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Old 07-15-2017, 08:19 AM
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Default 2017 - El Moto

Howdy you all!

I got a new project

...that used parts from another project

So, lets double down on this
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  #2  
Old 07-15-2017, 10:50 PM
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why must everything be electric 😥
look how nice the engine looks on it now...
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Old 07-16-2017, 08:07 AM
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Quote:
Originally Posted by 6.5hp View Post
why must everything be electric ��
look how nice the engine looks on it now...
Electric karts are new & exciting

Instant torque, different power curve, reconfigurable (can be set up different ways)

So, an electric motorcycle, Ya! do I need to say more?

...& that nice lookin' engine is seized.

So, this is kinda like a rebirth

Old life: 1980 Kawasaki 440 LTD

New life: El Moto (Electric Motorcycle)
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Old 07-16-2017, 09:49 AM
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Lets get started.

Motorcycle specs:

1980 Kawasaki 440 LTD

category: custom cruiser

Engine: 444 ccm. (27.09 cu. in.) 27 HP (19.7 kW) @ 7.000 rpm

top speed: 95.7 mph

Front tire: 3.25-19 Front brakes: single disc

Rear tire: 130/90-16 Rear brakes (expanding brake)

Weight (inc. gas & oil) 405.7 lbs

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Old 07-16-2017, 11:12 AM
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So, the plan is to:

A. Remove ALL electrical components off of El Dingo.

Why? It's not a good combination.

1. Using a motor with a 100+ amp draw & the batteries needed to power it is kinda ridiculous for a go kart.

2. Super over weight (~250 lbs.)
adding a ~40lb. motor + 60 lbs. in batteries (3 x20 lb.) & the controller, cables etc. is just toooo much.

3. Plus All that weight on top on a live axle = almost NO steering (when you turned the wheel it was more like a suggestion than a command)


B. Remove all ICE (internal combustion engine) parts off the motorcycle.

Why? Motor is seized (giving 'er a new life


C. Install an 1,800 watt brushless motor & speed controller on the Dingo

Why? It should be a better combination.

It's a lot lighter motor (weighs ~20 lbs.) with ~ a 30 amp draw

& it runs @ 48V (needs 4- 12V batteries) with a 4.500 max rpm.

D. Install the 8,000 watt brushed motor, off El Dingo, onto the motorcycle.

Why? It should be a better combination.

Having the weight (motor & batteries), centered on the vehicle, should provide better balance.

& being a bigger vehicle , it should carry the weight better.
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Old 07-16-2017, 11:40 PM
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As you can see in the 1st pic, I got everything off the Dingo.

Gonna start to reassemble El Dingo II first

Should go together pretty easy.

Goin' for lighter this time too because:

the motor we were using a big 8,000 watt motor (~40 lbs.) now using a smaller, 1,800 watt brushless motor ~20 lbs.)

controller: the brushless controller only weighs about 1/2 the weight of the Kelly controller

battery pack: was using 3-12V 35Ah batteries (~60 lbs.) now using 4-12V 20AH batteries (~45 lbs.)

battery cables: brushless motor/controller uses 10-12 g. battery/motor wires instead of 4g. cables)

So, we're ~ a 50 lb. reduction already

Next, was roundin' up stuff to make everything work together

The brushless motor came with a T8F 9t sprocket (metric)

I don't have anything like that but, the sprocket on the 450 watt motor that we have been using for the El Turbo bench tests looks similar

& if it fits, then we can probably use the extra #35 chain & rear sprocket that I took off the El Turbo kart (formerly Double Trouble)

Yup! it fits
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Old 07-18-2017, 12:59 PM
Bbqjoe Bbqjoe is offline
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You need to learn to speak Chinese so you can communicate better.

As a matter of fact, I think we'd all better learn Chinese soon.
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  #8  
Old 07-19-2017, 12:11 AM
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Pls contact the controller plug to your 3 Forward Reverse Switch ,that will be ok, pls help us try this,and let us knwo if all is ok later,Have a nice day

...translate that to English & you get: inverted gear must be hooked up


How does anyone get "3 Forward Reverse Switch" out of "inverted gear"?

...& maybe it would of been helpful to include 3 Forward Reverse Switch = inverted gear

& maybe even "is necessary or will not work" in the wiring directions

So, CHONG CHONG CHONG

Yup, I got this figured out (I think)

Lets give this a try

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Old 07-19-2017, 01:23 AM
Bbqjoe Bbqjoe is offline
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Crazy!
你完成了!現在你把它放正確,放大放大!
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Old 07-19-2017, 08:34 AM
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Good news & bad news,

it now works!

& we have reverse

The problem now is,

it goes forward kinda slow but, really fast - BACKWARDS

First thoughts was

...just gotta flip the motor & the axle sprocket to the other side

simple enough, tedious but, a simple fix

but, while I was out towing yesterday I was thinkin',

You can change the direction of many brushed motors just by reversing the positive (+) & negative (-) power input cables

I wonder if that is possible or recommended for brushless motors

I do NOT want to just assume that it can (the two have very different technology)

I again, emailed the place I got the motor from, thanking them for their help & asking if the direction, of this motor, can be switched



*Hello,

Yes that was helpful. It now rotates. But, it goes slow forward & really fast in reverse

Can the Thick Blue & Thick Yellow wires that are coming from the motor be switched with Thick Blue wire & Thick Yellow wires that are coming from controller? Like blue to yellow or yellow to blue? Or is that NOT recommended?

Dear friend
Pls don't worry ,Pls contact the motor blue contact controller green,motor Green contact controller blue wires,yellow color wire is still contact to yellow wires,
And the motor Holzer wires ,pls swap blue and yellow wire ,that will be ok.Hope you can help us try it again
Have a nice day


OK, I think they said

"yes you can, this is how"

So, if I am translating this right

They say

...contact thick blue motor wire to thick green controller wire

...thick green motor wire to thick blue controller wire

...keep thick yellow motor wire connected to the thick yellow controller wire

The motor Holzer wires (again, if I my translation is correct)

...is the 5 wire plug that connects to the controller

...& their saying to also swap the blue & yellow wires on that plug in

Does this sound right?

Does anyone know if you can or it's recommended to reverse the direction of a brushless motor?
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Old 07-19-2017, 08:49 AM
Bbqjoe Bbqjoe is offline
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Flip the whole mess around, put it on the front, and you'll have The first electric front wheel drive Kart.

Then move the steering to the back.

What do I know?
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Old 07-20-2017, 10:50 PM
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Quote:
Originally Posted by Bbqjoe View Post
Flip the whole mess around, put it on the front, and you'll have The first electric front wheel drive Kart.

Then move the steering to the back.

What do I know?
Really, Jo

Another project?

Like I don't have enough goin on already
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Old 07-21-2017, 12:01 AM
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I wasn't super confident in my translation

so, I sent a "double check" message



*I want to make sure I understand your directions.

1. contact thick blue motor wire to thick green controller wire

2. contact thick green motor wire to thick blue controller wire

3. leave thick yellow motor wire contact to thick yellow controller wire

4. then on the 5-wire plug (swap the thin blue & the thin yellow wires) that means contact thin blue wire to thin yellow wire & thin yellow wire to thin blue wire?

This is correct?

Thank you for your help

Kevin


they sent back:


Yes,Pls help us try it again
Regard,

OK, I feel better about this now

Don't wanna go cris-crossin' wires on a brand new brushless motor all "willy-nilly" like - without a clue

OK,

...Thick Blue & Thick Green wires are crossed

...Thin Blue & Thin Yellow wires are crossed too

also, made up a harness to run from the controller up to the "dash area" for the forward/reverse switch

...tinned the wire ends

...slid heat shrink onto wire (before soldering)

...solder (2) ends together

...slide heat shrink over splice

..shrink it down

repeat procedure for the (3) wires on plug end & then crimp (3) spade terminals on the other end of the wires going up to the (3) way (forward/reverse) switch

Until I find a proper one, we'll just use a micro switch for a (3) way (forward/reverse) switch for now

OK, lets give that a try

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Old 07-21-2017, 12:48 PM
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Ya, It worked!

It turns the right direction now

...& didn't have to remove motor

...switch the sprocket around or nothin'

...& we got reverse

Try that with a gas engine

Ready for a test run?

Me too.

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Old 04-29-2018, 04:29 PM
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No, I beat everyone to it^__^
Seems your all fairly young here? I'm an old fart!
I've been at it since the early 70's!
None of this is new! electric cars were around before gas!
I always wanted to do a steam engine! Gramp's was a train engineer!
Live long and ride sweet^__^
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Old 05-23-2018, 11:27 PM
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I got El Moto out today

But, she was TOTALLY DEAD

NOT just dead, "really" TOTALLY DEAD

Nothing lit up, buzzed, clicked or anything
...so, I grabbed the MM

The 48V battery pack showed 6.2V

Then, I checked them individually
...battery #1 (@ the positive output connection) showed 1.5V
...#2 showed 3.3V
...#3 showed 5.4V
...#4 (@ the negative out put connection) showed -3.9V
(seriously, it showed a minus)
(negative voltage, a new one on me)

So, yup
...I think I killed 'em &

I had the main cut-off, turned off while it was in storage for the winter
...but, yup another up

It seems that I didn't wire the DC to DC inverter to the cut-off switch
...I wired it straight to the battery pack
...it must have been drawin' a small amount of power all winter long

So, I'm guessin' (Naw, I'm pretty sure)
...that was a fatal (for the battery pack anyways) mistake

Well, can't get shook about it
...grandma always said "things happen for a reason"

* Note to self:
Don't do that again

Learning as I go
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Old 07-21-2017, 01:06 PM
Bbqjoe Bbqjoe is offline
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Faster, faster...Until the thrill of speed overcomes the fear of dying!!!!!!
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Old 07-21-2017, 03:43 PM
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Quote:
Originally Posted by Bbqjoe View Post
Faster, faster...Until the thrill of speed overcomes the fear of dying!!!!!!
I'm workin' on it
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Old 07-25-2017, 08:42 AM
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Picked up a switch, from Grangers that we can use to select forward or reverse for the El Dingo II kart

Wow! there are hundreds of different kinds of switches

Their are regular old on/off switches, two pole switches, 3 pole switches, momentary switches & many more

...then you get into amp ratings


Well, for our forward/reverse switch we need a switch that

...is considered an on/on switch

...it has 3 terminals (1) power in

...& (2) separate power outs (to send power out thru one circuit or the other)


I could of went with an on/off/on switch

...where the center position would be like a neutral position

...but, I thought that might just confuse things


So, I went with the on/on switch

I think, I have this figured out but, to be sure

...lets do a test

I hooked the center terminal, of the switch, to the positive (+) terminal of a 12V battery

...I hooked the power wire of a 12V bulb to the left terminal of the switch

...& the power wire of a second 12V bulb to the right terminal

...& the negative (-) of both bulbs to the negative (-) of the battery


That went well, lets get it mounted

...figured where to put it

...measured what dimensions were needed

...cut a piece of plastic out of an old TV back cover

...centered the switch

...drilled a couple of holes

...whittled a bit with a razor knife

...mounted it on the kart with a couple of screws

Yup!, that should do it

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Old 07-25-2017, 09:06 AM
Bbqjoe Bbqjoe is offline
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FA, your work is most impressive.
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