Beatrice Lang
Building an electric dirt bike is a challenging but rewarding endeavour. With the right tools, knowledge, and commitment to learning, it is possible to convert a traditional dirt bike into an electric-powered vehicle. The process involves removing the original engine and making adjustments to the frame, as well as selecting and installing the appropriate electric motor, controller, battery, and other components. Online communities and resources are available to provide guidance and share experiences, with some builders opting for kits from companies like Electro and Company or Vevor. The result is a fun, sustainable, and powerful mode of transportation that can navigate various terrains with ease.
| Characteristics | Values |
|---|---|
| Motor | QS cylindrical motors, QS 3000W (3kW) 138/70H V3 with a 45T/19T gear reduction, QS 138/90H |
| Controller | Curtis 48-volt 300-amp controller |
| Throttle | Twist grip throttle |
| Charger | Onboard charger |
| Switch | High-current switch |
| Fuse | 2 300-amp fuses |
| Sprocket | 10T and 11T sprockets for #428 chain, #520 sprockets |
| Gear ratio | Large gear ratio |
| Planning | Have a clear plan for how far, how fast, and how much |
| Budget | $1000-$1900 |
| Learning | Learn about electricity and electrical engineering |
| Conversion | Convert a gasser dirt bike to an electric drive system |
| Weight | 255 lbs |
| Frame | Add bracing to secure the frame |
| Battery | 72v battery, strong battery, 10-amp charger |
| Mounting | Cardboard cutouts to plan battery configuration |
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What You'll Learn
Planning and budgeting
Planning:
Before beginning your build, it is essential to have a solid understanding of electrical engineering, mechanics, and fabrication. This knowledge will guide your planning process and help you make informed decisions. Define the purpose and desired specifications of your electric dirt bike, such as speed, range, and performance expectations. This will influence the components you choose and the overall design.
Budgeting:
The budget for an electric dirt bike build can vary widely depending on the components and specifications you choose. It is important to create a comprehensive list of all the parts you will need and their estimated costs. Here are some key components to consider:
- Donor Bike: Start by finding a suitable donor bike that is in good overall condition. You can look for used bikes within your budget on Craigslist, local classifieds, or even on the side of the road. Ensure that the turn signals, headlights, and horn are functional, and avoid bikes that are heavily rusted.
- Electric Motor: The electric motor is a crucial component. QS motors, such as the QS 3000W 138/70H V3, are popular choices for dirt bike conversions. The size and power of the motor will impact your budget, with more powerful options typically costing more.
- Battery: Lithium batteries are excellent for weight, capacity, and power but come with a higher price tag. Sealed lead-acid batteries (VRLA) or gel batteries are more affordable options, but they may not provide the same performance as lithium batteries. Consider the range you want to achieve and calculate the total watt-hours capacity you will need.
- Motor Controller: You will need a motor controller, such as the Curtis 48-volt 300-amp controller, to regulate the energy sent to the motor.
- Throttle System: Choose a twist grip throttle that sends an electric signal to the controller, controlling the amount of energy drawn from the batteries.
- Charger: Invest in a suitable battery charger for your battery type.
- Mounting System: Design a custom mounting system to secure all the components in place, ensuring they are mounted securely and in a way that aids in handling, such as keeping the battery weight low and centered.
- Additional Components: Consider other parts like a high-current switch, a high-current fuse, and a large gear ratio for improved acceleration.
Remember, building an electric dirt bike is a complex project, and it is essential to be committed to learning and gaining the necessary knowledge to make informed decisions throughout the process.
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Choosing a dirt bike
Budget
It is essential to establish a clear budget before choosing a dirt bike. Building an electric dirt bike can vary in cost, so determining how much you are willing to spend will help narrow down your options. You can find electric dirt bikes ranging from \$1000 to \$2500 or more, depending on your requirements and features.
Type of Bike
The type of dirt bike you choose will depend on your intended use and preferences. You can opt for a turnkey dirt bike, which is ready to ride out of the box, or you can choose to build an E-conversion, where you convert a traditional gasser dirt bike to an electric drive system. This decision will impact the complexity of the build process and the cost.
Motor and Performance
The motor is a critical component of your electric dirt bike. Consider the power output, torque, and speed that suit your needs. Motors with higher wattage, like the QS 3000W 138/70H, tend to offer more torque and performance. Additionally, look for features like drive modes, which can include Eco and Sport options, allowing you to adjust the bike's performance according to your riding conditions.
Battery and Charging
The battery is another crucial aspect of your electric dirt bike. Look for batteries with higher kilowatt-hours (kWh) as they will provide more range. Consider the charging time as well; some batteries can recharge quickly, reaching 80% in 75 minutes, while others may take longer. Swappable batteries can also extend your ride time, allowing you to carry a charged backup.
Size and Weight
The size and weight of the dirt bike are important considerations, especially if you intend to ride off-road or perform tricks. Lighter bikes, such as the Electric Light Bee Sur-Ron X, are easier to manoeuvre and handle, making them ideal for off-road riding. Additionally, consider the weight distribution, aiming to keep the battery weight centred and low to improve handling.
Customization and Community Support
When choosing a dirt bike, consider the customization options available, such as body panels that can be swapped for different colours. Additionally, look for a model with an active community, as this can provide valuable resources, advice, and support during your build process.
Remember to do your research, read reviews, and join communities like ECR (Electric Cycle Rider) and r/electricvehicles on Reddit to make an informed decision when choosing a dirt bike for your electric conversion project.
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Conversion kits
The first step in converting a dirt bike to electric is to find a suitable donor bike. Choose a conventional dirt bike frame that is robust and has enough space to accommodate the electric components. Ensure that the frame can support the added weight of a battery pack and motor.
Next, gather your electric conversion kit. This typically includes an electric motor, speed controller, throttle, and battery pack. It is important to select a kit that aligns with your performance expectations in terms of speed, power, and range. For example, the KX80 to KX100 electric mod, 1991 to 2010 models, are said to be "real easy for great pit bike riding". Additionally, consider the compatibility of the components to ensure the smooth operation of your bike.
Remove the internal combustion engine and any other unnecessary parts from the donor bike, such as the fuel tank and exhaust. This will make room for the electric motor and battery. Install the electric motor by mounting it to the frame or using the existing engine mounts. Ensure that the motor is secured firmly in place as it will experience significant vibration and forces.
There are a variety of electric conversion kits available, and it is important to consider your needs and preferences when selecting one. For example, if you are looking for a budget-friendly option, you may want to consider a different kit than someone who is looking for easy installation or custom configuration.
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$142.49 $153.99
Electrical components
Building an electric dirt bike is an exciting project, but it's important to carefully select and install the electrical components to ensure safety and performance. Here is a detailed guide to help you navigate the electrical aspects of building your electric dirt bike.
Firstly, you need to select a suitable donor bike with a robust frame that can accommodate the electric components and support their weight, especially the battery pack and motor. A conventional dirt bike frame should be chosen, and it is crucial to ensure it can handle the power and weight of an electric motor. The suspension should also be able to provide the necessary support and control for off-road riding.
Next, you will need to gather your electric conversion kit, which typically includes essential components such as an electric motor, speed controller, throttle, and battery pack. The motor is a key component, and options like the Brushed 48v Etek Briggs and Stratton are recommended for their price, power, and availability. If you are on a budget, consider buying used parts or repurposing existing ones. The placement of the motor will depend on your kit and frame, but common options include mounting it to the frame or using existing engine mounts. Ensure the motor is secured firmly as it will experience significant vibration.
The battery is another critical component, and its placement should be carefully considered. Create cardboard cutouts the same size as your batteries to determine the best configuration. Keep the battery weight centered and as low as possible to aid handling.
Now, let's move on to the wiring process. Carefully lay out the wiring harness and locate the appropriate connectors for each component. Connect the wires to the brakes securely, then route the wires through the bike's frame, avoiding sharp edges or moving parts that could damage them. Once all the wires are in place, use zip ties or electrical tape to secure them and prevent unwanted movement or vibrations.
Finally, remember to regularly maintain and upgrade your electric dirt bike to ensure optimal performance and longevity. Checking and maintaining the battery is crucial for reliable performance, and investing in quality accessories will enhance your riding experience.
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Testing and troubleshooting
Before you begin testing, it is essential to have a clear plan and set realistic expectations. Building an electric dirt bike is not a simple task, and knowledge gaps should be addressed through learning and consulting resources. Online communities, such as those on Reddit, can be a great source of information and support. Additionally, having a budget in mind, such as between $1000 and $1900, will help guide your parts selection and purchasing decisions.
Start by testing the basic functionality of your electric dirt bike. Check the throttle input of the controller by connecting an ohmmeter to the wires leading to the throttle. Measure the resistance as you apply and release the throttle, ensuring that it falls within the standard ranges. If the resistances are incorrect, there may be an issue with the pot, wires, or throttle linkage. Verify the mechanical operation and replace the potbox if necessary.
Pay close attention to the suspension, bearings, and brakes of your electric dirt bike. Ensure that the front and rear suspension is in good condition and properly adjusted. Check the bearings for any signs of wear or damage, and make sure the brakes are functioning correctly. If you encounter any issues, refer to motorcycle repair guides or seek advice from experienced individuals or communities.
When it comes to the battery, focus on two main aspects: mounting and maintenance. Create cardboard cutouts of the same size as your batteries to determine the most suitable configuration. Aim to keep the battery weight centered and as low as possible to enhance handling. Additionally, remember that electric bikes require regular maintenance, including chassis and suspension checks, and managing gearbox oil and coolant.
Finally, don't underestimate the importance of real-world testing. Take your electric dirt bike for a ride and get a feel for its performance and handling. Be prepared to adjust your riding technique and power settings accordingly. Keep in mind that charging infrastructure is still evolving, so plan your rides accordingly, especially if you intend to race or ride on challenging tracks.
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Frequently asked questions
Start with a plan. Ask yourself: how far, how fast, how much? You can find inspiration and pictures of electric dirt bikes and their components on websites like http://www.evalbum.com/type/MTCY.
You'll need a battery, controller, and motor. You can find parts on websites like eBay, McMaster-Carr, and AliExpress, or from companies like Electro and Company.
The QS 3000W 138/70H V3 with a 45T/19T gear reduction built into the case (2.3:1 reduction) is a popular choice. If you want more torque, the QS 138/90H motor is rated at 4kW continuous.
Think about your ideal riding style and what's important to you, whether it's power, torque, speed, range, or weight distribution. A larger motor will provide more power, but also consider the size and weight of the battery.
You might encounter challenges when fixing components to the frame and electronics. Dirt bikes typically have integral engines that are part of the structure of the frame, so you may need to add bracing in place of the engine to secure the frame.
