I am in the initial planning stages of an EV conversion of a Honda ST1100 shaft drive, water cooled motorcycle (ICE curb weight ~700lbs) for commuting. I've looked at a lot of different motors and AC-15 or AC-20 look like they might be a good fit. I'm not sure yet what voltage I'll be running, but I'm shooting for somewhere between 72-120VDC and at least 10kWh. I have to get the ICE out so that I can measure and mock up pack and motor configurations. I'm sure I can find the ~75 liters of volume for a 10kWh pack of LiFePO4 prismatics, but I want more.
I believe that the shaft drive ratio is somewhere around 1.8:1, I think I'll need a gear box fabricated rather than a direct connection to the shaft. I think that I may be able to mount the drive vertically and have a 90 degree gear box attached to the shaft. I think that configuration would leave the maximum space available for a battery pack. I would really appreciate some thoughts/ideas about this. What type of gears should I look at for this type of configuration? Would such a mounting position require thrust bearings to be installed in the motor?
I will not be using the bike for racing, likely will never have it over 100mph, and am looking for range rather than acceleration. For a fairly large commuter bike like this, is the AC-15 or 20 a good fit? I've also looked a the NetGain and Kostov 9" DC Series motors, but the weight on those seems excessive for a motorcycle. If I end up with a DC Series motor, I'll likely use a SolJr controller. Whatever direction I end up going in, I plan on using the existing water cooling system for the controller and charger.
What motor/controller combo would you guys recommend? Am I nuts thinking about the 90 degree gearbox?