Kids Polaris Sportsman 90 Quad ATV EV Electric Motor Swap Conversion Using a QS138 70H V3 Gearbox - VOTOL EM-150-2 - DKD

[bastens_com]

I completed version 2 of my kids quad EV conversion. I figured y'all would like to see it in action and to know some details on how the build went.

https://www.instructables.com/Kids-Polaris-ATV-EV-Conversion/

Top speed well over 50mph, can support an adult rider. Very quick! I am getting about 81wh/mi with an adult rider.

1. QS 138 3kW Mid drive motor with 15T 428 sprocket adapter
2. EM150-2SPsine wave motor controller
3. DKD LCD speedometer
4. Z6 throttle with combination switch
5. 72V battery

 

[builder7]

Nice professional touch with the display.

I have been working on an extremely similar project, but yours has better electrics.
I have a Polaris 90cc frame from the early 2000's. Can't figure out the year or model, but I have been assuming sportsman.
Cyclone 3000w
72 Volt battery
Cheap 40amp control, non-programable that came with motor years ago.

 

[ElectricGreene]

Very cool build! Looks like you did a nice clean install!
I am looking at possibly using the same kit for an 80s Honda odyssey fl250 I would like to convert.
Do you think it would have enough torque for something twice the weight of your quad? And I was also wondering what you use for a charger? I've read lots about building batteries on various sites but I rarely see how people charge their batteries.

 

[bastens_com]

ElectricGreene, I have thought just about the same thing, would it work for a 500lb machine. I would say yes but probably not support faster than 30-40mph.

That being said I did build a second quad that is adult sized. I ended up with a ME1507 based design (later I swapped it for a Zero 75-7R) and it is quick, fast and a blast to drive. I posted info on my facebook account and I update it every once and a while as things change on the machine. Maybe my build will give you some ideas ...

https://www.facebook.com/patrick.basten/posts/10159933967594726

charges for lithium batteries are just a constant voltage / constant current power supply but if you don't know how to pick one of those there are many companies on Aliexpress that will build a charger for the pack you have. You can tell them the number of cells and chemistry and they will tweak their charger for your application. The question you have to decide is how much current your pack can handle AND how much power you do you have at the source. In other words do you want to use a US 110v 15Amp standard wall outlet then you would need a 1500w charger or less. Here is an example charger: https://www.aliexpress.com/item/1005001728208270.html