Kevin lives in a really hilly a part of Georgia, and he simply accomplished this conversion of a Suzuki DR650 from fuel to electrical. That by itself is actually cool, however the factor that stands out about this construct is that he put plenty of effort into having the ability to retain the inventory 5-speed gearbox, which is superb. So…let’s have a look!
I’ll begin by posting a transcript right here, of Kevin’s particulars from his youtube video…
“What’s up Youtube. I’ve been constructing this bike for about two years. Began with an RC outrunner motor, contained in the case of the inventory bikes transmission…and, uh…I might by no means actually get that working proper with the ASI BAC8000 controller, so I made a decision to modify the motor to a QS 138/90H. It’s additionally contained in the case.
Later within the video, I’m going to point out you ways I acquired all that to suit, with some photos and stuff I took alongside the best way. However, simply spent all weekend getting this factor buttoned up. Like I stated for the final two years, it’s [now] out of my storage. So, making an attempt to program the BAC8000 [controller], I’ve a love/hate with, however…it’s working now so…I assume I’m loving it now. I’m really discovering the controller fairly enjoyable to program, now that I’ve made some headway with it and began to know it a bit higher.
It runs two Kia Soul EV modules, that are 10S every (36V), so it’s a 20S pack (72V), so two of these modules in sequence. I haven’t wired within the BMS but, so this cost cable will go, however it’s hanging on there so I can cost it a bit bit. [You] is perhaps questioning what this gauge is for. That is really the oil strain gauge, as a result of there’s plenty of modifications to the oil system on this…as a result of the entire prime of the engine isn’t there anymore.
So, I wished to verify I used to be getting correct oil strain. It’s additionally the cooling system for the clutch, the electrical motor (the QS 138 is now oil-cooled), and it flows via the transmission as effectively, so…gotta be sure that oil’s flowing.
So you possibly can see a bit bit about the way it works right here. I re-plumbed the inventory oil system, so these oil strains return to an oil cooler that’s up at the back of the bike. [I’ll] most likely add a fan to it…it’s choosing up plenty of warmth, so…put a fan on that later.
And anyway, so the oil circulates again via the oil-cooler to the entrance to this manifold block the place it’s distributed out to issues just like the strain gauge, to the transmission, and sooner or later, to some extra oil-sprayers I’m going to put in across the motor. There’s additionally a big bypass valve in-between the 2 batteries which you could’t see with the bike assembled, so I’ll present you a slide of that afterward.
Simply acquired the lighting rigged-up in the present day. It’s acquired flip alerts, headlight, tail-light…in order that’s thrilling. It makes it extra pleasurable on the road, for positive. It’s acquired a brake gentle too. Yeah, that’s about it. I’m going to point out you some clips of it ripping and doubtless put some photos in of the elements I made.
Be happy to ask any questions within the feedback beneath. Thanks.
[Kevin followed up his build-and-ride video with a “Frequently Asked Questions” Q&A session]
“How briskly does this factor go?”
60-MPH (96 km/h)…sooner or later I’m going to have the ability to enhance the motor RPM’s with discipline weakening as much as round 5,000-RPM’s (from 4,000-RPM’s), and I’m additionally going to drop the rear sprocket down some tooth to most likely round 35T (from 42T). That is going to require a customized billet adapter to the cush-drive, which I’m gonna make in a future video. However, you possibly can see [in the graph], this actually spreads out my gear ratios, and makes every thing rather more helpful.
Within the final week of using, or so, I discover myself in fifth-gear on a regular basis…which is able to turn out to be the brand new third-gear, and that can give me an elevated top-speed within the fourth and fifth gears, in addition to the aptitude of getting out on the freeway for an exit or two between stops. So, I hope that helps on the top-speed query.
I stay up for seeing what it would really obtain when it’s geared correctly.
“What’s the vary, how far will this bike go?”
It can go about 40 to 50 miles of vary, primarily based on my miles-per-kilowatt-hour that I’m recording proper now.
“Why did I would like a gearbox?”
I dwell in Northern Georgia, and it’s tremendous hilly right here. I’ve executed a pair single-speed builds earlier than, and one factor I’ve discovered with single-speeds is I’m all the time wanting a distinct gear ratio. Within the hilly mountainous areas, I would like one thing shorter, and on the street the place it’s flat and open, I would like one thing taller. And I simply might by no means choose a [single-speed] gear ratio.
So, I figured with a gearbox, I might shortly click on into the gear that I would like for the scenario I’m in, and have plenty of enjoyable with it. It additionally provides like…a ton of enjoyable issue to using the bike. I’m a guide transmission man usually, I purchase solely guide transmission vehicles and autos.
And, It offers me that strong really feel with a contemporary bike with the electrical drive. So total I just like the enjoyable issue of driving a guide on an electrical motor, or a fuel motor, field truck, sports activities automotive, no matter…so long as it’s a guide, I prefer it.
So, that is particularly beauty. So, lots of people commented on the appears to be like of the bike. Some folks beloved it, some folks hated it. Both means, I believe everybody was proper on this case, there’s some issues that look actually good and, somethings that look yeah, actually dangerous. So, I do plan on doing a complete beauty restoration of the bike, as effectively. I wished to get the mechanical fundamentals set-up first. Subsequent shall be a resto on the cosmetics.
Scrambler fashion is what I’m going for. So, spherical headlight, reduce the tail down a bit bit (pic at 3:38), after which I’m going to make some carbon fiber trim items for the facet panels, and the fuel tank. I’ve executed carbon fiber physique stuff up to now. So…I’m trying ahead to a brand new carbon-fiber venture.
And, uh…we’ll do a video about the way you make carbon-fiber elements, and perhaps I’ll do a 3D-printed mould even, so…search for that sooner or later.
“What’s subsequent for the sequence on the DR650?”
I’m planning on doing a number of extra movies on the DR650. I wish to do the subsequent video on the design and the construct of the bike, so let’s go over the CAD-design (Laptop Aided Design), programming, and CNC set-up, fabrication of the elements, that type of factor. We’ll try this one subsequent, most likely.
Then I wish to do a video on the whole value evaluation, about prices to construct a venture like this, and the way a lot of the cash will get diverted into the machine itself, verses how a lot of it will get diverted into tooling that you should utilize for future tasks. I believe that’ll be enjoyable.
After which I wish to do a video on tuning the ASI [BAC8000] controller, which…is…really actually enjoyable to get to realize it a bit bit. However to start with, it’s very daunting, and…ASI refuses to open up their assist to the general public, which……is, I get it with this mannequin, however…I constructed my complete profession constructing gross sales and advertising and marketing applications for expertise corporations, and…I…can’t actually perceive what they’re doing. So, um, if you need any recommendation, ASI…I’m blissful to assist.
After which I believe I wish to do a video on the restoration of the bike itself, however that will be sooner or later, as a result of it’s going to be an extended course of. Very element oriented. Portray, powder-coating, and so forth, so…
That might be sooner or later, solely benefit from the bike for the summer season…most likely try this within the winter. So, yeah, little bit sooner or later. And the very last thing I wish to speak about on this video is that this channel and what we will do on this channel, so…
You may need already seen I promote applications. That’s what I’ve executed professionally my complete profession. I work in superior manufacturing. Taking…taking…merchandise like CAD software program, or 3D-printers, evaluation CT scanning machines, and software program for CT scanning machines to market…and, um…I wish to combine a few of that aptitude into this channel, so…I do know I wish to construct stuff, however I believe I additionally wish to cowl the companies that provide the machines and the parts that go into these builds.
I’d wish to know should you assume that’s attention-grabbing, should you assume that can make this channel distinctive. I’d love to listen to your thought on anything you’d wish to see, I imply, I believe it might be fairly cheap to interview engineers who design machines and elements that go into these builds.
I believe it’s additionally possible to go to some distributors that provide, , manufacturing machines…or, the elements that go into the builds, so…I believe all that’s fairly cheap. I’ve a comparatively broad community in that manufacturing area, and I believe we will provide you with some locations to go go to. That is perhaps attention-grabbing, so…Let me hear your ideas on the place you’d wish to see the channel go, and I would be capable of attempt to implement as a lot of that as I probably can.
Once more, thanks a lot for watching, and see you subsequent time.
Right here is the 7-minute construct and journey video…get pleasure from!
Our tackle this
I’m blissful to see extra builds utilizing hybrid cells from a hybrid EV wreck. Pure EV’s have an enormous battery, to allow them to simply present enormous amps, merely as a result of bodily dimension of the pack. this implies the designers are free to spec cells which can be optimized for lengthy vary.
A hybrid automotive is a bit completely different. Because it has an on-board engine, it isn’t involved with vary (A hybrid Chevy Volt can usually drive solely 80 miles in electric-only mode, whereas the Tesla Mannequin-S can simply do over 300 miles). This implies the costly battery could be a lot smaller. HOWEVER!….this small battery pack should be capable of propel the heavy automotive by itself once in a while, so the cells are the “high amp” cells we love (click here)…
Bikes want excessive amps to supply nice efficiency with out the cells getting sizzling, they usually should try this with a small pack that may slot in a decent bike body.
Transmissions on an EV?
If you’re designing an electrical bike from scratch, to be able to promote them to the general public…there are a number of good causes to decide on a big motor with no transmission, vs a smaller motor with some gears. Probably the most profitable electrical bike firm is the Zero, by far. Nonetheless…they use 28 cells in sequence (28S) which is roughly 104V nominal.
Kevin is utilizing a extra out there and inexpensive 20S / 72V battery, so he’s beginning off with much less energy. On prime of that, his user-profile is for a dual-use enduro. It’s major job is crawling up steep terrain of a extensively various grade, however every so often…it might be helpful for him to take a fast shot down a paved street at freeway speeds. Conducting that with solely 72V is a tall order.
If he had no transmission, the steep portion of the journey would suck down very excessive amps, which causes a number of warmth within the motor, controller, and battery…and likewise shortens his vary. Then, his top-speed on the streets could be compromised if he selected a sprocket-set that was lower-enough to run off-road effectively.
One of many advantages of an electrical drivetrain is the unimaginable torque that’s out there down low on the first RPM. However…there are nonetheless limits. If you wish to construct an electrical bike conversion that’s both “avenue solely” or “off-road solely”, there are present configurations that can try this with no transmission, making the ensuing bike less complicated to transform, and likewise leaving extra frame-room for a bigger battery pack.
Nonetheless, if you wish to have an enduro that may work effectively for a twin use (dust and avenue), then I’d humbly counsel that dozens of builds have confirmed repeatedly that having two widely-spaced gears is absolutely the minimal to tug that off (and I consider that three gears is near very best).
Kevin didn’t “select” 5-speeds. He already owned the Suzuki for a very long time after which the engine died. He determined to transform it, and it simply got here with the 5-speed. In truth, he particularly talked about that he spends most of his time in fifth gear. It was simply fortunate that this huge 650cc single cylinder had an infinite crankshaft and counter-weight, and in consequence he was in a position to take away them and match the QS 138/90H contained in the case (after shaving all of the elements!).
Right here is our current article on the Denzel “motor and 4-speed gearbox” (click here). And right here’s our article on bicycle multi-speed IGH transmissions (click here). When you perceive how the classic 3-speed internally-geared Hubs work, you possibly can see that there is no such thing as a purpose they couldn’t be scaled-up to bike dimension. I do know I’ll sound nuts for saying this, however the Ford Mannequin-T from the 1910’s had a “planetary gear” transmission that was a really compact and strong unit. It had two ahead speeds, a impartial, and one velocity in reverse (generally listed as a 3-speed). One thing like that will be an ideal choice for an electrical enduro…
For individuals who are curious concerning the QS cylindrical motors, here is our article on them (click here).
Written by Ron/spinningmagnets, July 2021