1970 Yamaha R5 "Rust Bucket" Build

[Ussyamoto]

I'll be keeping track of my E-Motorcycle build here, nick named Rust Bucket, for those who are interested. This is my first motorcycle build so any tips or tricks would be appreciated. I'll post my experiences and progress as they come.

Build plans:
Motor : Mars 4201
- Delivered
Controller : KBL72301X
BMS : Batteryspace kit
- Changed to 24s Orion BMS
Batteries : 24x 100Ah LiFePO4
- Changed to 24s 10kw+ LiPo 18650s
Donor Bike: 1970 Yamaha R5
Desired top speed ~70mph
desired range ~65miles

10/4/15
Finally got a bike, after searching on Craigslist for 2 weeks with the intent of finding and cruiser style frame with a good Title for under $400, I found what I was looking for.
A guy was leaving town due to work and needed is project gone by the end of the day, he wanted $800, I offered 6 and he said be the first on here and you can have it. I dont own a truck or have anyway of moving a bike around so I grabbed a friend and went to home depot to rent a truck on a Sunday but they were closed annoyingly enough. Then my friend said his parents have a truck over in Plano, and that's where the bike was anyways. Go figure, we got the their house and they were out of town and didnt leave the keys. Frustrated that I'm about to loose another buy I called the owner of the bike and told him what was going on. The guy was nice enough that he loaded it up and dropped it off at my friends parents house.
It came with 1 seized engine, 1 new 350cc with new exhaust, carbs, intake, and misc parts. While the frame was only lacking a front headlight and a seat.
I should be able to sell the parts for as much as I paid for the bike, so I got a lucky break there!

10/6/15
Got the bike home tonight. Spent some time going through everything and figuring out what needs to be replaced and what to sell. Found out the registration expired in 1979 and the license plate expired in 1981, so it's been sitting for quite a while.
Needs some new hardware, seat, front forks, headlight, and tires. All the bearings need to be repacked because the 45 year old grease is dried up . Besides that I'm good to advance.
So far all I've removed are the gauges and wire harnesses because I'll be making my own. I also have a new engine and exhaust system to sell... the exhaust and clutch cable were $500 alone, so I should be able to easily make back what i spent on the bike by selling unused parts. I got real lucky.

I've ordered the motor and a new head light.

 

[beast775]

Nice platform,those drum brakes already look like xlyte 5304s!

 

[Ussyamoto]

Thanks Beast775, I really like this frame too.

10/9/15
My motor just came in xD
Banana for scale of course

10/10/15
Finally sold the last of the old motor parts. Made a total of $570 USD from parts and I bought it all for $600 USD. Also found a guy who's been rebuilding these for the past 30 years so he's willing to trade me a seat and a new front end for my carbs.

10/12/15
Started cleading, de-rusting, and painting my bike parts. I'm not a huge fan of chrome, so I'm thinking about painting all the chrome white, and doing a black and white paint scheme. I'm using plastidip too so if it turns out bad it can be removed.

 

[oatnet]

Looks like a fun project, I'll be watching.

 

[Ussyamoto]

10/18/15
Got a "new" seat, front end with working suspension, changed from front drum to disk brakes,
and assembled everything for a test fit. I think I'll keep the white instead of chrome, doesn't look too bad.

10/23/15
New brakes came in today.
The brake handle comes with an integrated switch,
so I should be able to wire the brake light and regenerative breaking to it.

 

[Ussyamoto]

11/23/15
Not too much has been happening because of the holidays and waiting on parts. As parts come in I'll continue the project and posting updates.
I've redone all the blinkers and tail light with nice bright LEDs and installed a fuse box.

Parts on order:
Wolo mini Horn : http://www.amazon.com/gp/product/B00029XGIM?psc=1&redirect=true&ref_=oh_aui_detailpage_o04_s00
ATV/Motorcycle handlebar switches : http://www.amazon.com/gp/product/B00TX5SAU0?psc=1&redirect=true&ref_=oh_aui_detailpage_o04_s00
3amp Diodes to separate the Blinker from the Hazard circuits : http://www.amazon.com/gp/product/B0068AF32Q?psc=1&redirect=true&ref_=oh_aui_detailpage_o04_s00
Some additional Connectors : http://www.amazon.com/gp/product/B013G4OKAC?psc=1&redirect=true&ref_=oh_aui_detailpage_o04_s00

I got my new throttle in a few days ago, couldn't find one for a motorcycle, so i decided to go with a decent quality scooter throttle. It feels nice and solid.

LEDs in the socket

Left LED : Right Incandescent

 

[Ussyamoto]

Oh boy.... Ok so honestly I just forgot about this post for about a year.... HAHA!

....I've got some catching up to do...

4/16
Finally got the motor mount finished and the motor mounted up

I noticed the motor was crooked here, I did end up straightening it up

6/16
Started wiring up the motor to the motor controller and getting the phases matched up

Nice big juicy wiring for 300amps

Throttle wiring and started on the tail light/ turn signal harness

With the gas can on it

7/16
60T sprocket came in WOOT!

Compared to the old one

Test fitting the chain on the 12T 60T gears

Got everything mounted up and went for my first test ride... couldn't help myself. No brakes, no insurance, no license plate, on 37 year old tires, No Worries!
50mph top speed with some 5 yr old lipos 72v 10ah

Feeling motivated, got some new rear shocks

New wheel bearings!

8/16
Test fitting the 18650 mounts, looks like I'll be able to fit about 8kw in the frame.

New controller and DC-DC converter

Found a seat and strapped it on, I need to load up some newer pictures. At this point I've got everything wired up and cleaned but I've ran out of money for the batteries. I'll probably be able to pick this up again some time over the summer. All that's left is a battery pack and BMS and it's a finished project!