Owner | Ed Stepanic | ||||||
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Location | Burlington, Ontario Canada map | ||||||
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Vehicle | 1991 Suzuki GSX600F Road worthy motorcycle intended for in-town travel and capable on secondary highway use. | ||||||
Motor | Perm Motor PMG 132 Permanent Magnet DC 7.2 kW @ 72VDC The smallest PM DC motor for its power rating at the time. | ||||||
Drivetrain | 14t drive and 60t driven sprockets, #40 chain, more efficient for speeds <110km/h | ||||||
Controller | Curtis 1205M 72V, 400A PWM controller | ||||||
Batteries | 96 Headway 38120S, 3.20 Volt, Lithium Iron Phosphate Three 24V battery banks series-parallel configured for 40Ahr. | ||||||
System Voltage | 72 Volts | ||||||
Charger | unknown One 800W charger under the gas tank. One 2kW charger (custom design by ElectroCraft EV Systems) at home. | ||||||
DC/DC Converter | PST-DC4812 Powerstream 48 to 12V @12A (accepts 80V input - adjusted for 13.6V output) | ||||||
Instrumentation | stock speedo & Cycle Analyst | ||||||
Top Speed | 60 MPH (96 KPH) About 110km/h (68 mph) on slight downhill grade. | ||||||
Acceleration | With current set to 300A, pulls very well off the line. | ||||||
Range | 25 Miles (40 Kilometers) Farthest trip so far -- 45km (28 miles) at an average speed of 60km/h | ||||||
Watt Hours/Mile | 130 Wh/Mile Determined by time it takes to recharge the motorcycle x charger power draw from AC supply / distance traveled. This method includes losses. | ||||||
EV Miles |
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Seating Capacity | 2 adults | ||||||
Curb Weight | 400 Pounds (181 Kilograms) Just a guess but no heavier than stock. | ||||||
Tires | Metzeler Z8 | ||||||
Conversion Time | At least 140 hours research and buying parts, 150 hours building on and off... I really have no idea! | ||||||
Conversion Cost | Stopped counting but at least $10000CA, most of the cost was for lithium batteries, motor, motor controller and chargers. | ||||||
Additional Features | LED tail lights and signal lights. HID headlight. AC cord on retractor stolen from a vacuum cleaner. Custom control breakout box for vehicle control and future upgrades. Removed one front rotor/caliper to reduce weight. 72V battery common connected to chassis via 10k resistor for safety. Stash box under the seat where the old battery compartment was. | ||||||
Advice: Educate yourself about batteries, especially lithium. Had I taken the time to study up, I would have saved a lot of cash. Thanks to EV Album for ideas gleaned off other conversions. Thanks to my father for all the welding work, beer, conceptual ideas and allowing me to make a mess of his garage. Thanks to Ian for cutting the rear sprocket; looks stock. 7 September 2020 Over the years I have abused the cells sufficiently to the point of reducing max range to about 25km. Plans are underway to replacing the entire pack to 60Ahr. |