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  1. S

    Kelly KLS-H variable regen issue

    Thanks for the replies. I’ll just have to keep playing around with the settings to see if I can find the problem. My preference is to use variable regen but it’s just not very strong at the moment. The strange thing is it used to be stronger like when releasing the throttle but I played around...
  2. S

    1987 Yamaha FZR250

    OK so the latest drama was both sets of hall sensors had errors so I had to take the motor apart to replace them. It takes quite a lot of force to separate the stator and rotor but this technique worked quite well. The new sensors are Honeywell SS41 bipolar and while the motor was open, also...
  3. S

    Kelly KLS-H variable regen issue

    I have a Kelly KLS7250H and when I compare variable regen vs regen when releasing the throttle, the variable regen isn't as strong even though both are set to the same %. Settings for variable regen: RLS_TPS Brk %: 0 BRK_AD Brk %: 50 Brake Type: 1 Brake Dead Low: 15 Brake Dead High: 70 * When I...
  4. S

    1987 Yamaha FZR250

    Yes good point, I think the ANL fuses are good up to 80V which was ok before but I'm slowly climbing up in voltage so I will need to upgrade. Will order one now :thumb: I got part way there reading data out of the ANT BMS over Bluetooth and being able to see the correct values for current and...
  5. S

    300km/190mi Electric Moped on the Cheap

    Awesome work ... wiring burrito :lol:
  6. S

    INDEX, motorcycle and scooter E-Conversions

    viewtopic.php?f=12&t=114863 1987 Yamaha FZR250 2KR Motor: QS 273 6000W V3 hub motor Controller: Kelly KLS7250H Battery: 23s1p 117Ah NMC prismatic cells
  7. S

    1987 Yamaha FZR250

    OK so this is a bit embarrassing but also a bit of good news, for a while now I've been trying to work out why my initial acceleration has been underwhelming. I've read people say Kelly controllers aren't so good in this department and despite going through the user manual many many times to see...
  8. S

    1987 Yamaha FZR250

    Yes LiFePO4 max is 3.65V. I guess the same cell boxes are used for different chemistries. These are the ones I used which have the following specs: https://www.alibaba.com/product-detail/catl-3-7V-117ah-3-7v50ah_1600259771564.html?spm=a2756.order-detail-ta-ta-b.0.0.52222fc2vPa8E1 Rated...
  9. S

    1987 Yamaha FZR250

    Thanks, it's been quite a journey but heaps of fun. I finally feel like the bike is good enough to just ride without worrying about things failing and you're a test pilot! I really hope I didn't just jinx myself :lol:
  10. S

    1987 Yamaha FZR250

    So the battery is now 23s mainly because the controller can only handle 90V. At some point I'll upgrade and go to 26s. Max speed is now 110kmh and range is 150-200km (to be verified). Next step is to replace the DC-DC converter as I've now gone up in voltage a bit above what it's rated for and a...
  11. S

    1987 Yamaha FZR250

    The battery box was mostly built with rivets and glue but I had help from a friend for the mounting brackets which are welded.
  12. S

    1987 Yamaha FZR250

    And then lockdown happened and in one of my "I'm in need of a project" late night impulse purchases, I bought a bunch of 117Ah NMC cells!!!
  13. S

    1987 Yamaha FZR250

    I also started playing around with reading the current and battery SoC out of the ANT BMS and using an Arduino to drive the original gauges but unfortunately never got it working properly. I found an eBay seller that can make custom faces with the proper backlighting for a reasonable price too...
  14. S

    1987 Yamaha FZR250

    I also discovered the TeslAnything Adapter from EVolution that allows non-Tesla EVs to use their destination chargers and other Type 2 charge points. This paired with a faster charger setup meant I could explore a bit more...
  15. S

    1987 Yamaha FZR250

    So everything was going great and my range had increased to 50-70km which was pretty much double what I could do before and meant I could now do a bit more exploring. Here's a couple of nice shots down at La Perouse, Sydney.
  16. S

    1987 Yamaha FZR250

    Here's what the battery pack looks like installed.
  17. S

    1987 Yamaha FZR250

    OK so once again its been way too long between posts so I'll add some photos to try and fill the gap up to where the project is now! After sorting out the testing I used a fantastic 2p busbar kit made by Chris Jones which made assembly really easy. The panels for the box were cut on a friends...
  18. S

    1987 Yamaha FZR250

    OK so I just used a multimeter to test the voltage on the tabs and also where the wires connect to the PCB board and there’s a 0.3-0.4V difference when discharging the cell but they’re the same at rest. Any ideas what’s going on or how to fix it? It’s only a $50 device so maybe that’s my...
  19. S

    1987 Yamaha FZR250

    This is the setup I’m using inspired by someone on Endless Sphere. The tabs are pretty well clamped down and I get the same voltage drop if I put the alligator clips directly onto the tabs.
  20. S

    1987 Yamaha FZR250

    Also I've managed to get some A123 20Ah cells to upgrade my battery pack. These looks like pretty amazing cells compared to the Headways so I'm really looking forward to getting these in the bike and seeing how they go. I built some cardboard boxes to try out different configurations and...
  21. S

    1987 Yamaha FZR250

    I recently added a brake lever to the bike to control the amount of regenerative braking to use. Previously I was just using the percentage setting in the Kelly controller to control the amount but it was either just right at lower speeds and not enough at higher speeds or vice versa. This way I...
  22. S

    1987 Yamaha FZR250

    My biggest constraint is range which at the moment is only 25km. The 10Ah cells I bought on eBay and the 15Ah cells I got second hand. I’m not even sure if the 10Ah cells are original Headway cells or some other brand! I’ve got a couple of CellLog 8S from my previous project that I’m using to...
  23. S

    1987 Yamaha FZR250

    After the last lot of testing there was a fair bit of work to do getting ready for brake testing and inspection. Replace dead battery cells, wire in the emergency cutoff switch, replace oil in forks and add spacers, etc so after all that the bike pretty much looks the same but a lot has...
  24. S

    1987 Yamaha FZR250

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  25. S

    1987 Yamaha FZR250

    OK it’s been a while again so there are a few updates. The EV Expo was great to be part of. Lots of interesting conversations with people and great to see all the other conversions people have done. I didn’t quite manage to get it running for the show but it was all together at least. It didn’t...
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