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Old 11-30-2011, 07:44 PM
StanSimmons StanSimmons is offline
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Default Converting a large motorcycle: Honda ST1100

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?
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Old 11-30-2011, 10:03 PM
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RIPPERTON RIPPERTON is offline
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Default Re: Converting a large motorcycle: Honda ST1100

On the right track but your final drive ratio is 2.83:1
http://www.pan-europe.utvinternet.ie...ifications.htm
so think again about another gear box, I think its limit but
90 degree drive is smart, Yabert did it on his DRZ.
http://www.youtube.com/watch?v=Y8obaiqmVsg
Your idea about vertical axis motor straight up the middle of the bike is good
but longitudinal down in the belly might be better and belt or chain up to
the shaft
Your choice of cell is right for a commuter and you should easily get 10kWh in.
definitely keep the AC motor you will be on the regen all the time in the traffic. Kelly (165v) or Sevcon (96v) depending on you voltage choice.
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Last edited by RIPPERTON; 12-01-2011 at 02:19 PM.
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Old 11-30-2011, 10:41 PM
StanSimmons StanSimmons is offline
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Default Re: Converting a large motorcycle: Honda ST1100

Quote:
Originally Posted by RIPPERTON View Post
On the right track but your final drive ratio in 2.83:1
http://www.pan-europe.utvinternet.ie...ifications.htm
so think again about another gear box, I think its limit
I'm not sure what you mean here.
Quote:
Originally Posted by RIPPERTON View Post
but
90 degree drive is smart, Yabert did it on his DRZ.
http://www.youtube.com/watch?v=Y8obaiqmVsg
Your idea about vertical axis motor straight up the middle of the bike is good
Thanks for that link, I'll have to do some research on what Yabert did.
Quote:
Originally Posted by RIPPERTON View Post
but longitudinal down in the belly might be better and belt or chain up to
the shaft
I've also been looking at the Goodyear PD belt system for a belly mount similar to the LithiumHawk but I think I may have more room vertically, I'll know more after I remove the ICE and do some measurements.
Quote:
Originally Posted by RIPPERTON View Post
Your choice of cell is right for a commuter and you should easily get 10kWh in.
definitely keep the AC motor you will be on the regen all the time in the traffic. Kelly (165v) or Sevcon (96v) depending on you voltage choice.

Last edited by StanSimmons; 11-30-2011 at 10:46 PM.
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Old 12-01-2011, 02:21 PM
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Default Re: Converting a large motorcycle: Honda ST1100

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Originally Posted by StanSimmons View Post
I'm not sure what you mean here.
The 2.8:1 final reduction is almost short enough.
the rest you can do with the belt from motor to shaft.
maybe 3.5:1 overall
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Old 12-01-2011, 02:37 PM
StanSimmons StanSimmons is offline
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Default Re: Converting a large motorcycle: Honda ST1100

I was planning to measure the existing final gearing and calculate the gearbox to end up with a ratio somewhere between 2nd and 3rd gear. Hopefully the math will work out so that I can use off the shelf gears.

Does anybody have any comments about recommended motors?
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Old 12-01-2011, 02:53 PM
Rational Rational is offline
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Default Re: Converting a large motorcycle: Honda ST1100

Quote:
Originally Posted by StanSimmons View Post
Does anybody have any comments about recommended motors?
Post spec's for your candidate motors.

Range rather than accel or high top speed says w-h/kg rather than w/kg for the batteries, see fig. 9 below
http://web.mit.edu/sloan-auto-lab/re...owertrains.pdf

Last edited by Rational; 12-01-2011 at 02:59 PM.
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Old 12-01-2011, 04:25 PM
EV-propulsion.com EV-propulsion.com is offline
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Default Re: Converting a large motorcycle: Honda ST1100

For the ultimate in space for batteries and longer range, there is the Enertrac BLDC hub motor. A dual motor for heavier bikes shown here... use all the ICE space for batteries


mike
www.EV-propulsion.com
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Old 12-01-2011, 04:45 PM
StanSimmons StanSimmons is offline
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Default Re: Converting a large motorcycle: Honda ST1100

Quote:
Originally Posted by EV-propulsion.com View Post
For the ultimate in space for batteries and longer range, there is the Enertrac BLDC hub motor. A dual motor for heavier bikes shown here... use all the ICE space for batteries

mike
www.EV-propulsion.com
Thanks for the tip, I hadn't considered a hub motor for this size bike.

Your site says: "The Hub motor is designed for motorcycles weighing less than 400 pounds with the batteries (dry weight, no rider)."

My bike is ~700 pounds curb, ~650 dry.

Last edited by StanSimmons; 12-01-2011 at 04:49 PM.
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Old 12-01-2011, 04:48 PM
StanSimmons StanSimmons is offline
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Default Re: Converting a large motorcycle: Honda ST1100

Quote:
Originally Posted by Rational View Post
Post spec's for your candidate motors.

Range rather than accel or high top speed says w-h/kg rather than w/kg for the batteries, see fig. 9 below
http://web.mit.edu/sloan-auto-lab/re...owertrains.pdf
I've been looking at the AC-15, AC-20, WarP9 and Kostov 9. I'm unsure of the specs on the AC-15/20... different sites list different specs. I'll have to look up the 9" motors.

I was really asking to see if I had overlooked a good motor candidate.
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Old 12-01-2011, 05:21 PM
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Default Re: Converting a large motorcycle: Honda ST1100

Quote:
Originally Posted by EV-propulsion.com View Post
For the ultimate in space for batteries and longer range, there is the Enertrac BLDC hub motor. A dual motor for heavier bikes shown here... use all the ICE space for batteries


mike
www.EV-propulsion.com
what the torque of this motor? peak power - on what rpm? what the amp ratings?
why this data not available? is there a problem?
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