My YZ Electric Conversion

AgileMike
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AgileMike 10/20/2023 8:04pm
10/20/2023 8:04pm

Great write up!!  I did a conversion kit to create by first eMTB.  Over time I found the pre-built eMTB were much better than anything I could convert, but the e-moto market may end up with higher level conversion kits. 

The one think I love about your kit is you can build a battery for whatever range you would like.  I ride a lot of ametuer moto and practice days.  Most sessions are 12-15 minutes.  I would like a battery that only has 20-25 mins or range and is re-chargable within 40 mins for my next race/practice session.

I think it would shave 10ish pounds off the Stark to reduce the battery size, but I don't know for sure.

2
Bearuno
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Bearuno 10/20/2023 9:10pm
10/20/2023 9:10pm Edited Date/Time 10/20/2023 9:16pm

Geeze bayodome, now you've got me thinking.Dizzy

Next year I'm (hoping) to have both knees replaced, and, due to so many previous ops on them / hardware in my legs, they are going to be a BIG 'project' for me and my Ortho. If he can put  good knee joints in (other Docs have said it's impossible with the damage and hardware I already have, they are just offering the type of crap they put into palliative patients ) , he's warned me of a long, long recovery process to come.

So, with the downtime, I was going to make my own E bicycle frames - based on my DH frames, using either the Intradrive 8spd MGU, or the  (not coming to small makers like I, until 2025 at the earliest) Pinion 12spd MGU. And / Or, make a mini Desert X. I've worked out the geometry, designed the Jig (I make Ducati TT2 and TT1 chassis) Add Ons for the various differences required, and got a 400 bottom end (6spd, and a far Stronger set of cases than the 600 Pantah cases I have) that I'll put a 600 crank in, and 750 top end on. Makes for really nice little 705cc engine package, and potentially, a neat / light ADVer or Street Tracker.

But now, I'm thinking of doing an E Motorcycle, what with that / those Motors with the reduction gear / stepped back CS you've brought to light . 

I'll try to stay calm on this - I had determined Not to make one, and just buy a production bike, be it a Stark Varg, or what's sure to come from the Major Manufacturers. I might start looking out for a  22/23/24 roller. Sometimes they can be found from, or go in partnership with.  a Kart / Speedway / Buggy  builder, or a racer that wants a spare engine etc. 

Mounts  / Fitment are absolutely no problem for me, I'd make that all myself, but as for Batteries, well, I'll either purchase one, or, probably,  get a mate that's an 'E' head to make them up for me. My (Small and Old ) Bear Brain is too full to try to add Battery and Controller E Tech to it. 

3
Maico4
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Maico4 10/20/2023 11:22pm
10/20/2023 11:22pm
Bearuno wrote:
Geeze bayodome, now you've got me thinking. Next year I'm (hoping) to have both knees replaced, and, due to so many previous ops on them /...

Geeze bayodome, now you've got me thinking.Dizzy

Next year I'm (hoping) to have both knees replaced, and, due to so many previous ops on them / hardware in my legs, they are going to be a BIG 'project' for me and my Ortho. If he can put  good knee joints in (other Docs have said it's impossible with the damage and hardware I already have, they are just offering the type of crap they put into palliative patients ) , he's warned me of a long, long recovery process to come.

So, with the downtime, I was going to make my own E bicycle frames - based on my DH frames, using either the Intradrive 8spd MGU, or the  (not coming to small makers like I, until 2025 at the earliest) Pinion 12spd MGU. And / Or, make a mini Desert X. I've worked out the geometry, designed the Jig (I make Ducati TT2 and TT1 chassis) Add Ons for the various differences required, and got a 400 bottom end (6spd, and a far Stronger set of cases than the 600 Pantah cases I have) that I'll put a 600 crank in, and 750 top end on. Makes for really nice little 705cc engine package, and potentially, a neat / light ADVer or Street Tracker.

But now, I'm thinking of doing an E Motorcycle, what with that / those Motors with the reduction gear / stepped back CS you've brought to light . 

I'll try to stay calm on this - I had determined Not to make one, and just buy a production bike, be it a Stark Varg, or what's sure to come from the Major Manufacturers. I might start looking out for a  22/23/24 roller. Sometimes they can be found from, or go in partnership with.  a Kart / Speedway / Buggy  builder, or a racer that wants a spare engine etc. 

Mounts  / Fitment are absolutely no problem for me, I'd make that all myself, but as for Batteries, well, I'll either purchase one, or, probably,  get a mate that's an 'E' head to make them up for me. My (Small and Old ) Bear Brain is too full to try to add Battery and Controller E Tech to it. 

Hey this is Maico4 , you sound like a friend of Bayodome.  He put together a great build. Did a real clean job.  I am 78 years old and still building and riding these electric bikes.  They are great fun. You sound very experienced in building bikes, keep in touch with me and I'd be glad to help you with the battery and electrrical tech stuff.  I helped Bayodome on his build.  I help Bob (Cmotodad) too.  And just for reference, I had both knees replaced 6 years ago with the Stryker Triathlon model knees.  That has given me 6 more years of riding.  Get them both done the same day, the pain is no different, and the rehab is once , not twice. Dr. Copp at Scripps Clinic in La Jolla, California does them both in one day. 

7
Bearuno
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Bearuno 10/21/2023 4:05am
10/21/2023 4:05am Edited Date/Time 10/21/2023 4:11am

Maico4 :

 The Stryker Triathlon is what I went to various Orthos asking for!

I've got it as one of my Screen savers :

Stryker TriathlonTritanium - Printed Titanium - Cementless Knee Joint - Trick .jpg?VersionId=3 But, a few Orthos said my joints / legs are too far gone for them. I've got remnant staples and bolts in both legs, from previous recos, that they couldn't / didn't get out. And the Staples that hold the Ligastic ACL in my LH knee, and the through bolts that hold what's left of an ancient Gortex Ligament in the RH one.  I've No PCLs left, and Collaterals are pretty bloody stuffed. And, no cartilage at all in either one.

Other hardware in my Femurs and Tibias, meant no long pins into the Femur and Tibial tuberosity,  so I've kept my rotted  joints for about 30 / 35 years too long.  Seeing the new ones available, with their shorter multi pin and 'dagger' fixations,  have given me hope of being able to be able to ride / race again.

Part of the long process of replacement, is getting out as many bits of 'hardware' that are in the road of getting Good knee joints fitted. I'll have to have Ops to remove them, before the actual go at putting in Strykers / etc. The Ortho said he had access to even better ones now, than the Stryker, and I'm prepared to pay for them, if they cost more than Medicare / my Insurance will pay. 

This new, Good Ortho, has given me some hope - he had a demo Stryker on his desk as I walked in. I'm on crutches for any distance above a few steps now, and have been a  'always sitting down' rider on MCs for years now - which is Not a good / safe way to ride any form of 2 wheels.

If he can fit them, I hope he can fit a synthetic knee cap to what looks to be a 'carrier' on the Stryker, as my LH one has been missing for 43 years now . If he can attach the patella tendon to it, I might get a bit of leg extension strength on that knee after all these years.  Now that would be cool! Racing BMX, and DH with only one leg with any power, has been a pain in the arse for decades now. Still, I was able to win quite a few races / Titles, and represented my country in both of those sports. I'd like to get back to that, in my dotage. 

PS : don't know bayodome, but mighty glad I clicked on this thread and saw his conversion - seeing the CS to SA pivot distance got my attention, instantly. Any build I do, If I do one, has to be after Knee work - up until then, I need to make more of my 'things' and do my consulting work OS, to get through the down time I'll be facing. I've a few other operations to have done to other worn out / damaged bits of my body, too. 

1

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350ss
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350ss 10/21/2023 10:21am
10/21/2023 10:21am

this might be one of those if you have to ask you cant afford it situations but how much in parts do you guys have into these conversions?  seems like just the main parts (motor, controller, battery) are about 4-5k and then about another 1-2k or so in extras (mounts, sprockets,...)

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Camp332
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Camp332 10/21/2023 10:29am
10/21/2023 10:29am

Bayo, sure I'll buy the cold ones and burgers. I'm wondering if I can convert my 04 YZ125? Last year of the steel frame.

Cool

 

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OleTex
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OleTex 10/21/2023 11:02am
10/21/2023 11:02am

I remember the days when folks wanted a four stroke engine in their two stroke frames lol

Now we have very ingenious folks converting their four stroke bikes into electric. Amazing. 

I love the ingenuity of motocrossers. 
 

 

4
DA498
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DA498 10/21/2023 11:22am
10/21/2023 11:22am
350ss wrote:
this might be one of those if you have to ask you cant afford it situations but how much in parts do you guys have into...

this might be one of those if you have to ask you cant afford it situations but how much in parts do you guys have into these conversions?  seems like just the main parts (motor, controller, battery) are about 4-5k and then about another 1-2k or so in extras (mounts, sprockets,...)

This seems about right, I have a 2012 350sxf that Im getting very curious about converting as a retirement project. Appreciate the info you guys are providing

1
Maico4
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Maico4 10/21/2023 2:20pm
10/21/2023 2:20pm
350ss wrote:
this might be one of those if you have to ask you cant afford it situations but how much in parts do you guys have into...

this might be one of those if you have to ask you cant afford it situations but how much in parts do you guys have into these conversions?  seems like just the main parts (motor, controller, battery) are about 4-5k and then about another 1-2k or so in extras (mounts, sprockets,...)

I can speak from my experience, but the question is to Bayodome.  Motor/controller/wiring harness/ throttle and switches from ElectroandCompany.com  $1500 .  The battery can be $2000 to 4000. And truely the rest is just rebuilding a used bike and about $500 to put the motor and controller in the bike, if you do it..  There is a fair amount of labor. The most common bikes to convert, YZ250F-450F 2014 and newer, Honda 's all years CRF aluminum frames , and KTM's 2008 and up even earlier.  I can get the biggest battery in the KTM frames. Suzuki and Kawasaki are doable, I just haven't.  We have done many KX80,85,and 100's to electric, and YZ85, and CRF150's

3
brocster
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brocster 10/21/2023 2:42pm
10/21/2023 2:42pm

This is bad ass and very intriguing. Seems like it would be a fun project for a back up/play bike. 

2
midwestmoto 10/21/2023 3:02pm
10/21/2023 3:02pm

I would love to do this to a little pitbike for the backyard. 

When the battery starts to get low, does the performance slowly decrease or does it just stop running when the battery hits 0%?

 

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Maico4
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Maico4 10/21/2023 9:15pm
10/21/2023 9:15pm
midwestmoto wrote:
I would love to do this to a little pitbike for the backyard.  When the battery starts to get low, does the performance slowly decrease or...

I would love to do this to a little pitbike for the backyard. 

When the battery starts to get low, does the performance slowly decrease or does it just stop running when the battery hits 0%?

 

We have done a lot of KX80,85, and 100's, they make a great pit bike. So do YZ85's,  Crf 150's, we are doing an RM85 .  Same motor,  Smaller Controller, Votol EM150, battery to fit the frame you get about 25 miles to 40 depending on the size battery, And lately we have been putting in a Reserve small battery in them  good for 4 mile to get you home. They are great fun and easy to ride.

2
bayodome
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bayodome 10/23/2023 7:58am
10/23/2023 7:58am
Bearuno wrote:
Geeze bayodome, now you've got me thinking. Next year I'm (hoping) to have both knees replaced, and, due to so many previous ops on them /...

Geeze bayodome, now you've got me thinking.Dizzy

Next year I'm (hoping) to have both knees replaced, and, due to so many previous ops on them / hardware in my legs, they are going to be a BIG 'project' for me and my Ortho. If he can put  good knee joints in (other Docs have said it's impossible with the damage and hardware I already have, they are just offering the type of crap they put into palliative patients ) , he's warned me of a long, long recovery process to come.

So, with the downtime, I was going to make my own E bicycle frames - based on my DH frames, using either the Intradrive 8spd MGU, or the  (not coming to small makers like I, until 2025 at the earliest) Pinion 12spd MGU. And / Or, make a mini Desert X. I've worked out the geometry, designed the Jig (I make Ducati TT2 and TT1 chassis) Add Ons for the various differences required, and got a 400 bottom end (6spd, and a far Stronger set of cases than the 600 Pantah cases I have) that I'll put a 600 crank in, and 750 top end on. Makes for really nice little 705cc engine package, and potentially, a neat / light ADVer or Street Tracker.

But now, I'm thinking of doing an E Motorcycle, what with that / those Motors with the reduction gear / stepped back CS you've brought to light . 

I'll try to stay calm on this - I had determined Not to make one, and just buy a production bike, be it a Stark Varg, or what's sure to come from the Major Manufacturers. I might start looking out for a  22/23/24 roller. Sometimes they can be found from, or go in partnership with.  a Kart / Speedway / Buggy  builder, or a racer that wants a spare engine etc. 

Mounts  / Fitment are absolutely no problem for me, I'd make that all myself, but as for Batteries, well, I'll either purchase one, or, probably,  get a mate that's an 'E' head to make them up for me. My (Small and Old ) Bear Brain is too full to try to add Battery and Controller E Tech to it. 

Maico4 wrote:
Hey this is Maico4 , you sound like a friend of Bayodome.  He put together a great build. Did a real clean job.  I am 78...

Hey this is Maico4 , you sound like a friend of Bayodome.  He put together a great build. Did a real clean job.  I am 78 years old and still building and riding these electric bikes.  They are great fun. You sound very experienced in building bikes, keep in touch with me and I'd be glad to help you with the battery and electrrical tech stuff.  I helped Bayodome on his build.  I help Bob (Cmotodad) too.  And just for reference, I had both knees replaced 6 years ago with the Stryker Triathlon model knees.  That has given me 6 more years of riding.  Get them both done the same day, the pain is no different, and the rehab is once , not twice. Dr. Copp at Scripps Clinic in La Jolla, California does them both in one day. 

I didn't put Don's name in the original post simply because I wasn't sure if he wanted the attention.

Don/Maico4 was ABSOLUTELY INSTRUMENTAL in my conversion. He is a wealth of knowledge, gave me countless insights, answered all of my questions and there is no way my bike would have turned out as well as it did without him. I'm very fortunate to have connected with him. Thank you Don! Hopefully we can meet up one day and ride together!

Check out his YouTube channel: Donald Cox. He has several different builds in there. The latest is a beautiful 2023 CRF250R conversion.

Here's a step-by-step break down of one of his YZ250F conversions from last year. Although I made plenty of my own modifications I found this to be invaluable: YZ250F 2014 Build With QS 138 70H V3 Motor and 450A controller Part #1 and Part #2

3
JM485
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JM485 10/23/2023 8:48am
10/23/2023 8:48am
Camp332 wrote:
Bayo, sure I'll buy the cold ones and burgers. I'm wondering if I can convert my 04 YZ125? Last year of the steel frame.    

Bayo, sure I'll buy the cold ones and burgers. I'm wondering if I can convert my 04 YZ125? Last year of the steel frame.

Cool

 

The single backbone steel frame bikes are not the ones you want to start with unfortunately.  The reason being is that it's a lot easier to fit a larger battery in the twin spar aluminum frames since they can be installed from the top and drop down between the spars, rather than having to slide in from the side which doesn't leave a whole lot of room.  You may be able to make a fun trail bike out of it, but you will not have anywhere near the capacity necessary for moto.  If you want a project you would be a lot better off starting with a blown up four stroke as a rolling chassis donor.

5
bayodome
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bayodome 10/23/2023 8:55am
10/23/2023 8:55am
350ss wrote:
this might be one of those if you have to ask you cant afford it situations but how much in parts do you guys have into...

this might be one of those if you have to ask you cant afford it situations but how much in parts do you guys have into these conversions?  seems like just the main parts (motor, controller, battery) are about 4-5k and then about another 1-2k or so in extras (mounts, sprockets,...)

Maico4 wrote:
I can speak from my experience, but the question is to Bayodome.  Motor/controller/wiring harness/ throttle and switches from ElectroandCompany.com  $1500 .  The battery can be $2000...

I can speak from my experience, but the question is to Bayodome.  Motor/controller/wiring harness/ throttle and switches from ElectroandCompany.com  $1500 .  The battery can be $2000 to 4000. And truely the rest is just rebuilding a used bike and about $500 to put the motor and controller in the bike, if you do it..  There is a fair amount of labor. The most common bikes to convert, YZ250F-450F 2014 and newer, Honda 's all years CRF aluminum frames , and KTM's 2008 and up even earlier.  I can get the biggest battery in the KTM frames. Suzuki and Kawasaki are doable, I just haven't.  We have done many KX80,85,and 100's to electric, and YZ85, and CRF150's

Yeah, your estimates are not far off.

Like Don mentioned, one of the biggest variables is the battery. Lots of far more knowledgeable people than myself choose to build their own batteries. That helps offset the cost if it's DIY. Don builds his own as well and will do one for you if you go with his services. 

One of my many goals for my build was to make it as plug-and-play as possible. I wanted as much refinement/tested parts as were available at the time, so I went with the Chi Battery Systems Sur Ron battery option. They're made in Chicago and I waited for their Black Friday sale. I believe the battery ended up being about $2300.

There are a few other options out there for semi-mass produced batteries. Amorge.com is one company I've seen that people seem to be happy with (also customizable size and shape) but please do not go with the enticingly cheap  Amazon batteries. For one, they will not have the amperage output required for MX-style riding (my controller runs between 150a and 350a). But there's also little to no quality control. Think of all of those fires you keep hearing about on the news. Best to avoid that scenario.

Electro & Co also had their own Black Friday sale, so that saved me again. About $1350.

Rolling chassis was $1600. If you already have a chassis at the ready, you're saving a significant chunk right there.

Add in mounts and a few miscellaneous items and the total was just under $7000. Obviously that doesn't include labor, which I did all myself and would imagine most people on this forum would do the same.

3
bayodome
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bayodome 10/23/2023 9:02am
10/23/2023 9:02am
Camp332 wrote:
Bayo, sure I'll buy the cold ones and burgers. I'm wondering if I can convert my 04 YZ125? Last year of the steel frame.    

Bayo, sure I'll buy the cold ones and burgers. I'm wondering if I can convert my 04 YZ125? Last year of the steel frame.

Cool

 

JM485 wrote:
The single backbone steel frame bikes are not the ones you want to start with unfortunately.  The reason being is that it's a lot easier to...

The single backbone steel frame bikes are not the ones you want to start with unfortunately.  The reason being is that it's a lot easier to fit a larger battery in the twin spar aluminum frames since they can be installed from the top and drop down between the spars, rather than having to slide in from the side which doesn't leave a whole lot of room.  You may be able to make a fun trail bike out of it, but you will not have anywhere near the capacity necessary for moto.  If you want a project you would be a lot better off starting with a blown up four stroke as a rolling chassis donor.

I was about to say the same exact thing, Josh! 

You've done a conversion on an older YZ125 frame yourself, so you would know:

4afff4 6570c4da24794c678033394b344d94f0~mv2

Originally I wanted to convert my old YZ144 but at the advice of many including Josh and Electro, I decided to sell it to fund a more worthwhile build. No regrets in that department.

6
Camp332
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Camp332 10/23/2023 9:23am
10/23/2023 9:23am
Camp332 wrote:
Bayo, sure I'll buy the cold ones and burgers. I'm wondering if I can convert my 04 YZ125? Last year of the steel frame.    

Bayo, sure I'll buy the cold ones and burgers. I'm wondering if I can convert my 04 YZ125? Last year of the steel frame.

Cool

 

JM485 wrote:
The single backbone steel frame bikes are not the ones you want to start with unfortunately.  The reason being is that it's a lot easier to...

The single backbone steel frame bikes are not the ones you want to start with unfortunately.  The reason being is that it's a lot easier to fit a larger battery in the twin spar aluminum frames since they can be installed from the top and drop down between the spars, rather than having to slide in from the side which doesn't leave a whole lot of room.  You may be able to make a fun trail bike out of it, but you will not have anywhere near the capacity necessary for moto.  If you want a project you would be a lot better off starting with a blown up four stroke as a rolling chassis donor.

bayodome wrote:
I was about to say the same exact thing, Josh!  You've done a conversion on an older YZ125 frame yourself, so you would know: Originally I...

I was about to say the same exact thing, Josh! 

You've done a conversion on an older YZ125 frame yourself, so you would know:

4afff4 6570c4da24794c678033394b344d94f0~mv2

Originally I wanted to convert my old YZ144 but at the advice of many including Josh and Electro, I decided to sell it to fund a more worthwhile build. No regrets in that department.

Thanks, Josh, and Bayo. 

 

2
snillum
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snillum 10/23/2023 10:45am
10/23/2023 10:45am
haydug391 wrote:
Here is mine. Currently working on a YZ85 chassis now. Loads of fun but we’ve tried to finish a 45 minute GP race and made it...

IMG 0699Here is mine. Currently working on a YZ85 chassis now. Loads of fun but we’ve tried to finish a 45 minute GP race and made it about 40-41 minutes. Lol. Still. My son wanted it to ride on his property and not disturb the neighbors, race some fair races, and have fun riding a dirt bike. 

Do you mind to show some more of this build? I have a sweet spot for RM85s and I too want to ride on my property without irritating the neighbors any more. 

Pit Row

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haydug391
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haydug391 10/23/2023 11:06am
10/23/2023 11:06am
snillum wrote:
Do you mind to show some more of this build? I have a sweet spot for RM85s and I too want to ride on my property...

Do you mind to show some more of this build? I have a sweet spot for RM85s and I too want to ride on my property without irritating the neighbors any more. 

Check out bike builds forum. It’s in there. I did not use a mount kit. I cut the stock off and made my own. I’m doing a YZ85 now and I designed a bolt in bracket system for it. It’s as low as possible using the stock mounts but I think I’m gonna cut them and lower it 3/8” to keep that weight low. I have a JIG built to keep the countershaft location the same as the stock.  Not sure your location but I could build the RM for you. Trying to hijack this thread. 

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350ss
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350ss 10/23/2023 1:42pm
10/23/2023 1:42pm
350ss wrote:
this might be one of those if you have to ask you cant afford it situations but how much in parts do you guys have into...

this might be one of those if you have to ask you cant afford it situations but how much in parts do you guys have into these conversions?  seems like just the main parts (motor, controller, battery) are about 4-5k and then about another 1-2k or so in extras (mounts, sprockets,...)

Maico4 wrote:
I can speak from my experience, but the question is to Bayodome.  Motor/controller/wiring harness/ throttle and switches from ElectroandCompany.com  $1500 .  The battery can be $2000...

I can speak from my experience, but the question is to Bayodome.  Motor/controller/wiring harness/ throttle and switches from ElectroandCompany.com  $1500 .  The battery can be $2000 to 4000. And truely the rest is just rebuilding a used bike and about $500 to put the motor and controller in the bike, if you do it..  There is a fair amount of labor. The most common bikes to convert, YZ250F-450F 2014 and newer, Honda 's all years CRF aluminum frames , and KTM's 2008 and up even earlier.  I can get the biggest battery in the KTM frames. Suzuki and Kawasaki are doable, I just haven't.  We have done many KX80,85,and 100's to electric, and YZ85, and CRF150's

appreciate the insight

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mxracer666
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mxracer666 10/23/2023 2:17pm
10/23/2023 2:17pm
Bearuno wrote:
Geeze bayodome, now you've got me thinking. Next year I'm (hoping) to have both knees replaced, and, due to so many previous ops on them /...

Geeze bayodome, now you've got me thinking.Dizzy

Next year I'm (hoping) to have both knees replaced, and, due to so many previous ops on them / hardware in my legs, they are going to be a BIG 'project' for me and my Ortho. If he can put  good knee joints in (other Docs have said it's impossible with the damage and hardware I already have, they are just offering the type of crap they put into palliative patients ) , he's warned me of a long, long recovery process to come.

So, with the downtime, I was going to make my own E bicycle frames - based on my DH frames, using either the Intradrive 8spd MGU, or the  (not coming to small makers like I, until 2025 at the earliest) Pinion 12spd MGU. And / Or, make a mini Desert X. I've worked out the geometry, designed the Jig (I make Ducati TT2 and TT1 chassis) Add Ons for the various differences required, and got a 400 bottom end (6spd, and a far Stronger set of cases than the 600 Pantah cases I have) that I'll put a 600 crank in, and 750 top end on. Makes for really nice little 705cc engine package, and potentially, a neat / light ADVer or Street Tracker.

But now, I'm thinking of doing an E Motorcycle, what with that / those Motors with the reduction gear / stepped back CS you've brought to light . 

I'll try to stay calm on this - I had determined Not to make one, and just buy a production bike, be it a Stark Varg, or what's sure to come from the Major Manufacturers. I might start looking out for a  22/23/24 roller. Sometimes they can be found from, or go in partnership with.  a Kart / Speedway / Buggy  builder, or a racer that wants a spare engine etc. 

Mounts  / Fitment are absolutely no problem for me, I'd make that all myself, but as for Batteries, well, I'll either purchase one, or, probably,  get a mate that's an 'E' head to make them up for me. My (Small and Old ) Bear Brain is too full to try to add Battery and Controller E Tech to it. 

Maico4 wrote:
Hey this is Maico4 , you sound like a friend of Bayodome.  He put together a great build. Did a real clean job.  I am 78...

Hey this is Maico4 , you sound like a friend of Bayodome.  He put together a great build. Did a real clean job.  I am 78 years old and still building and riding these electric bikes.  They are great fun. You sound very experienced in building bikes, keep in touch with me and I'd be glad to help you with the battery and electrrical tech stuff.  I helped Bayodome on his build.  I help Bob (Cmotodad) too.  And just for reference, I had both knees replaced 6 years ago with the Stryker Triathlon model knees.  That has given me 6 more years of riding.  Get them both done the same day, the pain is no different, and the rehab is once , not twice. Dr. Copp at Scripps Clinic in La Jolla, California does them both in one day. 

bayodome wrote:
I didn't put Don's name in the original post simply because I wasn't sure if he wanted the attention. Don/Maico4 was ABSOLUTELY INSTRUMENTAL in my conversion...

I didn't put Don's name in the original post simply because I wasn't sure if he wanted the attention.

Don/Maico4 was ABSOLUTELY INSTRUMENTAL in my conversion. He is a wealth of knowledge, gave me countless insights, answered all of my questions and there is no way my bike would have turned out as well as it did without him. I'm very fortunate to have connected with him. Thank you Don! Hopefully we can meet up one day and ride together!

Check out his YouTube channel: Donald Cox. He has several different builds in there. The latest is a beautiful 2023 CRF250R conversion.

Here's a step-by-step break down of one of his YZ250F conversions from last year. Although I made plenty of my own modifications I found this to be invaluable: YZ250F 2014 Build With QS 138 70H V3 Motor and 450A controller Part #1 and Part #2

I'm "in" on this! Fascinating info (from people much more qualified than I) !

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early
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early 10/24/2023 3:23pm
10/24/2023 3:23pm
bayodome wrote:
Since people are asking, here’s a little more info/resources on my build: Motor and Controller kit - Electro & Co. Motor: QS138 70h V3 Controller...

Since people are asking, here’s a little more info/resources on my build:

Motor and Controller kit - Electro & Co.
Motor: QS138 70h V3
Controller: Votol EM260 preprogrammed by E&C with the 3 maps maxing out at 350amps 
Kit also includes pre-wired harness, throttle and volt meter. 

Votol now has a newer, smaller and water-cooled version now called the EM260s.

Battery - Chi Battery Systems
72v 51ah Gladiator Max: This is the highest-end Sur Ron Light Bee battery you can find in the US. It’s capable of 400 amps continuous and 520 amp bursts. 

Since I’m currently running well below that and the battery was designed for off-road use, I am very confident in it’s durability. If reprogrammed to higher amps and I would likely need to go for the water-cooled controller.

Chi Battery Systems recently upgraded their product line for even higher amperage and to a steel enclosure.

Little hint: if you’re interested in their products, wait for their Black Friday Sale!

Motor Mounts - MightE
MightE is out of the UK and has electric conversion kits for dirt bikes and go-carts. Pricey stuff but well made.

Front Sprocket - Lithium King
The countershaft on the QS138 motor is the size of most mini-bike countershafts, meaning the only sprockets mass produced for it are 428 or 420-pitch. Lithium King and Might E are the only two companies making 520-pitch sprockets for this motor. 

I went with the Lithium King option because it was 1/3 the price of MightE’s option, however it’s a bit on the soft side. I have about 10 rides on the bike now and the spline engagement has already warn out and loosened. Fortunately, they were already aware of the issue (the owner has his own RM125 conversion and is no slouch on the bike) and have already made a hardened steel version with double the shaft engagement. Mine is already in the mail.

If I were starting from scratch again, I would look to Lithium King as they are offering custom kit creation for a very reasonable price (this service didn’t exist when I started my journey), they have replacement parts, and sell most of the accessories needed for the process.

Battery Mount - Custom
I designed it to be somewhat hot-swap. The battery is mounted under the seat so I just pop off the seat, disconnect the battery from the controller and it slides right out just like on the Light Bee. If/when I have another battery, it would take about three minutes to change to a freshy.

Controller Mount - Custom
I am not a fabricator. Fortunately, I found someone who not only is a fabricator, he’d already done a conversion with the same exact frame, so that helped a ton. He’s also helped casmotodad with his builds I believe.

For pretty much any other frame, I believe you could probably mount the controller directly to the subframe under the seat. However, with the Yamaha’s non-parallel lower seat stays, some creative engineering is required.

OLU08994

What's the weight difference between the conversion and the gas bike?

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Maico4
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Maico4 10/25/2023 3:11pm
10/25/2023 3:11pm
bayodome wrote:
Since people are asking, here’s a little more info/resources on my build: Motor and Controller kit - Electro & Co. Motor: QS138 70h V3 Controller...

Since people are asking, here’s a little more info/resources on my build:

Motor and Controller kit - Electro & Co.
Motor: QS138 70h V3
Controller: Votol EM260 preprogrammed by E&C with the 3 maps maxing out at 350amps 
Kit also includes pre-wired harness, throttle and volt meter. 

Votol now has a newer, smaller and water-cooled version now called the EM260s.

Battery - Chi Battery Systems
72v 51ah Gladiator Max: This is the highest-end Sur Ron Light Bee battery you can find in the US. It’s capable of 400 amps continuous and 520 amp bursts. 

Since I’m currently running well below that and the battery was designed for off-road use, I am very confident in it’s durability. If reprogrammed to higher amps and I would likely need to go for the water-cooled controller.

Chi Battery Systems recently upgraded their product line for even higher amperage and to a steel enclosure.

Little hint: if you’re interested in their products, wait for their Black Friday Sale!

Motor Mounts - MightE
MightE is out of the UK and has electric conversion kits for dirt bikes and go-carts. Pricey stuff but well made.

Front Sprocket - Lithium King
The countershaft on the QS138 motor is the size of most mini-bike countershafts, meaning the only sprockets mass produced for it are 428 or 420-pitch. Lithium King and Might E are the only two companies making 520-pitch sprockets for this motor. 

I went with the Lithium King option because it was 1/3 the price of MightE’s option, however it’s a bit on the soft side. I have about 10 rides on the bike now and the spline engagement has already warn out and loosened. Fortunately, they were already aware of the issue (the owner has his own RM125 conversion and is no slouch on the bike) and have already made a hardened steel version with double the shaft engagement. Mine is already in the mail.

If I were starting from scratch again, I would look to Lithium King as they are offering custom kit creation for a very reasonable price (this service didn’t exist when I started my journey), they have replacement parts, and sell most of the accessories needed for the process.

Battery Mount - Custom
I designed it to be somewhat hot-swap. The battery is mounted under the seat so I just pop off the seat, disconnect the battery from the controller and it slides right out just like on the Light Bee. If/when I have another battery, it would take about three minutes to change to a freshy.

Controller Mount - Custom
I am not a fabricator. Fortunately, I found someone who not only is a fabricator, he’d already done a conversion with the same exact frame, so that helped a ton. He’s also helped casmotodad with his builds I believe.

For pretty much any other frame, I believe you could probably mount the controller directly to the subframe under the seat. However, with the Yamaha’s non-parallel lower seat stays, some creative engineering is required.

OLU08994

early wrote:

What's the weight difference between the conversion and the gas bike?

They all come in right about 230lbs.  That is with a 72V 50AH battery.   Good for most single 20 minute motos..  Recharge in about 45 minutes. I built one battery in a KTM frame (2017 150SX) and it was 63AH.  It would make a 30 minute moto, and it weighed 245

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snillum 10/30/2023 5:55am
10/30/2023 5:55am

Well thanks a lot guys... Now I am on the journey of building an electric bike... my wallet hates me and you. I think it will be a fun project though. 

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Maico4
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Maico4 10/30/2023 11:01am
10/30/2023 11:01am Edited Date/Time 10/30/2023 11:02am
snillum wrote:
Well thanks a lot guys... Now I am on the journey of building an electric bike... my wallet hates me and you. I think it will...

Well thanks a lot guys... Now I am on the journey of building an electric bike... my wallet hates me and you. I think it will be a fun project though. 

Let the journey begin.  These E-bikes are just fun.  We all still love the smell of 2 stroke Castor, and VP fuels, but these E-bikes are just fun.  Trey Canard , an ex Pro Motocrosser, who is now the test rider and racer for the Honda E-bike project, said after his first ride on it, I just  all smiles.

https://www.swapmotolive.com/checking-in-with-trey-canard-4/videos-thea…

Bayodome , I am sure, will be glad to help you and so will I.  If you want to start a private conversation, go to ElectriDirtRiders.com and start a conversation we me and Bayodome. It is easier to reference material etc. there. 

What bike do you plan on building?  They all work quite well now a days. We have all built e-Pit bikes too, like a KX85-100, YZ85, RM85, Crf 150.  They are all so fun and as fast as you want or as slow as you want for kids and beginners.  Here is my YouTube channel link to one of my builds being raced at Pala pit bike race.  You can see a lot of my other builds there. 

The race starts at 2:00 minutes in. The KX100 is street legal and has its headlight on.

 https://www.youtube.com/watch?v=-VnKSM0nWzg&ab_channel=DonaldCox

Definitely keep in touch, and let's get building.

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bayodome
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bayodome 10/30/2023 12:47pm
10/30/2023 12:47pm
snillum wrote:
Well thanks a lot guys... Now I am on the journey of building an electric bike... my wallet hates me and you. I think it will...

Well thanks a lot guys... Now I am on the journey of building an electric bike... my wallet hates me and you. I think it will be a fun project though. 

Maico4 wrote:
Let the journey begin.  These E-bikes are just fun.  We all still love the smell of 2 stroke Castor, and VP fuels, but these E-bikes are...

Let the journey begin.  These E-bikes are just fun.  We all still love the smell of 2 stroke Castor, and VP fuels, but these E-bikes are just fun.  Trey Canard , an ex Pro Motocrosser, who is now the test rider and racer for the Honda E-bike project, said after his first ride on it, I just  all smiles.

https://www.swapmotolive.com/checking-in-with-trey-canard-4/videos-thea…

Bayodome , I am sure, will be glad to help you and so will I.  If you want to start a private conversation, go to ElectriDirtRiders.com and start a conversation we me and Bayodome. It is easier to reference material etc. there. 

What bike do you plan on building?  They all work quite well now a days. We have all built e-Pit bikes too, like a KX85-100, YZ85, RM85, Crf 150.  They are all so fun and as fast as you want or as slow as you want for kids and beginners.  Here is my YouTube channel link to one of my builds being raced at Pala pit bike race.  You can see a lot of my other builds there. 

The race starts at 2:00 minutes in. The KX100 is street legal and has its headlight on.

 https://www.youtube.com/watch?v=-VnKSM0nWzg&ab_channel=DonaldCox

Definitely keep in touch, and let's get building.

Ask away! Don is a guru. I'm just a neophyte in all of this but happy to help however I can.

It's a journey for sure, but a game changer too. I've gone from riding once or twice a year to riding once or twice a week.

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bayodome 10/30/2023 1:05pm
10/30/2023 1:05pm
bayodome wrote:
Since people are asking, here’s a little more info/resources on my build: Motor and Controller kit - Electro & Co. Motor: QS138 70h V3 Controller...

Since people are asking, here’s a little more info/resources on my build:

Motor and Controller kit - Electro & Co.
Motor: QS138 70h V3
Controller: Votol EM260 preprogrammed by E&C with the 3 maps maxing out at 350amps 
Kit also includes pre-wired harness, throttle and volt meter. 

Votol now has a newer, smaller and water-cooled version now called the EM260s.

Battery - Chi Battery Systems
72v 51ah Gladiator Max: This is the highest-end Sur Ron Light Bee battery you can find in the US. It’s capable of 400 amps continuous and 520 amp bursts. 

Since I’m currently running well below that and the battery was designed for off-road use, I am very confident in it’s durability. If reprogrammed to higher amps and I would likely need to go for the water-cooled controller.

Chi Battery Systems recently upgraded their product line for even higher amperage and to a steel enclosure.

Little hint: if you’re interested in their products, wait for their Black Friday Sale!

Motor Mounts - MightE
MightE is out of the UK and has electric conversion kits for dirt bikes and go-carts. Pricey stuff but well made.

Front Sprocket - Lithium King
The countershaft on the QS138 motor is the size of most mini-bike countershafts, meaning the only sprockets mass produced for it are 428 or 420-pitch. Lithium King and Might E are the only two companies making 520-pitch sprockets for this motor. 

I went with the Lithium King option because it was 1/3 the price of MightE’s option, however it’s a bit on the soft side. I have about 10 rides on the bike now and the spline engagement has already warn out and loosened. Fortunately, they were already aware of the issue (the owner has his own RM125 conversion and is no slouch on the bike) and have already made a hardened steel version with double the shaft engagement. Mine is already in the mail.

If I were starting from scratch again, I would look to Lithium King as they are offering custom kit creation for a very reasonable price (this service didn’t exist when I started my journey), they have replacement parts, and sell most of the accessories needed for the process.

Battery Mount - Custom
I designed it to be somewhat hot-swap. The battery is mounted under the seat so I just pop off the seat, disconnect the battery from the controller and it slides right out just like on the Light Bee. If/when I have another battery, it would take about three minutes to change to a freshy.

Controller Mount - Custom
I am not a fabricator. Fortunately, I found someone who not only is a fabricator, he’d already done a conversion with the same exact frame, so that helped a ton. He’s also helped casmotodad with his builds I believe.

For pretty much any other frame, I believe you could probably mount the controller directly to the subframe under the seat. However, with the Yamaha’s non-parallel lower seat stays, some creative engineering is required.

OLU08994

early wrote:

What's the weight difference between the conversion and the gas bike?

Finally got a chance to throw the bikes on the scale.

YZ-E came in at 221 lbs.

YZ250F came in at 226 lbs. with 2/3 of a full tank. The claimed curb weight of the 2015 YZ250F is 231 lbs.

So I was about right in my guess.  A little off but the conversion is definitely lighter. Add in the lack of rotational mass with eMotos, as every likes to mention, and it feels even more than just 5-10 pounds lighter. 

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ksithumper 10/30/2023 3:33pm
10/30/2023 3:33pm
Bearuno wrote:
Maico4 :  The Stryker Triathlon is what I went to various Orthos asking for! I've got it as one of my Screen savers :  But, a...

Maico4 :

 The Stryker Triathlon is what I went to various Orthos asking for!

I've got it as one of my Screen savers :

Stryker TriathlonTritanium - Printed Titanium - Cementless Knee Joint - Trick .jpg?VersionId=3 But, a few Orthos said my joints / legs are too far gone for them. I've got remnant staples and bolts in both legs, from previous recos, that they couldn't / didn't get out. And the Staples that hold the Ligastic ACL in my LH knee, and the through bolts that hold what's left of an ancient Gortex Ligament in the RH one.  I've No PCLs left, and Collaterals are pretty bloody stuffed. And, no cartilage at all in either one.

Other hardware in my Femurs and Tibias, meant no long pins into the Femur and Tibial tuberosity,  so I've kept my rotted  joints for about 30 / 35 years too long.  Seeing the new ones available, with their shorter multi pin and 'dagger' fixations,  have given me hope of being able to be able to ride / race again.

Part of the long process of replacement, is getting out as many bits of 'hardware' that are in the road of getting Good knee joints fitted. I'll have to have Ops to remove them, before the actual go at putting in Strykers / etc. The Ortho said he had access to even better ones now, than the Stryker, and I'm prepared to pay for them, if they cost more than Medicare / my Insurance will pay. 

This new, Good Ortho, has given me some hope - he had a demo Stryker on his desk as I walked in. I'm on crutches for any distance above a few steps now, and have been a  'always sitting down' rider on MCs for years now - which is Not a good / safe way to ride any form of 2 wheels.

If he can fit them, I hope he can fit a synthetic knee cap to what looks to be a 'carrier' on the Stryker, as my LH one has been missing for 43 years now . If he can attach the patella tendon to it, I might get a bit of leg extension strength on that knee after all these years.  Now that would be cool! Racing BMX, and DH with only one leg with any power, has been a pain in the arse for decades now. Still, I was able to win quite a few races / Titles, and represented my country in both of those sports. I'd like to get back to that, in my dotage. 

PS : don't know bayodome, but mighty glad I clicked on this thread and saw his conversion - seeing the CS to SA pivot distance got my attention, instantly. Any build I do, If I do one, has to be after Knee work - up until then, I need to make more of my 'things' and do my consulting work OS, to get through the down time I'll be facing. I've a few other operations to have done to other worn out / damaged bits of my body, too. 

Small world. My son just started a new job at Stryker today.

I hope he will be eligible for staff discount by the time I need new knees !

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racingfortheson 11/20/2023 1:35am
11/20/2023 1:35am

Don is an American Hero!!! 
The dude has no reason to be so helpful but is. I hope to take him out for a steak dinner someday. I can 100% say that if you aren’t someone who wants to build your bike because of the work involved, Don will be the guy for you. 

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cmotodad
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cmotodad 11/20/2023 8:42am
11/20/2023 8:42am

Agree with Racing, If Don had not replied to my email, I would not have the CRFE I have. Since contacting Don, I now have a fun bike and a good friend. Thank You

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