How to Build a 72Volt Electric Motorcycle

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Every motorcycle is totally different however the primary parts may be the identical. Below is an inventory of the components I used and the place I acquired them, however you’ll have to perform some research to determine what matches your bike and necessities. Check out the images on the backside to see what I purchased and the EVAlbum for different electrical automobile initiatives.

Frame: I checked out many alternative bike types and selected a 1984 Honda Interceptor for just a few causes:
1) I just like the type of motorbike, not a complete crotch rocket however not a hog both, with room for batteries contained in the body.
2) The vendor on Ebay was near my home. And the bike did not run, so it solely value $600. If you have got an outdated bike or somebody will donate one then that is great–but for the remainder of us, attempt the native paper, junk yards, Craig’s List or ebay motors.

Motor: After studying different EV bike specs (and understanding that I wished to go quicker than a moped), I selected a 72V Advanced DC motor, as a result of it is weight and dimensions the place good for my body. I ordered it on-line

Batteries: I went with 6 Yellow Top Optima batteries from as a result of they’re sealed and have obtained nice evaluations. After making cardboard mock ups of the D23 mannequin I noticed that there was no method six full sized batteries would match and nonetheless look good. I ended up getting the D51 mannequin. Half the scale and weight but additionally half the storage.

Controller: You should match your controller to your voltage however the amperage is as much as your price range. More amps = extra energy and extra value. It appears that there are solely two actual decisions: Alltrax or Curtis. You’ll should resolve for your self, however I went with the 72V 450Amp Alltrax from cloudelectric. Don’t waste your time attempting to construct a potimeter on an outdated throttle–just purchase a pre-made one and be finished with it. I acquired the Magura Zero-5K Twist grip throttle from

Charger: You should match your charger along with your voltage however the pace of cost in Amps can be as much as your price range. I went with a Zivan NG1 from EVAMERICA I’ve just lately switched to 6 particular person 3amp Soneil chargers to assist stability the batteries.

DC/DC Converter: It’s most secure to run with a DC/DC converter and an additional 12V battery backup however bikes have restricted area so I’m solely utilizing the converter. I bought a Sevcon 72V Input 13.5V output from evparts and it has working completely.

Fuses: You’ll wish to get a fuse that matches your setup. I purchased mannequin ANN 400 w/ holder from EVAMERICA.

Contactor: This is a tool that you simply hook as much as your present key ignition on 12Volts and it’ll shut the loop so that you get the total energy to your controller. I purchased an Albright SW-200 from EVAMERICA

Battery cable and connectors– I purchased about 10 ft of two GA wire from WAL-MART and reduce it to size. Using Lugs from cloudelectric I soldered and used warmth shrink tubing on every finish. I extremely suggest battery terminal covers for security.

Instruments I selected an E-meter(Link 10) w/ Prescaler add on for 72V use as a substitute of a bunch of various meters. As an added characteristic I wired up the ignition swap to the impartial indicator to indicate me when the bike was on.

Other components
Wire – 12GA totally different colours and warmth shrink tubing (massive and small sizes)
Electrical tape
Wire connectors
Wire wrap

Basic store instruments are required resembling a socket set, screw drivers,wire stripper, and many others. Additionally a volt meter, metallic grinder and crimper are used on this venture.

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