E-Busa

[Frank06]

The motor is cooled with ATF and I'm using a scavenge pump to ensure oil doesn't back up inside.  The small pump in front is for anti-freeze that cools the controller.  Small heat exchangers are mounted at the rear of the bike.  Both the motor and anti-freeze reservoir are vented to atmosphere i.e. not pressurized.  Both pumps will be inside the fairing and are serviceable from below.

[Frank06]

Finding real estate for everything is always a challenge, especially when adapting to an OEM frame.  Next time I'll build my own I think.  Main fuse, DC/DC converter, precharge circuit, main contactor, etc. all sit on top of the motor.

[Frank06]

I decided to keep using terminal strips (for now.)  They simplify trouble-shooting but could all be replaced by a couple of cable connectors.

[saltwheels262]

I think that motorcycle will go very fast.

But, that's a lot of wires that are basically only two colors.

Very good luck to you,
Bf262

[Frank06]

Thanks.  I've taken a few rides, trying to make sure I haven't missed anything major.  It'll be a screamer!  I took a couple of low-power rides to exercise the batteries a bit.  I then cranked up the motor controller settings and just got back from a 10-mile loop.  Fun stuff!  It weighs in about 550# although it feels lighter than my gas 'Busa.  I love the EV grin!

Speaking of batteries, here's a couple of shots of the new pack.  Back: (one cell near top right shifted a bit during transport.)



This is a 540kW pack (700+HP) even though the setup in this bike will never use more than 1/3 of that.  I've been drag racing another electric bike this year and have plans for this pack in another machine.

Front (you think there was a lot of wires in that other pic?):



We decided to keep the main power connection wires outside the box for cooling.  This application doesn't really need much cooling but a drag machine will.  The exposed wires wick heat away from the cells.

[Frank06]

I built an aluminum frame to support/protect the pack.  Installed in the bike it's a lot neater looking.  I still have some guards to install.

[Frank06]

In addition to being a lot lighter this version will let me get down right behind the windscreen for (hopefully) improved aero.  Version 1.0 had a bunch of batteries mounted up high and you couldn't really get down that much.  Here's what it looked like at Loring:



The pack is much more compact now.  I'll build a top cover that will support a rider's upper body this winter.  I also have to clean up the fairing patches which were put in place to block off unneeded air.

[Koncretekid]

Frank,
I plan on coming to the July meet so I hope you bring that bike.  I get confused just wiring a standard bike, so I'm sure I'd get lost with an electric one.  Electric seems so simple, yet so foreign to those of us used to internal combustion that I'm at a loss for words.
Tom

[Frank06]

Hi Tom,

I'm planning to be there with this bike.  I'm a mechanical guy too so the learning curve is/was pretty steep.   

[Frank06]

I should add though that this isn't my first conversion (4th or 5th I think.)  I drag raced another e-bike this year too.

[Frank06]

A friend pointed out that I had neglected to update this thread so here goes...

Bike as raced at Loring's Maine Event this past July:



had the following result:



There's not much left power-wise but the bike was still accelerating so I'm hoping with some gearing changes (and minor aero mods) that I'll get over the magic number at the Labor Day "Harvest Event".

[Koncretekid]

Best of luck, Frank.   I'm thinking that removing that passenger hand hold on the rear fender and the license plate might do the trick!  Unfortunately, I'll still be out west for the fall event.
Tom

[Frank06]

Thanks Tom, both those items are coming off.

[Frank06]

Are you going to be at BMST?

[55chevr]

A Charlie Toy fairing would give significantly better aero.


Joe