Designing and Building an Electric Drive System

for a Honda 250 XL Dirtbike

-------updated: 5/16/03------------

Ceara J. McNally,
Engineering Physics
Physics and Astronomy Department
University of Maine Orono   
Advisor: Mick Peterson, Mechanical Engineering Department

I'm in the NEWS!!!!....check it out:   http://www.bangornews.com/editorialnews/article.cfm/ID/400305/cfid/8161622/cftoken/69864596

Below you will find  images(NEW)of the motor, battery, and chassis I am using for my electric dirtbike.  The calculations and theory can be found here.

*****new images

Ceara Welding  Ceara Welding 2  Ceara Welding  Electric Bike Top View

The motor and controller combination I chose is the Etek 48V DC electric motor with Sevcon Millipak 4Q motor controller rated at 48V.  This motor controller can be programmed to perform regenerative breaking and increase the range of my bike. 

Controller    <!--[if !vml]--> Motor / Controller Specs

The Battery Pack option I chose is four Universal Sealed Lead Acid 12Volt 40Ah batteries.  Each weighs 27lbs.  

Universal Battery 12V 40Ah

 

dirtbike chassis   chassis(3)   chassis(4)

Above are images of the 1981 Honda XL 250 chassis before removing the engine, exhaust and other unecessary parts.

 

Below are images of the old engine vs new motor, and stripped chassis. 

stripped chassis     without motor right view    without motor left view  

Below are images of the carboard models of the batteries and motor for my system and their position on the bike.

cardboard model left side     cardboard model right side     cardboard model closeup right     cardboard model closeup left

Below are images of the system almost complete.  The controller still needs to be mounted.  

 electric bike     closeup battery pack    closeup battery pack 2

Specifications

Top speed: 50 mph

Range: 30 miles, max traveling 20mph

Acceleration: 0-30 in 4s

Total Weight: 250 lbs?...need to weigh it

Cost to build: $1100 including charger

The cost is not bad compared to a similar production bike like Blade retailing for $5,995, of course that bike comes with a super fast charger that only takes 20-30 minutes to charge the 48 volt battery pack.  I need to get one of those!!!!!.....alas...they're $495. 

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Observatories:     KPNO    Palomar    
Other cool links:    SIRTF    GOODS        

Email me:   Ceara McNally