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User:Rjf/Electric Kawasaki

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I'm in the process of converting my Kawasaki EX-500 motorcycle from gas to electric with the intension of utilizing the stock transmission coupled to a ~$400 48v eTek motor and Sevcon 4QD 24-48V regen capable controller capable peaking to ~330A. This was my first bike and I rode it to work for nearly an entire wet winter while repairing my VW Vanagon. Eventually I stopped riding it but couldn't bring myself to part with it even though it's engine was seized and no longer ran.

I currently need to create a motor shaft to clutch adapter and a motor mounting plate to take the place of the old clutch cover. The motor will directly drive the input shaft of the transmission, but I also need to figure out how to keep the main output shafts needle bearing lubed so not to burn it out. The result should be an electric conversion with about the same levels of torque as it originally had, per my most likely incorrect calculations. Though the motor will only be capable of about half the RPMs as the engine once had.

Below are my own notes regarding various components which I already have or need to acquire.

I'll post photos and video of conversion once they are ready..

Other Bike Conversions

Sevcon

The ~$320 Sevcon 4QD 24-48V controller, Type 633T43802, SW 1.50.03 has armature current limits of 330A @1min and 130A @1hour. The Sevcon PCPak software for a windows PC is used as the programming interface.

  • 12.17 Digital Configuration = 15 footbrake @06, FS1@04, Seat@05
  • 12.18 Analogue Configuration = 3 0-5K throttle(10) and brake(11)

Sevcon 4QPM Manuals and Documentation:

Wiring

 Wiring for Sevcon 4QD 24-48V controller. ($320)
 Armature Current 330A @1min, 130A @1hour
 
 -ve  +ve---~fuse~---/Key>--------|-----\
  |                        *(01)--|      \
  |______./Forward>--------*(02)          \
  |Clutch| Reverse>--------?(03)           \
  |______./FS1-Bel>--------*(04)      -ve   \   +ve
  |_______/Seat-Sw>--------*(05)       |     \   |
  |_______/FootBrk>--------*(06)       |      \  |
  |->  P. Steer Trigger <---(07)       |       | |
  |                        *(08)--Contactor_1--| |
  |         Contactor_2 <---(09)       |         |
  |-------~0-5K Throttle --*(10)       |         |
  |-------~0-5K RegenBrk --*(11)       |         |
     <-?-------12V Out-----?(12)    !==|=========|==!
    extra supression 1  <---(13)    !  B+        B- !
    extra supression 2  <---(14)    !   SEVCON 4Q   !
     horn supression    <---(15)    !  M1        M2 !
             program        (16)    !==|=========|==!
                                       |__MOTOR__|    
  • Ignition to main power(01), with 110/220vac grid charge interlock.
  • Seat(05) to wrist strap kill switch. Set "Seat Delay"=0.1s
  • Throttle(10) to new after market twist grip, will loose original run/stop and starter buttons.
  • Forward(02) and FS1(04) to NC Clutch switch, open on clutch to "freewheel" for shifts and coasting. Set "decel delay"=1.8s, "neutral braking level"=1 for coasting.
  • RegenBrk(11) original choke & FootBrk(06) to brake light switch per additional relay. Set "footbrake level" to regen preference for when footbrake is applied.
  • Contactor drives(08,09) are rated at 3A peak (10s) and 1.5A continuous. Use Albright aux contactors to drive a contactor status light.
  • Pin 12 is available for 100mA supply, typically used for (but not limited to) accelerator modules. 12V system with DC-DC converter (per Contactor_2 or Pin 12 signal). Drive a controller system status light.
  • Pins 13,14 & 15 are general-purpose suppression connections, may be used to suppress spikes generated by contactors opening / closing.
  • Left grip: Head Light, Tail Light, instrument lights, Brake Lamps, Blinkers. Modified Clutch and Choke.


Fault Codes

Fault Finding - The Diagnostic LED next to the calibrator connectors

  • ON -No fault, normal condition
  • OFF -Internal controller fault
  • 1 flash -Personality out of range
  • 2 flashes -Illegal start condition (Traction)
  • 3 flashes -MOSFET Short Circuit
  • 4 flashes -Contactor fault or Motor Open Circuit
  • 5 flashes -Not used
  • 6 flashes -Accelerator wire off fault
  • 7 flashes -Low or High battery voltage or BDI cutout operating
  • 8 flashes -Over temperature or timed cutback
  • 10 flashes -Power Up Autozero has not yet been completed


Table 10: Flash Fault Descriptions
In addition to the LED indication a more detailed description of any faults detected may be found by using the calibrator. Menu item number 13.01 gives a code which corresponds to the following detected faults:

  • ID -Flash -Fault Description
  • 0 -On -System OK.
  • 1 -8 -Thermal Cutback, power is reduced.
  • 2 -8 -Timed Current Limit.
  • 3 -6 -Accelerator Wire Off.
  • 4 -6 -Accelerator Pressed at Power Up.
  • 5 -2 -Belly Fault The Belly switch function has occurred.
  • 6 -2 -Seat Fault Drive selected and no seat switch closed.
  • 7 -10 -Autozero Not Taken.
  • 8 -2 -FS1 Recycle, FS1 switch closed during a direction change.
  • 9 -2 -SRO Fault, Direction selected for >2 seconds with FS1 open.
  • 10 -2 -Two Direction Fault Two directions selected together.
  • 11 -2 -Sequence Fault Direction or FS1 switch closed at power up.
  • 12 -7 -Low Battery Fault Battery voltage is too low.
  • 13 -7 -High Battery Fault Battery voltage is too high.
  • 14 -7 -High Battery Fault with Line Contactor Open.
  • 15 -1 -Configuration Range Fault, A personality is out of range.
  • 16 -1 -Configuration CRC Fault, The personality CRC is incorrect.
  • 17 -4 -Line Contactor Welded Fault, Line contactor is welded.
  • 18 -4 -Line Contactor did not Close Fault Line contactor is open.
  • 19 -3 -Lower MOSFETs Short Circuit on Q2/Q4 Armature MOSFETs detected.
  • 20 - -Reserved for future use
  • 21 -0 -MOSFETs did not pulse during power on, failsafe enabled.
  • 22 -0 -MOSFETs pulsed during power on failsafe disabled.
  • 23 -3 -Upper MOSFETs Short Circuit on Q1/Q3 Armature MOSFETs detected.
  • 24 -0 -Contactor 2 did not pulse during power on failsafe enabled.
  • 25 -0 -Contactor 2 pulsed during power on failsafe disabled.
  • 26 -0 -Contactor 1 did not pulse during power on failsafe enabled.
  • 27 -0 -Contactor 1 pulsed during power on failsafe disabled.

Soneil.com Battery Chargers

  • 4804SR - 48v @ 2A (90~264vac) - 6.9*3.4*2.3" (174*86*57mm) - 1.1lbs (500g) - cc/cv 57.6v, float 55.2v
  • 4808SRF - 48v @ 3.5A (115/230vac) - 6.9*3.7*1.9" (175*94*48mm) - 1.7lbs (750g) - cc/cv 57.6v, float 55.2v - EVP:$190
  • 1205SR - 12v @ 3A (90~264vac) - 4.7*2.9*1.6" (119*73*41mm) - 0.5lbs (220g) - cc/cv 14.4v(Factory Adjustable), float 13.8v - EVP:1206S/R:~$44
  • 1212SR - 12v @ 5A (115/230vac) - 6.9*3.7*1.9" (175*94*48mm) - 1.5lbs (700g) - cc/cv 14.4v, float 13.8v - EVP:$90
  • 1214S - 12v @ 7A (90~132vac) - 6.8*3.4*2.0" (173*86*52mm) - 1.3lbs (600g) - cc/cv 14.7v, float 13.8v
  • 1214R - 12v @ 7A (192~264vac) - ^ - ^ - ^
  • 8x 4808SRF ~$1520 (13.6lbs) (28A 3360W)
  • 4x 1205SR ~$176 ( 2.0lbs) (12A 1440W) (Equalization Charging)


Honda EU saddle Gens

http://www.hondapowerequipment.com/gensup.asp

  • Two like EU series generators can be linked in parallel to increase available wattage.
  • EU1000i-$ 789.95 - 120V 1000W max. (8.3A) 900W rated (7.5A) B 15A 125V Duplex" 5-15P - 0.6 gal - 17.7 x 9.4 x 15.0" - 29.0lbs - 59db - 31ZT3610.pdf
  • EU2000i-$1079.95 - 120V 2000W max. (16.7A) 1600W rated (13.3A) C 20A 125V Duplex" 5-15P or 5-20P - 1.1 gal - 20.1 x 11.4 x 16.7" - 46.3lbs - 59db - 31Z07610.pdf
  • EU2000 (13.3A) (3*3.5A@48v = 10.5A 1260W 1.69HP) *2(21A 2520W 3.38HP) Under rating
  • EU2000 (13.3A) (4*3.5A@48v = 14.0A 1680W 2.25HP) *2(28A 3360W 4.50HP) Over rating 0.7A (80W) each
  • 2x EU2000 ~$2160 (92.6lbs)

Gear Ratios

http://en.wikipedia.org/wiki/Kawasaki_Ninja_500R

Engine speed @ 60 mph, top gear: 4935 rpm  redline: 11,000 rpm
power: 52 bhp (39 kW) @ 9500 rpm (103 hp/L)
torque: 30.86 lbf·ft (41.84 N·m) @ 8000 rpm
Primary Drive 23/61, 2.652
Final Drive 42/16 sprockets 2.625
Rear Wheel Size 120/90-16 63H
gear ratios (overall)  1)17.87        2)12.37       3)9.60        4)7.83        5)6.88        6)5.92
ratios (transmission)  1)36/14, 2.571 2)32/18, 1.78 3)29/21, 1.38 4)27/24, 1.12 5)25/26, 0.96 6)23/27, 0.85
max speed @ICE redline 1)44 mph       2)63 mph      3)82 mph      4)101 mph     5)118 mph     6)133 mph
max speed @Etek ~4000 RPM limit is slightly less than @ICE due to the lack of the Primary Drive.
Etek should produce slightly more torque at the rear wheel than the original ICE.