Andis Flitzer

This was my original plan. In the mean time, I know that the batteries won't fit under this cover...
After my sons had so much fun with their electric Like a Bike, I was encouraged to do some real stuff! I want to convert a proper motorbike into an electric one, suitable for my daily commute.
I discovered this motorcycle which I found ideal for my plans. After some research on the internet I got the confidence that I can do this project with no major risks. Motor, batteries and controller should find space. Some good advice from the local motor vehicle registration officer also helped a lot.
Soon the old engine was out, ready for some more detailed feasibility studies. Hiding all the batteries will be tricky ;-)
The bike needed a lot of restoring. Removing rust with electrolysis worked quite well. YouTube is a great thing! I learned so much. I hope my contribution also helps someone :-) Watch this if you need to disassemble old stile forks: https://www.youtube.com/watch?v=0CWO1mAWceQ
The Golden Motor HPM-10KW fits perfectly. But I had troubles to get a standardized declaration for continuous power output according to IEC 60034-1. This is needed for a legal registration in Switzerland. Finally, the registration officer could assure me, that they won’t ask for such a paper, as long as the declaration on the motor is trustworthy. I’ll hope and see… I also learned something about CAD (Cardboard Aided Design ;-) The box is a prototype of the battery pack I want to build out of aluminium.
With a little bit of luck, I found these amazing Graphene Lithium Ion batteries (http://www.szwestart.com/ProductView.asp?ID=1082#.Vz4SRr4Tg0g). 10C continuous discharge is what I needed! Most batteries don’t deliver enough amps for my 10kW motor and more batteries don’t fit on the bike.
I discharged the batteries to measure the heat they produce. At a full discharge with 1C they went from 18 to 45°C. So I decided to find a cooling system for the battery box, to be on the safe side under harder conditions. I also measured the capacity of each cell so I can optimize the capacity of the pack when I pair the cells.
This cooling system should do the trick. All in copper, because it is easier to solder. I tried to solder/braze aluminium, but I was not happy with the result.
Specifications: Model: YAMAHA RS 125 RX, Year 1981 - - Motor: Golden Motor HPM-10KW, 10kW (14HP), 4000 RPM - - Batteries: Graphene Lithium Ion Polymer, Shenzhen WESTART Technology Co. Ltd, 40 cells, 40Ah, 72V, 2.96kWh - - Links: http://evalbum.com/5185
Oops! That could have been worse. Currently, I’m still working on the best way to solder the aluminum contacts and how to pack the cells. I'll keep you up to date with my progress.

Discuss This Project: (4 Comments)

Comments

Nice bike. I love electric conversions!

I use a golden motor 5k on my bike.

Jalapi, I've seen your movie on facebook, you on your 5kW bike. Owesome! I want to use my bike for commuting. On the road, not on the dirt! And for the registration I need some more paper about the motor. I'm still working on it...

Andi, if your on facebook. Check out "Electric Motorcycle Builds" facebook group. It's my new playground for sharing my electric motorcycle builds. Hope to see you there.
  • admin
    Nice bike. I love electric conversions!
  • admin
    I use a golden motor 5k on my bike.
  • Andi
    Jalapi, I've seen your movie on facebook, you on your 5kW bike. Owesome! I want to use my bike for commuting. On the road, not on the dirt! And for the registration I need some more paper about the motor. I'm still working on it...
  • jalapi
    Andi, if your on facebook. Check out "Electric Motorcycle Builds" facebook group. It's my new playground for sharing my electric motorcycle builds. Hope to see you there.