Trystan Casey
There has been a recent surge in electric drive conversions for dirt bikes. This is partly due to the growing availability of older dirt bikes on the used market, which tend to have worn engines that need to be rebuilt. In addition, a major shift in frame designs a decade ago from a single back-bone top-tube to a twin spar has made it easier to design large single battery packs. There are several electric conversion kits available for dirt bikes, such as those offered by MightE and Lithium King, and it is also possible to build your own electric dirt bike on a budget.
| Characteristics | Values |
|---|---|
| Reason for conversion | Dirt bikes are getting cheaper on the used market due to their age and worn engines. |
| Frame design | The shift from a single back-bone top-tube to a "twin spar" design has made it easier to fit a large single battery pack. |
| Electric motorcycles | Turn-key E-motorcycles are hard to find for a test ride. |
| Electric conversion kits | Available from MightE (UK) and Lithium King. |
| Electric motor | Brushed 48v Etek Briggs and Stratton is recommended due to its price, power, and availability on eBay. |
| Battery | Chi Battery Systems 72v 51ah Gladiator Max is the highest-end Sur Ron Light Bee battery available in the US. |
| Motor controller | A Curtis 48-volt 300-amp controller can be purchased on eBay for $150. |
| Recharge cost | Less than a penny per mile. |
| Cost | $1,000 for a 40-mile range and 40mph speed. |
| Time | It can take up to 10 months to complete the conversion. |
| Weight | 10-15 pounds lighter than a four-stroke engine. |
| Ride time | 25-30 minutes of ride time on a single charge, depending on conditions. |
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Electric conversion kits
One of the most well-known electric conversion kits is the Yamaha YZ-EMX by Electro & Co., designed for Yamaha YZF chassis from 2018 onwards. This kit is a favourite among Yamaha enthusiasts who appreciate the bike's durability, handling, and performance, now enhanced with an electric powertrain. The YZ-EMX offers impressive power output, balance, and seamless integration, retaining the beloved Yamaha features like the aluminium chassis, KYB suspension, and Nissin brakes. The kit is also configurable, allowing riders to choose specifications that fit their budget and performance needs.
For those seeking a turnkey e-motorcycle, the Sur-Ron has gained popularity in the US for its motorcycle-grade components and powerful performance. The Kuberg is another excellent option, especially for younger riders, as it uses mountain bicycle components and is very lightweight. The 48V Kuberg Freerider can be ordered with either 20-inch or 24-inch MTB bicycle wheels.
When it comes to motors, the QS cylindrical motors, such as the QS138 70h V3, have been widely used for dirt bike conversions. The Lithium King offers a more affordable option for front sprockets, although their softer material may require hardening to prolong its lifespan.
Converting a dirt bike to electric power offers several advantages, including increased torque and a quieter ride. With the availability of electric conversion kits and turnkey e-motorcycles, riders can now easily make the switch to electric and enjoy the benefits of sustainable, high-performance off-road riding.
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Battery capacity
When converting a dirt bike to electric, one of the most important considerations is battery capacity. The battery capacity will determine the range and performance of the electric dirt bike. The owner of the bike can choose between two main types of batteries: Lead-acid batteries and Lithium-ion batteries.
The choice of battery type depends on various factors such as cost, ease of maintenance, and performance expectations. Lithium-ion batteries, for example, are more expensive but offer higher energy density and longer ranges. The chemical composition of the material used inside the Lithium-ion battery is LiCoO2 (Lithium Cobalt Oxide). This is the material used for making the cathodes inside the Li-ion batteries, and for the anodes, graphite is a common choice. The normal range of voltages for electric dirt bike batteries is 24, 36, or 48 volts, with current ratings of 7Ah to 10Ah (Ampere hours).
It is important to ensure that the dirt bike frame has enough space to accommodate the battery pack. The battery pack should be placed in the box or slot provided by the designer of the bike, ensuring that the frame can support the added weight of the battery and motor.
Additionally, when choosing a battery, it is crucial to consider the motor rating, as it determines the speed the electric dirt bike can achieve. A higher-capacity battery will enable the bike to achieve higher speeds and travel longer distances on a single charge.
Some electric dirt bike owners have reported achieving 25-30 minutes of ride time on a single charge, while others have managed to finish a 45-minute race with a Lithium-ion battery. The battery capacity and performance will also depend on the conditions in which the bike is being ridden.
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Motor options
One popular option for motor conversions is the Quan Shun/QS cylindrical motors. These motors have gained popularity in recent years due to their compatibility with the “twin spar” frame design, which has become common among dirt bikes. This design allows for a larger single battery pack, making it easier to power a more capable motor. The QS motor family offers various options, such as the QS 3000W 138/70H and the larger 8000W 171/100H, which users have mounted on KTM 200 EXC bikes.
Another option for motor conversions is to use an electric conversion kit. These kits provide an easy way to add a motor to your existing bike. For example, the Rubbee X e-bike conversion kit offers a slick-looking 250-watt motor with a single battery, providing a range of up to 10 miles. If you need more range, Rubbee offers the option to add additional batteries, increasing both distance and power. Swytch is another company that provides conversion kits, focusing on a seamless integration of the motor and battery system.
For youth or pre-teen riders, the Kuberg is a popular choice, with its lightweight design using mountain bicycle components. The Sur-Ron, with its 60V model, has also gained popularity in the US for mid-sized adult dirt bikes, offering motorcycle-grade components. Finally, for a full-sized off-roader, the Zero FX model is an option to consider.
When choosing a motor, it's essential to consider the intended use, terrain, and desired performance. Factors such as riding uphill or in cold temperatures will impact the power consumption and range of your electric dirt bike. Additionally, the weight of the motor and its compatibility with your bike's frame and battery are crucial considerations.
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Weight and handling
The weight distribution of the electric components can affect the bike's handling characteristics. It is recommended to keep the battery weight as low and centred as possible to improve handling. Additionally, the type of motor and its placement can also influence weight distribution. Mid-drive motors, for example, tend to deliver a more natural ride feel as the weight sits low in the frame, but they can be complex to set up.
Swapping out the front or rear wheel for one with a hub-mounted motor is another option that can provide a good balance in weight distribution. However, powering the wheel can change the power delivery, and having a heavy front wheel can affect handling. The Yamaha YZ400F, for instance, may be challenging to handle in big whoops and deep sand despite its smooth power delivery from batteries and sizable girth.
The brakes are another critical consideration when converting to electric. The increased weight and potential for higher speeds will put more stress on the braking system. Therefore, it is advisable to choose a donor bike with disc brakes, as they offer superior braking performance compared to other types.
Overall, when converting a dirt bike to electric, carefully considering the weight distribution and handling characteristics is essential. The placement of the motor and battery, as well as the type of braking system, can significantly impact the bike's performance and ride quality. It is always recommended to consult a professional mechanic if you are unsure about any aspect of the conversion process.
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Cost
The cost of converting a dirt bike to electric depends on several factors, including the type of bike being converted, the chosen electric kit, and the cost of labour.
Firstly, you need to consider the cost of the donor bike. If you already own the bike, the conversion may be a cost-effective way to upgrade to electric power without purchasing a new bike. However, if you need to buy a donor bike, you should factor in the cost of acquiring one. It is recommended to choose a conventional dirt bike frame that is robust and has enough space to accommodate the electric components.
Next, the electric conversion kit will be a significant expense. Basic kits typically include an electric motor, speed controller, throttle, and battery pack. The cost of these kits can vary widely depending on the specifications and quality. For example, the TongSheng kit offers a lightweight, high-torque motor for around $600, but the battery must be purchased separately. In contrast, the Swytch kit is simple to install and includes a compact battery, but it may be more expensive. Long-range kits with larger batteries will also be more expensive. It is important to select a kit that aligns with your performance expectations and ensure that it is compatible with your bike's specifications, such as wheel diameter and brake type.
In addition to the kit, you will likely need various tools for the conversion process, including wrenches, screwdrivers, a soldering iron, and possibly a drill. These tools can add to the overall cost of the project.
Finally, unless you have the necessary skills and experience, you may need to hire a professional to perform the conversion. This labour cost can vary depending on the complexity of the installation and the rates of the technician.
Overall, the cost of converting a dirt bike to electric can range from a few hundred to a few thousand dollars, depending on the choices made during the process. It is important to carefully consider your budget, performance expectations, and the potential for reducing car running costs when deciding whether to undertake such a project.
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Frequently asked questions
Converting a dirt bike to electric can be a fun project that allows you to reduce automobile pollution and save money on gas. Additionally, with the rise of electric drive conversions for dirt bikes, you can find cheap bikes on the used market that have worn engines that need a rebuild.
You will need a donor motorcycle or rolling chassis, an electric motor, batteries, a motor controller, and a twist grip throttle. You can find these parts on eBay, Craigslist, or at your local golf shop.
A popular option for a mid-sized adult dirt bike is the 60V Sur-Ron, which has gained popularity in the US. For a full-sized off-roader, the Zero FX model is an option. For a youth or pre-teen, the Kuberg is a popular choice.
This will depend on your plan for the bike's range. For a 30+ range, deep cycle batteries from Walmart are an affordable option at $62 each. If you are looking for higher-end batteries, Chi Battery Systems offers the 72v 51ah Gladiator Max, which is capable of 400 amps continuous and 520 amp bursts.
