All-Encompassing EV Conversion Supersite Diary (Entry 172)

Saturday November 26, 2005 - EV2 My Electric Kawasaki

Update:

This past week I was given two motorcycles (1980 Kawasaki 400 and a 1982 Kawasaki 440 LTD) from which to construct my next electric vehicle project. I am going to take parts from both motorcycles so that I can make one roadworthy vehicle. The first job was to de-ICE and degrease the 1980 bike as this will be my starting point.

The Etek and Curtis controller mounted on my EV2 test bed. I mounted all of the new EV gear onto a quickly-assembled testbed while trying to decide what sort of vehicle to use for my next generation EV project. The limited power and torque of the Etek dictated something small and light. (8-15hp and 32 lb-ft. torque). At first, I started trying to scratch build a small vehicle chassis but soon found out that fabricating the needed suspension and steering parts would soon break the bank. I was able to build this aluminum chassis from scrap and soon had the complete EV drive train working.

A single ratio chain drive transmits power from the Etek to the ATV drive axle below. I mounted the throttle pot box just beside the Curtis controller on an aluminum plate.

It's funny how these projects get started and then take on a life of their own. Take the average guy, several bottle of beer, his garage, some scrap metal, his trusty tools, and a few nuts and bolts and stand back!

Eventually things just started to go together as I thought about building a small commuter EV. What would it look like? What was really needed? Where would the batteries go?

I was on an extremely limited budget, and so I did a lot of scrounging at the scrap metal yard and amongst my neighbours. One of the retirees down the block found a donor Honda ATV from which I extracted a front end for my "creation".

The parts have been removed from this mockup for use in the electric Kawasaki, but this creation allowed me to test the circuits and drive train for later.

Before this ATV front end I simply bolted a large caster wheel to the front of the chassis for testing the motor. I loaded 4 Optima batteries into the frame and dragged the whole contraption out to the back lane. Line the caster up with the ruts in the lane, straddle the chassis (bareback) and yank on the pot box throttle lever. What a hoot!!. Go about 4 houses down the lane hoping to hell the caster keeps to the ruts. Then pick up the front end and swing around for the return "voyage" back down the lane to the bat cave. Kids!!!

Improvise; that's the name of the game. When you really have to try out your new electric vehicle. Why wait for small things like steering gear and suspension parts to be completed.

Ten, nine, eight,... We have liftoff! Launching out of the garage was hoot! Of course, the neighbours think you a little strange to be running up and down the back lane in this...

The Etek permanent magnet dc motor is quite popular. For its size, it puts out a good bit of power.

The two donor Kawasakis will set the tone for EV2. This is the 1982 Kawasaki 440 LTD with rubber belt drive. It had last seen service on the street and was complete with lights, fenders, etc.

This 1980 Kawasaki 400cc motorcycle was used for flat track racing in the dirt and had all of the "street" parts removed during the conversion. This is going to be the starting point for the EV2 project as the fork seals are not leaking as they are with the other unit and the tires and brakes are in good shape.

The racing bike has no front brake (not needed on dirt tracks), and fortunately for me, it was removed and stored in good condition.

It is very important to note the relationship of the front drive sprocket to the swing arm pivot point. This geometric alignment must be maintained when the Etek is mounted in p lace of the original gas engine. Otherwise the drive chain will be under too much stress and may break or jump off of the sprockets.

Take a last look at this 1980 Kawasaki. When completed later next spring this motorcycle will be battery-electric powered and charged by solar panels.

The original racing motor will be returned to a high school auto shop class for recycling. It will be used to train future mechanics. Not much gets thrown out into landfills around our house.

This is what is left when all is removed. No more sucking gas for this baby!

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Note:
Roger Ramjet he's our hero. Leader of our nation. His adventure has just begun, so stay tuned to this station..." I always wondered what watching that cartoon when I was a kid would do to me. More to follow...