that we will make removable to access the insides

And then started welding

We plan to grind down the welds to a clean finish and have the whole frame polished/buffed up to a shine. However this is now how far we have gotten with that project.

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What brought me to wanting to build an electric motorbike was an unexpected gift from another friend, Who gave me a bunch of parts that hes taken off his Ninja 250, while heavily modifying his bike. i got the original Rims, rear swing-arm, whole front end, and an extra brake caliper (so got both front and back calipers!)

Both Stock and KTC calipers had a horrible paint jobs done to them, which im stripping back off, lol

My friend is replacing his whole front end with a R1 replacement (left of the pic), lol

So i took the opportunity to sell all my e-bicycle parts to go to the other custom e-bike that we are working on, so the money from that can go towards the new E-motorbike im building! :wink:

At this point im trying to figure out what controller, motor and batteries to use.

What i have access to (ready stock here, which saves me ordering parts from china) here through my e-bike mecanic is:
Kelly controller: KLS7230H (72V, 100A continuous & 300A burst Sinusodal) http://kellycontroller.com/kls7230h24v-72v300asealed-sinusoidal-wave-bldc-motor-controll-p-1449.html
Golden Motor: 5Kw water cooled 72V BLDC. http://www.goldenmotor.com/eCar/HPM72-5000Curve .pdf
Battery: build packs from 18650 cells or 26650 cells or something like Headway LifePO4 38120S cells (can imagine it would be easier to bolt these larger cells together rather than using tons of nickle ribbon).

As for the bike, i will probably have to get a custom frame fabricated to attach all the parts i was given from the Donor Ninja 250.
I am leaning towards a retro look (cafe racer) bike theme~ inspirational pics along these lines:

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Im hoping that some vetrans could give some insight into this build that im getting my self into, and the dos and donts of E-motorbike builds~

Thanks in advance, and i hope to post update on the progress as things come together here 8)

 

[amberwolf]

My first recommendation is to look at the other MC build threads, and then the high power bicycle threads, especially a couple of recent ones by r58 where advice has been given regarding batteries.

 

[Wayan]

Managed to buy a frame from a Suzuki Bandit 400.

So now the inspirational design will come from something like this:

Since i have the same frame at least, and it gives me a decent idea what the bike could look like once its been trimmed down.

Im in contact with Revolt to see if their RV-160-Pro is a suitable fit for my bike.

Im also trying to source larger Lifepo4 Cells from Headway. Would love to get their 10~12 or 15 ah cells. would mean a lot less work connecting fewer cells compared to using 18650 cells.

Thats about all for now with the progress here

 

[SlowCo]

Managed to buy a frame from a Suzuki Bandit 400.

Im in contact with Revolt to see if their RV-160-Pro is a suitable fit for my bike.

Im also trying to source larger Lifepo4 Cells from Headway. Would love to get their 10~12 or 15 ah cells. would mean a lot less work connecting fewer cells compared to using 18650 cells.

Nice builds!
Regarding the revolt motors, they don't seem very well suited for ebike use:
https://endless-sphere.com/forums/viewtopic.php?f=28&t=86532

https://endless-sphere.com/forums/viewtopic.php?f=30&t=85534

It may be better to get a more rugged motor like a 18 kW Cyclone:
http://cyclone-tw.com/order-motors.htm
Or a 20kW BLDC GoldenMotor:
http://www.goldenmotor.com/

Regarding batteries search for threads on here about Nissan Leaf, Chevy Volt or other OEM car manufacture battery packs

Good luck building!

 

[Wayan]

So some progress has been made with the custom alu frame box for my friends E bike~

Loaded with as many 18650 cells that we could cram in.

Sadly there was a mistake done by the welder, and the internal space was about 10~15mm narrower than what i asked for, so the battery cells could ont be oriented the way we wanted to.

So in the config we are running a 48V and 14ah battery pack i belive, with a kelly sinosidal controller and a 1000w rear hub.

We have now taken it all apart again and brought it to get buffed and polished up to a shine.

On a side note, back to my E-Motorbike build, im trying to figure out if we should use Lithium cells or Lifepo4.

My e-bike friend has a BMS for lifepo, but has lost all specs for it, and also cant get through to the supplier anymore.

The brand is KEVIN (i searched it online but didnt find anything)

Would anyone know where i could find any info for this BMS? or maybe a link to a thread where this unit has been possibly used by someone else.

Thanks!