RMZe my first attempt to electricity

[Pete's moto]

I've been navigating these forums for a while now and try to retain and learn as much as i can.
I'm very new to this, more mechanically inclined than electronics but my background is in construction. Not new to motorcycles and I own a couple.
I keep revisiting this project of mine and finally I have made some progress to post some pictures and hopefully get some suggestions on how should i continue with my build.
Donor bike is a RMZ250
QS138 70H+ EM-260 from Electro co.
Built my own 20s14p molicel p42a pack + ant bms
There are mixed information and opinions, so once again I'm stuck not knowing what to do next.
So here some pictures of what have i achieved so far. I'm not rich in knowledge like some of you are but im good with executing and attention to detail.
Awaiting your comments
Peter

 

[fechter]

Not sure where you're planning to put the controller, but it needs to dissipate a fair amount of heat. If there's a way to make good thermal contact to the frame, the frame might be a good heat sink. Otherwise it needs a lot of air flow.

It looks really great so far. I like the charge connector in the gas filler. You can screw on the cap to keep water and dirt out when riding.

The battery needs to dissipate some heat also. Do you have any pics of the insides? If the ends of the cells are against the housing, it gives the heat somewhere to go. The battery mounts look beefy, but a hard landing off a jump will place very large shock loads on them. Not sure what the material is. Very pretty though.

 

[amberwolf]

The battery needs to dissipate some heat also. Do you have any pics of the insides? If the ends of the cells are against the housing, it gives the heat somewhere to go. The battery mounts look beefy, but a hard landing off a jump will place very large shock loads on them. Not sure what the material is. Very pretty though.

Some stuff here;
https://endless-sphere.com/forums/viewtopic.php?f=14&t=118832
older, not sure how applicable
https://endless-sphere.com/forums/viewtopic.php?f=10&t=114642

 

[Pete's moto]

I'm thinking to put the controller where the radiator was under the faring scoop. Not sure how yet, looking for ideas.

 

[rivvs]

That battery looks good! But you cut the frame for the battery making it a lot weaker. I personally would never jump a frame cut like that.

 

[SlowCo]

Great project, I'll follow your progress.

 

[Eastwood]

That battery looks good! But you cut the frame for the battery making it a lot weaker. I personally would never jump a frame cut like that.

I just noticed that! I guess he could make new supports that go around the outside of the battery box and weld it back together. Or maybe that’s what he plans on doing. But yeah, to your point the frame is definitely weaker if left like this.

I'm thinking to put the controller where the radiator was under the faring scoop. Not sure how yet, looking for ideas.

Your battery looks really good, great job on that! :thumb:

Do you plan on welding the frame back together where you cut it? Its nice to see another Rmz being converted

 

[Pete's moto]

That battery looks good! But you cut the frame for the battery making it a lot weaker. I personally would never jump a frame cut like that.

I'm not planning to be airborne with this and do jumps. Most likely will end up getting supermoto wheels.

 

[speedy1984]

looks great :thumb:

 

[Pete's moto]

Some things I'm not sure of? Do i need a contactor or just a switch for the wires from the battery to the controller? Do i need additional fuse or the 400A fuse on the controller is sufficient?
This kit from Electro is supposed to be plug and play but i never got or found any guide or wiring diagram. It's color coded connections from the controller to the motor and controls, but no details on wire gauge, wire length, switch, fuse or contactor coming from the battery to the controller.
I have this switch and the qs8-s connectors not yet soldered to the battery wires because im not sure how long the wires shoud be. I read that wires from the battery to the controller should be kept as short as possible.

 

[fechter]

The battery is beautiful. That should work very nicely. The controller fuse should be enough. The BMS is the primary line of defense in case of a short. A big circuit breaker as a shut off switch would be one idea, but it needs to be properly rated and will be physically large and pretty expensive. I don't think it's really necessary. I guess it's nice to avoid getting a huge spark when you plug in the controller.

 

[Pete's moto]

The QS8 connector supposed to be anti spark. Would it be sufficient? Should I still add a cut off switch for safety?

 

[fechter]

I'd say it's optional and not normally needed as long as the connector is anti-spark (and it works). A switch is actually going to be another possible failure point. If something shorts out, you won't have time to hit a switch in most cases.

 

[harrisonpatm]

I'd say it's optional and not normally needed as long as the connector is anti-spark (and it works). A switch is actually going to be another possible failure point. If something shorts out, you won't have time to hit a switch in most cases.

I agree with that, it's just that many anti-spark connectors are also frequently failure points in themselves. As long as you know what you have works, tested...

 

[Pete's moto]

Is testing these connectors is as easy as checking the resistance?

 

[harrisonpatm]

Is testing these connectors is as easy as checking the resistance?

Easiest way to test is to just use it. Plug it into your charger or motor, see if it sparks or not. If it still sparks on plugin, chuck it and go with a different model or a switch. I don't disagree that switches can be failure points, but they are also frequently cheap and easy to replace if they do fail.

 

[bayodome]

Gorgeous build so far! I will definitely be following this one.

What kit did you get from Electro? I went with the EM260 for my YZ250F conversion. They said the QS8 would be fine and they've never had any issues, but I went with the QS10 just to be on the safe side.

 

[Pete's moto]

I can confirm that the qs8 connector does work without any issues using 6awg cable to connect the battery to the controller.
If i was to use a dc to dc converter for lights and indicators(LED) how many amps should that be?

 

[fechter]

Depends on what lights you use. I’d guess between 5-10 amps. I have a 20A unit that’s pretty small and was not too expensive. The Chinese ones tend to exaggerate their ratings so get something bigger than you really need.