Molly Ayala
Electric motorcycles are becoming an increasingly popular alternative to traditional gas-powered bikes. They are clean, quiet, and can be built with 100% off-the-shelf parts, making them an accessible DIY project for enthusiasts. When building an electric motorcycle, it's important to consider factors such as range, speed, and budget. The choice of battery is crucial, with lithium-based batteries offering higher performance but at a significantly higher cost compared to lead-acid batteries. Additionally, legal requirements such as registration, insurance, and licensing must be complied with to ride the motorcycle on public roads. Building an electric motorcycle can be a rewarding experience, offering the thrill of high speeds and the environmental benefits of reduced pollution. With the right planning, research, and engineering design, anyone can build their own fast electric motorcycle.
| Characteristics | Values |
|---|---|
| Top Speed | 40 mph |
| Range | 40 miles |
| Cost | $1000 |
| Charging Time | Less than 10 hours for a full charge |
| Battery | Four Optima Yellow Top sealed (AGM) lead-acid batteries |
| Motor | Briggs & Stratton Etek electric motor |
| Registration | Same as a gasoline-powered cycle |
| Insurance | Required |
| License | Required |
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What You'll Learn
Choosing a donor motorcycle
The first step to building your own electric motorcycle is to choose a donor motorcycle or a rolling chassis. You can find these on eBay or Craigslist, with prices varying depending on the make and model of the motorcycle. For example, a 1967 Honda Dream (ca160) can be purchased for $275, while a name-brand Brammo model can cost up to $16,000. It is also important to consider the range and speed that you desire for your electric motorcycle. A good benchmark for a budget electric motorcycle is a range of 40 miles and a speed of 40 mph.
When choosing a donor motorcycle, it is essential to consider the legal requirements for riding an electric motorcycle in your area. Registration, insurance, and licensing are crucial aspects to look into before beginning your project. In some places, vehicles must pass a smog test, but motorcycles are usually exempt from this requirement. Additionally, certain vehicles may be exempt from specific tests or requirements if they are antique, classic, or intended for part-time use.
Another critical factor to consider when choosing a donor motorcycle is the type of battery you will use. Lithium-based batteries offer higher performance but are more expensive and complex than lead-acid batteries. Lead-acid batteries, such as Optima Yellow Top sealed (AGM) lead-acid batteries, are a more cost-effective option and have been proven to work, as seen in the example of a converted 1981 Kawasaki KZ440.
Lastly, it is essential to have a plan and do your research before starting your project. This includes understanding the design and engineering aspects of electric motorcycles and setting a budget for yourself. There are various resources available online, such as build instructions and conversion pictures, that can provide valuable information and help you avoid common mistakes. By taking the time to plan and research, you can ensure a more successful outcome in building your fast electric motorcycle.
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Sourcing an electric motor
When sourcing an electric motor, it is important to consider the power, price, and availability of the motor. One popular option is the Brushed 48v Etek Briggs and Stratton motor, which can be found on eBay. This motor is a good choice for its balance of performance and cost. However, as it is no longer in production, your options are either to buy a used model or a clone.
Another motor to consider is the Briggs & Stratton Etek electric motor, which powers the 1981 Kawasaki KZ440 electric motorcycle. This motor is driven by four Optima Yellow Top sealed (AGM) lead-acid batteries. Lead-acid batteries are a tried and true option, but they are heavier and have less performance than lithium-based batteries. If you are looking for higher performance, lithium batteries may be worth the higher cost, increased complexity, and charging costs.
When planning your electric motorcycle project, it is important to consider the range and speed you are aiming for, as this will impact the type of motor and batteries you will need. For example, a motorcycle with a range of 40 miles and a speed of 40 mph can be achieved on a budget of $1,000.
In addition to the motor and batteries, you will also need to source other components such as the sprocket, chain, and controller. The sprocket can be purchased from a farm store or industrial supplier for around $20, and the #40 chain can be found at a tractor aisle for about $10 for ten feet. For the controller, you can follow guides online to work with the motor, batteries, and mounting components.
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Selecting the right batteries
First, it's essential to understand the two primary types of batteries commonly used in electric motorcycle conversions: lithium-based batteries and lead-acid batteries. Lithium-based batteries, including lithium-ion and lithium-polymer variants, offer higher performance, lighter weight, and faster charging times. However, they come with a significantly higher price tag and can be more complex to work with. On the other hand, lead-acid batteries, such as AGM (Absorbent Glass Mat) or gel cell types, are more affordable, tried-and-true options. They are heavier and may not provide the same performance as lithium batteries, but they are a more economical choice for hobbyists and those on a budget.
When selecting batteries, consider the range and speed you want to achieve with your electric motorcycle. Lithium batteries typically offer a longer range and higher top speeds but come at a higher cost. If you're aiming for a faster motorcycle, be prepared to invest in higher-performance batteries to get the most out of your vehicle. Additionally, take into account the charging infrastructure available to you. Lithium batteries often charge faster, which can be advantageous if you're looking for quick turnaround times between rides.
The availability of replacement parts and the ease of maintenance should also factor into your decision. Lead-acid batteries are more widely available and easier to source, making them a practical choice for maintenance and repairs. They are also a good option if you're converting a motorcycle as a hobby or for personal use, as they are more accessible and cost-effective for non-commercial endeavours. However, if you're seeking cutting-edge performance and are willing to take on the added complexity and cost, lithium batteries might be the right choice.
Lastly, safety should be a top priority when working with batteries. Electric motorcycles require a significant amount of power, and it's crucial to ensure that your batteries can handle the load safely. Always follow best practices for battery installation, wiring, and maintenance to mitigate the risk of electrical issues or fires. Proper ventilation and cooling systems are also essential to prevent overheating and ensure the longevity of your batteries.
In summary, selecting the right batteries for your fast electric motorcycle depends on your specific needs, budget, and performance goals. Carefully consider the trade-offs between lithium-based and lead-acid batteries, keeping in mind factors such as range, speed, charging times, cost, and maintenance. Remember to prioritize safety and adhere to best practices to ensure a reliable and enjoyable electric motorcycle experience.
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Legal requirements
Electric motorcycles are regulated in a similar way to their gas-powered counterparts. If you're building your own electric motorcycle, it's important to understand the legal requirements to ensure your vehicle is road legal and safe. Here are the key legal considerations:
Licensing
Obtaining a license for an electric motorcycle is a crucial step. In the United States, you need a motorcycle license to operate any electric motorcycle legally. Electric bicycles, on the other hand, typically do not require a license unless they exceed certain speed or power limits. The specific requirements vary from state to state, so it's important to refer to your local Department of Motor Vehicles (DMV) resources and website for detailed information. Some states have different classes of motorcycle licenses, such as Class M1 and Class M2, which depend on the specifications and type of electric motorcycle. It is recommended to obtain a Class M1 license, as it allows you to ride any type of electric motorcycle.
Registration
Registering your electric motorcycle is another essential step. The registration process may differ slightly depending on your state, but generally, you'll need to visit the DMV with your Certificate of Title or lienholder information if you have a loan. Similar to licensing, it's important to consult your local DMV to understand the specific registration procedures for electric motorcycles in your state.
Insurance
Insuring your electric motorcycle is not only a legal requirement but also crucial for your safety and the protection of others. While the specific insurance requirements may vary by state, it is generally mandatory to have insurance before taking your electric motorcycle on public roads.
Vehicle Specifications
It is important to ensure that your electric motorcycle complies with all relevant vehicle specifications and safety standards. This includes factors such as lighting, turn signals, and speed restrictions, especially if your motorcycle resembles a moped or bicycle-style vehicle. Check with your local DMV and road authorities for specific guidelines.
Age Requirements
Age requirements may vary depending on your location, but generally, you must be at least 15 to 16 years old to be eligible for a motorcycle license. Again, refer to your state's specific regulations for accurate information.
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Braking systems
Early motorcycles did not have any mechanical braking systems and relied on cutting the power and waiting for the motorcycle to slow down enough to put a foot out. Drum brakes were the first type of mechanical brake used on motorcycles, acting on both the front and rear wheels. However, they have largely been superseded by disc brakes due to their improved heat-up time and better performance in wet weather. Drum brakes are now typically used for rear-braking only or have been replaced entirely by disc brakes. The first modern production motorcycle with a disc brake was the Lambretta TV125 Series 3, followed by MV Agusta's limited-production 600 cc touring motorcycle in 1965, which featured a pair of cable-actuated Campagnolo front disc brakes. The 1969 Honda CB750 brought disc brakes to the mass market, utilising a hydraulically operated single-piston sliding caliper with a solid front disc. Early disc brake calipers were placed in front of the fork leg for better heat removal, but modern motorcycles have calipers mounted to the rear of the fork leg to improve low-speed handling and reduce the angular momentum of the fork assembly.
Radial brake calipers, which are mounted parallel to the forward direction, offer several advantages over traditional axial calipers. They are more rigid and not prone to torsional flexing, resulting in more precise and crisper feeling brakes. Additionally, radial calipers simplify modifications by only requiring a spacer between the mounting bracket and the caliper, rather than replacing the entire bracket. In 1989, BMW released the first motorcycle equipped with an assisted braking system (ABS), and subsequent innovations have focused on reducing stopping time and distance while maintaining lateral stability.
While regenerative braking is common in electric cars, it may not provide noticeable benefits in smaller DIY electric motorcycles due to the added cost and complexity. Plug braking, which is used in vehicles that reverse the motor to change direction, is also unnecessary for motorcycles as their motors only spin in one direction.
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Frequently asked questions
Electric motorcycles are clean, quiet, and can reduce the amount of automobile pollution caused by short to mid-range driving trips. They are also cheaper, simpler, and more efficient than traditional motorcycles.
You will need a donor motorcycle or a rolling chassis, which you can find on eBay or Craigslist. You will also need an electric motor, which you can purchase from a local golf shop or online. Other required parts include a sprocket, chain, and batteries.
There are two main types of batteries to choose from: lithium-based batteries and lead-acid batteries. Lithium batteries offer better performance but are more expensive and complex. Lead-acid batteries are a tried and true option but may not provide the same level of performance.
You will need to comply with the registration, insurance, and licensing requirements in your area. Make sure to check the specific rules and regulations for your location before building and riding your electric motorcycle.
