How difficult could it be to build an electric motorcycle!?
Kind of difficult.
I bought this 2002 ZX6E from a salvage shop, which had been selling parts off of it for a few years. Salvaged for rod knock rather than crash damage, and for $275, it's a good candidate for the electric conversion. Its aluminum frame is strong and light, and has room for batteries.
I've got to mount this 4.2 kW motor in the frame, getting the output shaft of the motor as close to the position of the original as possible.
|It should sit about here?|
I used the rear engine mounts in the frame to mount the motor. I cut and ground and filed 1/4 inch steel to make a mount to accommodate the motor. I bought an old drill press at a yard sale for this job.
I have very little welding experience and no welding equipment, but I was able to fit the bike in my car and my brother taught me how to use his gas-shielded MIG welder.
|Pieces cut, prior to welding|
|Welded and painted!|
|If it looks good, it doesn't have to do anything, right?|
The capacitors were difficult to solder to the 1/8th inch copper plate, I had to use two soldering irons for enough heat capacity.
|Bus Bars and capacitors mounted|
Next is to build the gate driver, mount the IGBT driver in a waterproof box with a heatsink, and install batteries!