Umair Gaines
With the ever-increasing cost of petrol, it is becoming more and more appealing to convert petrol scooters to electric. The conversion process involves removing the petrol engine, fuel tank, and silencer, and replacing them with an electric powertrain and battery. This can be done through a variety of conversion kits, with companies such as Zuink Retrofit, Starya, and Green Tiger offering kits for as low as Rs. 26,999 and Rs. 55,000, respectively. The benefits of converting your scooter include convenience, sustainability, and reduced pollution, as well as the ability to retain your familiar ride.
| Characteristics | Values |
|---|---|
| Time taken for conversion | 4 hours |
| Cost | Rs 26,999 or Rs 55,000 or Rs 72,500 (smart i-Hybrid) or Rs 67,500 (non-smart i-Hybrid) |
| EMI options | Rs 899 per month or Rs 1 per kilometre |
| Engine | 3000w BLDC motor |
| Battery | 2 kWh lithium-ion battery |
| Top speed | 55 kmph |
| Range | 55 km |
| Battery replacement | Rs 8,000-9,000 |
| Conversion companies | Zuink Retrofit, Starya, Green Tiger |
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What You'll Learn
Removing the petrol engine, fuel tank and silencer
To convert a petrol scooter to electric, the first step is to remove the existing petrol engine, fuel tank, and silencer. This process will vary depending on the scooter model and your level of mechanical expertise. Here is a step-by-step guide to removing these components:
- Strip down the scooter: Start by removing all the body panels and custom parts. This will expose the internal components, including the engine, fuel tank, and silencer. Take your time and carefully set aside each part, keeping them organized for potential reuse or recycling.
- Remove the petrol engine: The engine is the heart of the scooter, and its removal requires caution. Start by disconnecting all attached components, such as the head block, piston, crankshaft, air filter, and magneto assembly. Be sure to also remove the CVT side engine cover and any other relevant engine parts.
- Seal the engine compartment: Once the engine is removed, seal the empty space with a steel plate to prevent dust and debris from entering the engine compartment. This ensures that the remaining chassis is protected.
- Remove the fuel tank and silencer: With the engine out of the way, you can now access the fuel tank and silencer. Carefully detach the fuel lines and any other connections to the fuel tank. The silencer, also known as the muffler, will also need to be removed. It is typically connected to the exhaust system, so ensure you disconnect all relevant pipes and fasteners.
- Clean and prepare the chassis: After removing the petrol engine, fuel tank, and silencer, clean the chassis thoroughly. Inspect it for any damage or issues that may need to be addressed before installing the electric motor and other components.
Remember to follow safety protocols and wear appropriate protective gear during the disassembly process. Working with a partner or a professional mechanic is recommended if you have limited experience with scooter maintenance or conversions.
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Installing an electric powertrain and hub motor
Converting a petrol scooter to an electric one involves removing the scooter's engine, fuel tank, and silencer, and installing an electric powertrain and hub motor. This process can be done by companies such as Zuink Retrofit, which offers conversion kits, or one can choose to perform the conversion themselves.
The first step in installing an electric powertrain and hub motor is to select the right motor for your scooter. The motor should be able to produce enough torque to move the scooter, and the voltage and wattage should match your desired performance. For example, a 3000w BLDC motor was used in one DIY conversion project.
Next, gather the necessary tools and materials. Aside from the motor, you will need a battery, controller, throttle, and mounting hardware. Tools such as wrenches, screwdrivers, and possibly a drill will also be needed.
The scooter then needs to be prepared for the conversion. This involves removing the rear wheel, which will be replaced with the powered wheel that houses the motor, or the motor can be attached to drive the existing wheel.
The motor can then be mounted. It should be secured firmly, ensuring proper alignment with the scooter's frame and drivetrain. Bracket kits or custom fabrications may be required for a secure fit.
Finally, the drive mechanism can be installed. This could involve adding a motor cog to the scooter's chain drive or ensuring that a hub motor is properly seated in the wheel.
It is important to note that the complexity of this project can vary depending on the scooter and the motor kit being used. It is always essential to prioritise safety and consider seeking assistance from professional mechanics if needed.
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Wiring harness and battery installation
The wiring harness and battery installation is a crucial aspect of converting a petrol scooter to an electric one. Here is a detailed guide on how to approach this process:
Firstly, it is important to source a suitable wiring harness for your electric scooter conversion. You can purchase a wiring harness kit that is specifically designed for electric scooter conversions, ensuring it is compatible with your scooter's voltage and motor type. These kits typically include insulated terminals and connectors to prevent electrical hazards during operation.
Next, you will need to remove the old wiring harness from the scooter. This step may vary depending on the make and model of your scooter, but it typically involves disconnecting the battery and carefully removing the wiring harness from the scooter's frame. Label the wires before detaching them to make it easier to remember where each wire goes during reassembly.
Now, it's time to install the new wiring harness. Start by identifying the main power wires, which will connect to the battery. Ensure these wires are long enough to reach the battery and allow for some slack. Connect the positive wire from the wiring harness to the positive terminal on the battery, and the negative wire to the negative terminal. Use appropriate connectors and ensure secure connections to prevent sparking or short circuits.
After the main power wires are connected, move on to the other wires in the harness. These may include wires for the throttle, LCD display, brakes, lights, and any other accessories. Refer to the wiring diagram provided by the wiring harness manufacturer to identify each wire's function and proper connection point. Use zip ties or other fasteners to neatly secure the wires along the scooter's frame, ensuring they don't interfere with moving parts.
Finally, install the battery. Depending on the type of battery and your scooter's design, you may need to fabricate a custom battery mount. Ensure the battery is securely fastened and won't shift during scooter operation. Connect the battery to the wiring harness, following the specific instructions provided by the battery manufacturer.
It is important to note that working with electricity can be dangerous. Always exercise caution and refer to detailed guides or seek expert advice if you are unsure about any aspect of the wiring harness and battery installation process.
With these steps, you can successfully install the wiring harness and battery for your electric scooter conversion, ensuring a safe and functional electric scooter.
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Custom crankshaft and adapter plate
A custom crankshaft is an essential component of the conversion process. It is fabricated from an iron bar to prevent unnecessary offset weight rotation and maintain system balance. This is achieved by coupling the custom shaft from the fan side to the motor with a toothed nylon transmission geared drive.
The crankshaft is designed to work seamlessly with the electric engine, eliminating the need for a piston. The custom crankshaft's specific dimensions and materials ensure that it can withstand the unique demands of an electric powertrain while maintaining optimal performance and efficiency.
The adapter plate, on the other hand, serves as the mounting base for the motor. It is crafted from aluminium to be fixed on the fan side of the crankcase. The adapter plate is designed to securely hold the motor in place, ensuring proper alignment with the driveshaft. This plate is crucial for transferring power from the motor to the rest of the scooter's drivetrain.
The combination of the custom crankshaft and adapter plate ensures a smooth and efficient transfer of power from the electric motor to the scooter's wheels. The crankshaft's ability to couple with the motor and the adapter plate's secure mounting position contribute to a stable and balanced electric scooter.
Additionally, the adapter plate also acts as a structural component, providing support to the motor and the overall frame of the scooter. The plate's design and material selection ensure that it can withstand the vibrations and stresses associated with the electric motor's operation, contributing to the overall durability and reliability of the converted scooter.
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Cost-effectiveness and sustainability
Converting a petrol scooter to electric can be a cost-effective option, especially when compared to buying a new electric scooter. For example, Zuink Retrofit, a company based in Bengaluru, India, offers conversion kits for as low as Rs 26,999, which is significantly more affordable than purchasing a new EV two-wheeler that can cost upwards of Rs 70,000. This conversion kit also offers an EMI payment option of Rs 899 per month, making the transition to electric more accessible and affordable.
Additionally, converting to electric can result in significant savings on monthly fuel costs. According to Zuink Retrofit, consumers can expect a reduction of more than 50% in fuel expenses. For instance, a petrol scooter may incur costs of Rs 3-3.50 per km, while an electric scooter can offer a lower rate of Rs 1.50 per km. This substantial decrease in fuel costs can lead to notable financial savings over time.
The age of a petrol scooter is also an essential factor in considering a conversion to electric. Older petrol scooters tend to have higher emissions due to the nature of their IC-engines. By converting these older models to electric, emissions can be reduced to zero. This not only contributes to environmental sustainability by reducing air pollution but also allows for the retention of the sturdier chassis typically found in IC-engine variants.
Furthermore, companies like Starya in India offer petrol-to-electric conversion kits with Lithium-Ion batteries, which are known for their stability and high energy density. Their EPK 1.0 model claims to offer a 70% reduction in initial investment and running costs compared to new EVs, making electric vehicle technology more accessible and affordable for the average family.
Overall, converting a petrol scooter to electric can be a cost-effective and sustainable option. It allows individuals to reduce their environmental impact, lower fuel costs, and access the benefits of electric vehicles without the high upfront cost of purchasing a new EV. With companies like Zuink Retrofit and Starya offering affordable conversion kits and battery-swapping networks, the transition to electric mobility becomes more feasible and financially viable for a wider range of consumers.
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