Hello reader,
This will be my thread documenting the conversion of a 2006 Honda CRF250R. I hope to provide as much detail as I can to possibly help anyone who is also interested in doing something similar.
Goals:
The bike will hopefully be used for casual off-roading/enduro type riding rather than race/motocross.
I hope to achieve a range of atleast 3 hours though I'm well aware that depends on the riding style etc.
Such a use case wouldn't require a lot of power but I'll be honest, I am aiming for around 60hp for a nice round value for bragging rights That would be about 46-47kW before factoring in various losses.
Hopefully it ends up looking like this, minus the exhausts and ICE ofcourse.
Choices made so far:
So to meet the power requirement I decided to go for a combination of a Zero 75-7 motor and a Sevcon Gen 4 Size 6.
Regarding the battery I've done a lot of research, measuring and designing to come to the conclusion of making a 28s20p pack of VTC5As. Such a pack should be able to do about 50kW peaks with ease, I will explain later on how I came to this conclusion.
Motor:
Zero Z-Force 75-7 SPM, I paid for and was trying to buy a 75-7R IPM motor but the seller turned out to be mis-informed on what exactly he had and it turned out to be a 75-7 SPM. No worries, it should still be able to do the job of 47kW peaks and we are in the discussion of a partial refund as of this post, hopefully this happens and I don't end up having to file a dispute for a complete refund and returning the motor...
Controller:
Sevcon Gen 4 Size 6, essentially the same controller that Zero uses with their own bikes though I sourced this new from a friend who works for a company that converts vehicles for customers. They do not supply either the IXXAT cable or the Sevcon DVT software so I got those from Voltsport.co.uk
Battery:
28s20p configuration of VTC5A's, I would need to pull about 500A (25A/cell) to achieve the 47kW because looking at pulse discharge curves/graphs I shouldn't face a voltage drop lower than nominal at full stage of charge (ie fully charged battery shouldn't drop beyond 3.7V/cell under a 10 second pulse discharge of 25A/cell). Even at a continuous discharge rate of 25A/cell the pack would average a voltage of around 3.3V/cell from full to empty. I ordered 600 to have 40 spare on hand.
Components bought/sourced so far:
Zero Z-Force 75-7 SPM Motor
Sevcon Gen 4 Size 6
Sevcon IXXAT Cable & DVT Software
600* VTC5A cells
Ampseal 35Pin Connector Kit (for the Sevcon)
Domino Twist Grip Throttle IP67 0-5K Ohm
Tyco 5 Pin Connector Kit (for the Domino Throttle to Sevcon)
DB9 Female DIY Connector (for the IXXAT cable to Sevcon)
Delphi 8 Pin Male Connector Kit (for the 75-7 to Sevcon)
Tyco LEV200A4NAF Contactor (compatible with the Sevcon and 116V friendly)
Schneider XB4BG21 Key Switch (will take pack voltage)
other:
kWeld Complete Kit
Turnigy Graphene Panther 6600mAh 3s 75C Battery
Turnigy P403 Battery Charger
Turnigy Fire Retardant Battery Bag
Will update the list as I need more components.
This will be my thread documenting the conversion of a 2006 Honda CRF250R. I hope to provide as much detail as I can to possibly help anyone who is also interested in doing something similar.
Goals:
The bike will hopefully be used for casual off-roading/enduro type riding rather than race/motocross.
I hope to achieve a range of atleast 3 hours though I'm well aware that depends on the riding style etc.
Such a use case wouldn't require a lot of power but I'll be honest, I am aiming for around 60hp for a nice round value for bragging rights That would be about 46-47kW before factoring in various losses.
Hopefully it ends up looking like this, minus the exhausts and ICE ofcourse.
Choices made so far:
So to meet the power requirement I decided to go for a combination of a Zero 75-7 motor and a Sevcon Gen 4 Size 6.
Regarding the battery I've done a lot of research, measuring and designing to come to the conclusion of making a 28s20p pack of VTC5As. Such a pack should be able to do about 50kW peaks with ease, I will explain later on how I came to this conclusion.
Motor:
Zero Z-Force 75-7 SPM, I paid for and was trying to buy a 75-7R IPM motor but the seller turned out to be mis-informed on what exactly he had and it turned out to be a 75-7 SPM. No worries, it should still be able to do the job of 47kW peaks and we are in the discussion of a partial refund as of this post, hopefully this happens and I don't end up having to file a dispute for a complete refund and returning the motor...
Controller:
Sevcon Gen 4 Size 6, essentially the same controller that Zero uses with their own bikes though I sourced this new from a friend who works for a company that converts vehicles for customers. They do not supply either the IXXAT cable or the Sevcon DVT software so I got those from Voltsport.co.uk
Battery:
28s20p configuration of VTC5A's, I would need to pull about 500A (25A/cell) to achieve the 47kW because looking at pulse discharge curves/graphs I shouldn't face a voltage drop lower than nominal at full stage of charge (ie fully charged battery shouldn't drop beyond 3.7V/cell under a 10 second pulse discharge of 25A/cell). Even at a continuous discharge rate of 25A/cell the pack would average a voltage of around 3.3V/cell from full to empty. I ordered 600 to have 40 spare on hand.
Components bought/sourced so far:
Zero Z-Force 75-7 SPM Motor
Sevcon Gen 4 Size 6
Sevcon IXXAT Cable & DVT Software
600* VTC5A cells
Ampseal 35Pin Connector Kit (for the Sevcon)
Domino Twist Grip Throttle IP67 0-5K Ohm
Tyco 5 Pin Connector Kit (for the Domino Throttle to Sevcon)
DB9 Female DIY Connector (for the IXXAT cable to Sevcon)
Delphi 8 Pin Male Connector Kit (for the 75-7 to Sevcon)
Tyco LEV200A4NAF Contactor (compatible with the Sevcon and 116V friendly)
Schneider XB4BG21 Key Switch (will take pack voltage)
other:
kWeld Complete Kit
Turnigy Graphene Panther 6600mAh 3s 75C Battery
Turnigy P403 Battery Charger
Turnigy Fire Retardant Battery Bag
Will update the list as I need more components.