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.
This YAMAHA RS 125 DX seams ideal for my plans. After some research 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 to keep it road legal.
Soon the old engine was out, ready for some more detailed feasibility studies. Hiding these batteries will be tricky ;-)
The bike needed a lot of restoring. Removing rust with electrolysis worked quite well. If you are interested to see how to disassemble the old forks, watch this: https://www.youtube.com/watch?v=0CWO1mAWceQ
The Golden Motor HPM-10KW fits perfectly. But I didn't get a standardized declaration for continuous power output according to IEC 60034-1 for it. 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 hope I can trust him… I also learned something about CAD (Cardboard Aided Design ;-) The box is a prototype of the battery pack that I want to build out of aluminium.
With a little bit of luck, I found these powerful Graphene Lithium Ion batteries (http://www.szwestart.com/ProductView.asp?ID=1082#.Vz4SRr4Tg0g). 10C continuous discharge sounds amazing! Most other batteries didn'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. During a full discharge with 1C they went from 18 to 45°C. So I decided to build a cooling system for the battery box. I also measured the capacity of each cell so I can pair the cells to optimize the capacity of the entire pack.
This cooling system should do the trick. All in copper, because it is easy to solder. Then I inserted the cells and screwed the contacts together. I built 5 packs with 8 cells each. Connected together it will be 2p20s, 72V, 40Ah, 2.88 kWh.
The bench test was successful! Controller, throttle and solenoid I got from Kelly (KLS7250D). The Golden Motor HPM-10KW revved up to 4600rpm. Now it’s time to build everything into the frame. I’ll keep you posted :-)
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
In this video you can see how I assembled the battery packs.

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.