Otis Singleton
Converting a motorcycle into an electric bike is a complex process that requires careful planning and execution. It involves removing the engine and replacing it with an electric motor and battery, as well as making changes to the bike's frame and other components. The first step is to source a donor motorcycle or rolling chassis, which can be found on platforms like eBay and Craigslist. The next step is to choose an electric motor and battery that fit the bike and meet your desired specifications. The process also involves calculating the best arrangement of teeth on the sprockets and integrating the electrical systems. Resources like online forums, YouTube videos, and books can provide valuable guidance for those interested in attempting this conversion.
Characteristics and Values Table for Converting a Motorcycle into an Electric Bike
| Characteristics | Values |
|---|---|
| Cost | $1,000 |
| Range | 40 Miles |
| Speed | 40 mph with current sprocket setup |
| Curb Weight | 320 Pounds |
| Recharge Cost | Less than a penny per mile |
| Battery Voltage | 48V |
| Old and New Electrical Systems | Keep separate or integrate |
| Basic Parts | Rolling chassis, electric motor, batteries, controller, charger, converter, cables, custom sprockets, tools |
| Resources | Honda Rebel service manual, 21 Wheels plans, Electric Motorsport consultations, Make Magazine gear calculator |
| Donor Bike | Honda Rebel 250, Honda Goldwing, Yamaha XS400, BMW electric scooter, Honda Dream (CA160) |
| Motor Options | Brushed 48V Etek Briggs and Stration, QS 3.5x 17-inch BLDC Hub Motor 72V 8000W, QS273 hub motor |
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What You'll Learn
Choosing a suitable motorcycle frame
Frame Material
The frame's material is an important consideration. Steel frames are often recommended for electric conversions due to their strength and ability to handle more weight compared to cheaper new alloy or aluminium bikes. Steel bikes with steel dropouts are ideal, as they provide strong support for the wheels' axles. While aluminium bikes can be used, they typically require an additional torque arm to reinforce the dropouts. It is worth noting that some cheaper steel bikes may have stronger dropouts than more expensive aluminium options.
Frame Condition
It is advisable to choose a motorcycle frame that is in good condition, especially if it is an older model. Old frames may have issues like rust, broken parts, or missing components, which can complicate the conversion process and add to the overall time and cost. Ensure the frame is thoroughly inspected and, if necessary, refurbished before starting the conversion.
Dropout Design
The dropout design is crucial when selecting a frame for electric conversion. Dropouts are the parts of the frame that hold the axles of the wheels. Look for "beefy" or thick dropouts, as they provide a stronger hold. Additionally, consider frames with a large, flat area around the axle, as this can accommodate the torque arm if needed. Some manufacturers, like Currie Izip and Sondors, are known for their well-designed dropouts.
Suspension
For your first electric motorcycle conversion project, consider choosing a motorcycle frame without suspension. Frames without suspension are generally simpler to work with and can be more cost-effective. You can always plan to add upgrades later as you gain more experience with electric motorcycle conversions.
Brakes
Brakes are a critical safety feature, especially for electric bikes, as they will be subjected to higher speeds and need to handle the additional weight of the electric motor and battery. Disc brakes are recommended for electric conversions as they provide superior braking performance. Ensure the frame you choose can accommodate the type of brakes you plan to use.
Legal Requirements
Before choosing a frame, it is essential to consider the legal requirements for registering and operating an electric motorcycle in your region. In some areas, you may need to buy a frame with a title and then discreetly modify it into an electric motorcycle. Check with your local DMV or equivalent agency to understand the specific rules and regulations that apply to your project.
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Selecting the right electric motor
Firstly, you need to decide between a Hub Motor and a Mid-Motor. Hub Motors are installed in the wheel of the motorcycle and offer a compact, cost-effective, and robust solution with high starting torque. They are commonly used in lower-cost electric motorcycles and DIY e-bike conversions. On the other hand, Mid-Motors are mounted at the centre of the bike, providing better balance and handling. They are driven by a belt or chain and are typically found in higher-end electric motorcycles. Mid-Motors offer higher efficiency, better performance, and a longer lifespan, but they are more complex and expensive.
The next step is to consider the power rating of the motor, which will determine the speed and acceleration of your bike. If you're planning to use your converted bike for urban commuting, a lower power motor may be sufficient. However, if you intend to ride on highways or go off-roading, you will likely need a motor with higher power.
In addition to power, you should also consider the voltage and power capacity of the motor. Depending on where you plan to ride your converted bike, you may opt for a lower or higher-range capacity motor. Smaller range capacity motors are suitable for flat areas, while higher-range capacity motors are ideal for hilly terrain and carrying loads.
Lastly, it's important to keep in mind that the choice of motor can impact the safety and handling of your motorcycle. Ensure that the motor suits your riding skills and that it is compatible with your bike's design to avoid stability issues.
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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Integrating electrical systems
The first option is to keep the old and new electrical systems separate. This involves running the old system off a small rechargeable 12V battery. This method has the advantage of keeping the wiring simple. However, it requires maintaining two separate battery and charging systems, which can be inconvenient.
The second option is to integrate the two systems using a DC-to-DC converter. This converter steps down the power from 48V to 12V, allowing the new and old systems to work together. While this option requires a more complex wiring setup, it offers the convenience of a single charging system for both setups. This is the approach chosen by many DIY enthusiasts as it is more convenient for day-to-day use.
When integrating the electrical systems, it is essential to carefully plan the placement of the new electronic components, such as the motor controller, charger, and fuses. The performance of the electric bike will also be influenced by the arrangement of teeth on the sprockets (one on the motor and one on the rear wheel). A gear calculator can help determine the ideal sprocket sizes before purchasing them.
Additionally, it is important to consider the battery setup. The battery weight should be kept as low and centered as possible to enhance handling. Creating cardboard cutouts of the batteries can help determine the optimal configuration. It is also worth noting that a shaft drive is often considered the trickiest obstacle when converting a bigger motorcycle.
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Battery placement and mounting
When it comes to battery placement and mounting, there are a few key considerations to keep in mind. Firstly, it is essential to choose a battery that fits the dimensions of your motorcycle frame. You can create cardboard cutouts the same size as your chosen battery to experiment with different configurations and find the best arrangement. This will save you from having to move around large, heavy batteries during the testing phase.
It is recommended to keep the battery weight centred and as low as possible to aid with handling. The battery placement should also consider the other components of the motorcycle, such as the motor controller, charger, and fuses, ensuring that they can all fit within the frame.
If you are using a separate battery system for accessories like the speedometer and lights, you will need to decide on the placement of these batteries as well. You may choose to keep the old and new electrical systems separate, using a small rechargeable 12V battery for the old system, or integrate them using a DC-to-DC converter to step down the power from 48V to 12V.
When mounting the battery, you can utilise the original frame and engine mount as much as possible. Steel or other sturdy materials can be used to create steady battery mounts that securely hold the battery in place.
Remember to also consider the range and speed requirements for your electric motorcycle when selecting a battery. For example, a higher-capacity battery will be needed if you plan to reach 60 mph and maintain that speed for a 20-mile commute.
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Testing and troubleshooting
Testing
Before testing, it is important to ensure that you have planned your wiring diagram carefully and used high-quality wires and connectors. You should also waterproof all the connections.
Once you have installed the electric conversion kit, test your electric motorcycle for any faults and make necessary adjustments. Check the battery and motor system, and ensure all wires and connectors are secure and properly connected. Check the battery to see if it is outputting the correct voltage or any voltage at all. You can use a Digital Multimeter to check the voltage.
If your motorcycle has a display, ensure that it is showing the correct information, such as speed, battery level, and distance travelled. You can also adjust the motor settings, PAS levels, and throttle response to personalize your riding experience and maximize performance.
Troubleshooting
If you encounter any problems during testing, you may need to troubleshoot. Some common issues include battery and motor malfunctions, loose connections, or issues with the throttle or controller.
For simple problems, replacing the affected part is usually straightforward. For more complex issues, such as the motorcycle not powering on, check the connections and pins on electrical components. If the problem is with the controller, you may need to plug in a new, fully functional replacement to see if it solves the issue.
Always refer to the manufacturer's instructions and consult online resources for specific troubleshooting steps related to your particular conversion kit. It is also helpful to seek advice from the DIY e-bike conversion community and qualified e-bike mechanics.
Finally, be aware of the legal and safety considerations specific to electric motorcycles. These classifications can vary by region, so check your local regulations, registration, and licensing requirements. Wear a properly fitted helmet, and be mindful of increased stopping distances.
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Frequently asked questions
The basic parts required are a donor motorcycle or a rolling chassis, an electric motor, and a battery.
Popular electric motors used for motorcycle conversions include the QS cylindrical motor and the Brushed 48v Etek Briggs and Stratton motor.
When choosing a donor motorcycle, consider the frame size and weight, suspension, and drivetrain type. Smaller to midsize bikes with hub drives are generally easier to convert.
Some challenges include calculating the correct gear ratios and teeth arrangements for optimal performance, integrating the electrical systems, and ensuring that the brakes and suspension are adequate for the new electric powertrain.
