Molly Ayala
Electric motorcycles are an innovative and eco-friendly alternative to traditional motorcycles. Converting a motorcycle to an electric vehicle is a feasible project that can be done cheaply, with second-hand parts, and with 100% off-the-shelf parts. The cost of such a project varies, but it is possible to convert a motorcycle to an electric one for under $1000. This process requires careful planning and research, and the consideration of various components such as the type of battery, voltage, and motor. The range and speed of the electric motorcycle will depend on these components. Building an electric motorcycle can be a cost-effective way to own an electric vehicle, but it is important to ensure that the final product complies with local regulations and is safe to ride.
| Characteristics | Values |
|---|---|
| Cost | $1,000 |
| Range | 40 miles |
| Speed | 40 mph |
| Curb Weight | 320 pounds |
| Recharge Cost | Less than a penny per mile |
| Battery Cost | $62 each |
| Motor Controller Cost | $150 |
| Electric Motor Recommendation | Brushed 48v Etek Briggs and Stration |
| Electric Motor Cost | $275 |
| Battery Type | Lead acid |
| Registration | Same as a typical gasoline-powered cycle |
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What You'll Learn
Plan your build
Planning is a crucial step in building an electric motorcycle, especially if you're aiming to do it on a budget. Here are some detailed guidelines to help you plan your build effectively:
Define Your Requirements
Start by asking yourself some essential questions: How far, how fast, and how much? Answering these questions will give you a clear set of goals for your project. For example, if you need a motorcycle for commuting to college, you might want a range of 30-45 miles with a speed of 30-35 mph.
Choose the Right Donor Motorcycle
You can save money by choosing a motorcycle with a bad engine or transmission but ensuring the rest of it is in good condition. Keep the engine and transmission aside to confirm proper registration, and then carefully remove them. You can sell these parts to recoup some of your investment. Look for a donor bike with a chain drive, as it will give you more flexibility and efficiency. Keep an eye out for deals on Craigslist or eBay.
Select the Appropriate Electric Motor
There are various options for electric motors, but a Brushed 48v Etek Briggs and Stratton motor is a good choice due to its price, power, and availability on eBay. You can also explore the option of a hub motor, which saves space on the bike.
Decide on the Battery Type
The choice of batteries depends on your budget and performance requirements. Lithium-based batteries offer higher performance but are more expensive and complex. Lead-acid batteries are a more affordable and reliable option, but they may not offer the same level of performance. Consider the range you need and the voltage of your system to determine the number and type of batteries required.
Plan the Conversion Process
Research and understand the conversion process thoroughly. Study build instructions available online, and learn from the experiences of others who have undertaken similar projects. You can also consult college research labs and professional racing teams for more technical insights.
Legal and Safety Considerations
Ensure that you comply with the legal requirements in your area, including registration, insurance, and licensing. Additionally, pay attention to safety considerations, especially when dealing with electrical components and high-speed vehicles.
By following these planning steps, you'll be well on your way to building your cheap electric motorcycle, and you'll have a clear understanding of the process and the components required.
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Source a donor motorcycle
Sourcing a donor motorcycle is the first step in building an electric motorcycle on a budget. A donor motorcycle is a bike that you can use as a base for your electric conversion. It can be a rolling chassis or a non-operational motorcycle that you can find on eBay or Craigslist. For example, you could look for a classic motorcycle like a 1967 Honda Dream (CA160) with a frozen motor, which can be a great starting point for your project.
When searching for a donor motorcycle, it's important to consider your budget and the condition of the bike. You can find donor motorcycles at various price points, from free parts to $10,000, depending on your requirements and the components you plan to use. It's also worth considering the range and speed you desire, as these factors will influence the type and size of the donor motorcycle you need. For instance, if you're aiming for a 30-45 mile range and a speed of 30-35 mph, you'll need to choose a donor bike that can accommodate the necessary battery capacity and motor type.
Online platforms like eBay and Craigslist are excellent sources for finding donor motorcycles. Set up an RSS feed or create alerts for specific search terms to easily find potential donor bikes within your budget and requirements. Additionally, local golf shops can be a great option to source electric motors, as they often have suitable motors sitting around that they may be willing to sell at a reasonable price.
If you're open to supporting charitable causes, you can also explore motorcycle donation programs. Organizations like Wheels for Wishes, Vehicles for Veterans, Cars2Charities, Habitat for Humanity, and Goodwill accept motorcycle donations. These programs offer free towing services and tax benefits, making it a convenient way to source donor motorcycles while contributing to worthy causes.
Remember to plan carefully before sourcing your donor motorcycle. Define your goals, budget, and desired specifications to guide your search effectively. With a clear vision and some resourceful hunting, you'll be well on your way to building your cheap electric motorcycle.
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Choose an electric motor
Choosing the right electric motor for your motorcycle is critical to ensuring an optimal riding experience. The motor defines the performance characteristics of the bike, including its speed, torque, range, efficiency, and lifespan. Therefore, it is essential to select a motor that aligns with your unique needs, preferences, and budget.
There are two main types of electric motors used in motorcycles: Hub Motor and Mid-Motor. Hub motors are installed in the wheel of the motorcycle, offering a compact and cost-effective solution. They are commonly used in lower-cost electric motorcycles and DIY e-bike conversions due to their simplicity, robustness, and high starting torque. However, hub motors may have issues with unsprung weight, and it can be challenging to find one that meets your requirements without being too expensive. Mid-motors, on the other hand, are typically more expensive but offer higher torque and power output.
When choosing a hub motor, consider the amount, thickness, and height of magnetic steel, as these factors affect the power and torque of the motor. For example, a 10-inch 600-800W motor should use 24H magnetic steel, while a 1500W-2000W motor should use 40H magnetic steel. Additionally, the sealing process is crucial, especially if you plan to ride in rainy conditions, as water ingress can cause rust and short circuits, rendering the motor useless.
If you opt for a mid-motor, consider the DJI Avinox electric bike motor, which made its debut at Europe's largest trade show in 2024. This mid-motor weighs 2.52 kg, and its high-torque drive unit delivers 105Nm of torque, making it suitable for off-road applications. The DJI Avinox Drive System offers two high-energy density battery options: 600Wh and 800Wh, and its Smart-Assist Algorithm automatically adjusts the level of assistance based on riding conditions.
Remember, the choice of motor will also depend on your riding style and skills. A motor that is too powerful for your bike's design can lead to stability issues, while an underpowered motor may not provide sufficient torque for safe manoeuvring in traffic or challenging terrains. Take the time to research and compare different motors, consult experts, and consider insights from top electric motorcycle manufacturers to make an informed decision.
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Select the right batteries
Selecting the right batteries for your electric motorcycle is crucial, as they are one of the most important components, influencing your bike's performance, range, and overall price. There are several factors to consider when choosing the right battery for your electric motorcycle.
Firstly, determine the ideal battery capacity by calculating your expected power consumption based on riding conditions. Use the formula: Battery Capacity (Ah) = (Power Consumption (W) / Voltage (V)) x Time (h). Assess your typical ride duration and terrain type to select a battery that balances range and weight. For example, if you require a longer range, larger batteries are preferable as they provide extended distances per charge. However, they are heavier, which can affect handling and performance. On the other hand, smaller batteries are lighter but offer a limited range and require more frequent charging.
Secondly, consider the battery's voltage. The battery voltage needs to match the motor rating. Most motorcycles use 12-volt batteries, while a few older models may require a 6-volt battery. Additionally, the battery voltage should be high enough to power the motorcycle. For a lightweight electric motorcycle, a minimum battery voltage of 48V is recommended.
Thirdly, pay attention to the battery's chemistry. Different battery chemistries have their own pros and cons. Lithium batteries are widely used due to their higher energy density, allowing more electricity storage in the same weight and volume compared to nickel-cadmium batteries. They are also lightweight, have fast charging times, and do not produce explosive gases during charging or discharging. However, they may be more expensive. Lead-acid batteries are a more economical option but are less efficient, have shorter lifespans, and require additional maintenance. AGM (Absorbed Glass Mat) batteries are sealed, spill-proof, and maintenance-free. Gel motorcycle batteries are also maintenance-free, leak-proof, and resistant to harsh climate conditions and strong vibrations. Pure Lead batteries offer extreme performance and are ideal for power-hungry electronic equipment.
Other factors to consider include the charging method, charging time, and charging voltage. Inappropriate charging can damage the battery and affect its lifespan. Additionally, ensure that the battery size matches the physical dimensions of your bike to avoid compatibility issues. Lastly, consider the starting power or Cold Cranking Amps (CCA) of the battery, which indicates how well it will perform in cold weather.
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Add a motor controller
Adding a motor controller is an essential step in building an electric motorcycle. The motor controller acts as the "brain" of the bike, regulating the energy flow from the battery to the motor and managing the signalling between various components, including the battery, motor, and pedal-assist system. Here are the steps and considerations for adding a motor controller:
- Plan and Compatibility: Before purchasing a motor controller, it's crucial to have a clear plan for your electric motorcycle's desired speed, range, and performance. Ensure that the motor controller is compatible with the motor, battery, and other components of your electric motorcycle, especially in terms of power and voltage parameters. Check if the controller can handle the voltage and amperage requirements of your system.
- Sourcing the Motor Controller: You can find motor controllers through online platforms like eBay or specialised electric vehicle retailers. Consider the Brushed 48v Etek Briggs and Stratton motor, which is recommended for its price, power, and availability on eBay. Alternatively, you can opt for a used motor or a clone.
- Connection: When connecting the motor controller, start by disconnecting the battery power to avoid the risk of short circuits or electric shocks. Refer to the product manual for specific connection instructions, as each controller may have a unique connection method. Typically, you'll connect the red wire of the battery to the red terminal of the controller and the black wire to the black terminal, ensuring a tight connection.
- Wiring: The motor wires usually consist of three thick wires and five thin wires. Thick wires transmit current, while thin wires are for signal transmission. Match the colours of the thick and thin wires between the controller and the electric bicycle to avoid issues like motor vibration or abnormal operation.
- Brake Cable Connection: Most brake cables have two wires, typically black and yellow. Connect the black wire to the ground interface of the controller, and the yellow or other coloured wire to the brake signal port. Test the brake function to ensure the motor stops rotating immediately when braking for safety.
- Throttle Connection: The throttle sends an electric signal to the controller, determining the amount of energy sent to the motor. Ensure that the throttle is properly connected and calibrated, allowing the controller to manage the power delivery effectively.
- Testing and Calibration: Once the motor controller is connected, test the motorcycle to ensure all components are functioning correctly. Fine-tune the settings to optimise performance and efficiency, referring to the controller's manual for specific instructions.
By following these steps and considerations, you can successfully add a motor controller to your electric motorcycle, ensuring a smooth and safe riding experience.
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Frequently asked questions
The cost of building an electric motorcycle can vary from free if you use parts you already have, to $10,000 for a high-performance vehicle. A typical conversion will cost somewhere in between.
You will need a donor motorcycle or a rolling chassis, an electric motor, batteries, a motor controller, and a twist grip throttle. You may also need a battery charger.
You can find parts for an electric motorcycle conversion on eBay, Craigslist, and from local golf shops.
To make your electric motorcycle road legal, you will need to register it, insure it, and ensure you have the correct license to ride it.
