RMZ 450 electric conversion

R

rivvs

100 W
Joined
Nov 17, 2019
Messages
182
Location
Quebec
Hi, I wanted to show the bike I built this summer maybe it can give idea for a build you want to do.
Bike: 2010 rmz 450
Motor: qs138 90h
controller: ASI bac 8000
Battery: 20s20p molicell p26a with cell level fuse. 3.7kwh
6.23:1 gear ratio
Right now I am at 450 battery amp and 600 phase amp.
Anybody familiar with ASI controller here? I have got two problems first I was not able to get the motor temp sensor to work and is it possible to set regen as engine breaking? I would like regen to work when i let off the throttle.
Video of the bike in action
https://www.instagram.com/p/CIZPpj7BruU/?utm_source=ig_web_copy_link
20200815_175559.jpg20200821_153247_HDR.jpg20201001_184210.jpg20201002_164357.jpg128551031_677840502879441_2242137685330690804_n.jpg
 
Oh wow, great job.

Do you have any more pictures of the primary reduction?

Always wanted to make my own battery pack with cell level fusing, maybe in the future. What is the total weight of your battery pack and total bike weight now?
 
The bike weight 255lbs so around 20 lbs lighter than the original and the battery pack weight 46.2lbs.
20200903_152205_HDR.jpg20201130_132837.jpg
 
Hi from Portugal. thats a really nice bike with decent performance.
Im trying to build a bike also with the qs 138 90h so i wonder were did you get that small sprocket for the motor?
Mine come with 14 tooth only and cant find anywere to buy a smaler like 11 or even 12 tooth.

Best regards
 
guiga said:
Hi from Portugal. thats a really nice bike with decent performance.
Im trying to build a bike also with the qs 138 90h so i wonder were did you get that small sprocket for the motor?
Mine come with 14 tooth only and cant find anywere to buy a smaler like 11 or even 12 tooth.

Best regards
Click to expand...

I bought a sproket for a ktm then I machined both the sprocket and the pulley from the motor then welded them together.
 
rivvs said:
guiga said:
Hi from Portugal. thats a really nice bike with decent performance.
Im trying to build a bike also with the qs 138 90h so i wonder were did you get that small sprocket for the motor?
Mine come with 14 tooth only and cant find anywere to buy a smaler like 11 or even 12 tooth.

Best regards
Click to expand...

I bought a sproket for a ktm then I machined both the sprocket and the pulley from the motor then welded them together.
Click to expand...

Agreed, this looks awesome!

Do you have any concerns about chain wrap angle? That sprocket is pretty small, you may see some issues, or at the very least excessive noise.
 
Additional question, if you had to start this process again from scratch, would you do anything differently?

Very inspiring, I am looking to do something like this myself.
 
dforesi said:
Additional question, if you had to start this process again from scratch, would you do anything differently?

Very inspiring, I am looking to do something like this myself.
Click to expand...

If I would start again I would use gear for primary reduction because the chain is very noisy.
 
I just saw this come up, haven't been able to find much info on it:

https://www.aliexpress.com/item/1005001515841817.html?spm=5261.ProductManageOnline.0.0.7c004edfcrfahE&fbclid=IwAR3B3RrTTphuAqVwaOXSwbdE2qZs8qNfVWZv2WvSkNgXZraNbUad7bRfvkQ
 
What details do you have on the battery pack? How was it constructed, strip dimensions, materials, bms ETC.
 
What kind of phase amps and battery amps have you been able to pull from the ASI 8000? Thoughts on using the ASI instead of the Votol 150?
 
dforesi said:
What kind of phase amps and battery amps have you been able to pull from the ASI 8000? Thoughts on using the ASI instead of the Votol 150?
Click to expand...
I'm at 450 battery amp and 600 phas amp. The bac 8000 can go to 800 phase amp.
 
Looks great! Please post some more videos! How do you handle balancing? Done off board during charging or do you have a built in?
 
Routybouty said:
Looks great! Please post some more videos! How do you handle balancing? Done off board during charging or do you have a built in?
Click to expand...

Bluetooth BMS in the battery pack.
 
I am curious about the cell level fusing. I can't tell from the picture what you are using. I used 7mm of tinned copper 28 awg wire on a battery build. It was inside of a small Teflon tube and soldered at both ends. Good for around 30 Amps. My method is labor intensive and I wouldn't mind finding a better way. BTW did you get your regen working?
 
cell level fusing is made using resistor legs. I spot welded the resistor legs to the battery. I still waiting for the snow to melt here so no testing have been done yet.
 
Very nice, so with that fusing, what's your calculated max draw?
I have a bunch of molicel P42As that I need to build a pack out of.
What's the spec on the resistor leg? Looks alot like a tesla build.
 
With this battery desing I was maxing out the controller at 450 battery amps.It worked very well no overheating etc. the max temp i saw from the battery was 37 degree celsius after an hour of riding. Then out of nowhere it caught on fire while parked in the garage.169686319_453055079299650_4466506163224294137_n.jpg
 
Condolences thats a damn shame 😔.

Lets us know if an autopsy reveals anything.
 
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