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[Lecram]

Is it possible to increase the max. rpm from 6,000 to 7,000? I have replaced the front sprocket for a smaller one and I occasionally need a higher speed than 135 km/h. Regards a 2015 Zero DS. If yes, how can I do that?
Many electric motors can rev at a higher rpm, even more than 10,000 rpm. So I can't imagine that the Zero motor cannot occasionally rev at a higher rpm

[KrazyEd]

Aftermarket vs OEM can generally be tweaked. If someone sells an aftermarket part they can make it do whatever they want with disclaimers stating that they aren't responsible for any issues.
OEM has to make sure that it works the way it is supposed to for the greatest number of people for the longest period of time. If Zero were to allow us to make the change the first time that
there was an issue, they would be sued. Everyone says that THEY are competent enough to handle the changes it is THE OTHER GUY who is the idiot. We are looking at THE OTHER GUY.
Who do you think that HE is looking at. There are usually safeguards built in, not sure if a 15% increase in RPM would be within the range of safety.

[Lecram]

Aftermarket vs OEM can generally be tweaked. If someone sells an aftermarket part they can make it do whatever they want with disclaimers stating that they aren't responsible for any issues.
OEM has to make sure that it works the way it is supposed to for the greatest number of people for the longest period of time. If Zero were to allow us to make the change the first time that
there was an issue, they would be sued. Everyone says that THEY are competent enough to handle the changes it is THE OTHER GUY who is the idiot. We are looking at THE OTHER GUY.
Who do you think that HE is looking at. There are usually safeguards built in, not sure if a 15% increase in RPM would be within the range of safety.

I am responsible for the risks. The higher revs are only needed occasionally, for example to overtake a slower vehicle.

[Electric Terry]

There are 2 issues.

One is on a 2015 motor the magnets are surface mounted to the rotor with glue.  The magnets can have a tendency to break the glue and fly off over 6000 rpm, causing catastrophic motor failure.

Second is Sevcon processing speed.  There can be ride through cutouts over 6000 rpms also as the sevcon can not reliably sense the speed of the encoder data.

Good news, if you were to upgrade to a newer bike one day, the danger of spinning the motor over 6000 rpm from magnets is removed, as the motor design is now that of an IPM or internal permanent magnet where the magnets are inserted into the rotor laminations starting in 2016, and in 2017 the shaft got splined and the belt got stronger and the motor controller got more power to quickly take the SR to 164 km/h even without changing the RPM limit.

I know at least one person with a new motor and belt who rides with a 7000 rpm limit and hasn't had a ride through fault, you would need to get a shop like Hollywood Electrics to program that for you and of course it's not recommended and if anything failed it would be out of warranty, but if it's worth it, you get to make that choice.

Test ride a 2017 SR and see if just the 164 km/h works for you before you try to change anything.  The 2017 SR will also accelerate hard right to 164 km/h where earlier models would tend to slow down acceleration slightly over 100 km/h like your 2015.

[Lecram]

Thank you, Terry.

I just bought myself a 2016 KTM 1190 Adventure (next to my Zero and 5 Honda CB750s), so my wife will divorce when I spend more €€€ for a new 2017 SR 

[Electric Terry]

Hahaha understood, could you negotiate and sell the Zero and perhaps one or two of the 1970's CB's to make it a financially even choice plus there would be less total motorcycles and more space in the garage?   Hahaha you'll have to figure that one out on what everything is worth to you.  But it seems if you think creatively there should be a way to do it and trade up and get your passing speed you need.

Yes even if you had the 2015 SR or 2016 DSR (if you like the dual sport) vs the just the DS it would help give you the 164 km/h top speed, but surely if and when you do upgrade it's worth it to get the stronger belt and more power of the 2017, and of course you gain your passing speed automatically.  One day perhaps.  Good luck!

[Erasmo]

Thank you, Terry.

I just bought myself a 2016 KTM 1190 Adventure (next to my Zero and 5 Honda CB750s), so my wife will divorce when I spend more €€€ for a new 2017 SR 

Get you wife a motorcycle license, WAF-problem solved

[Lecram]

Thank you, Terry.

I just bought myself a 2016 KTM 1190 Adventure (next to my Zero and 5 Honda CB750s), so my wife will divorce when I spend more €€€ for a new 2017 SR 

Get you wife a motorcycle license, WAF-problem solved

I tried, but she refused. At the other hand, I am afraid that I fall asleep when I ride with her 

[gyrocyclist]

Is it possible to increase the max. rpm from 6,000 to 7,000? I have replaced the front sprocket for a smaller one and I occasionally need a higher speed than 135 km/h. Regards a 2015 Zero DS. If yes, how can I do that?
Many electric motors can rev at a higher rpm, even more than 10,000 rpm. So I can't imagine that the Zero motor cannot occasionally rev at a higher rpm

I have *absolutely no data* to back this up, but my guess is that Zero, like all other vehicle (and other device) manufacturers build in a safety factor. What I mean is, they know their product is probably safe at 10%+ performance,  but there's no way they're going to market a product that actually performs at the upper limit. Legal issues, and all that.

[hubert]

+1

"many electric motors can rev at >10000rpm". All sizes of e-motor exist. The tiny servo-micro-motor can rev at 40000rpm, and the very big nuclear submarine motor maybe 250rpm or so. Somehow size matters. The bigger the slower. Therefore I can imagine that the medium-sized Zero motor is safe at 6k rpm, probably usable at 7k and may explode at 10krpm....

[Lecram]

+1

"many electric motors can rev at >10000rpm". All sizes of e-motor exist. The tiny servo-micro-motor can rev at 40000rpm, and the very big nuclear submarine motor maybe 250rpm or so. Somehow size matters. The bigger the slower. Therefore I can imagine that the medium-sized Zero motor is safe at 6k rpm, probably usable at 7k and may explode at 10krpm....

The motor of my BMW i3 revs more than 11,000 rpm. That motor is bigger and stronger than the Zero motor.

[MrDude_1]

+1

"many electric motors can rev at >10000rpm". All sizes of e-motor exist. The tiny servo-micro-motor can rev at 40000rpm, and the very big nuclear submarine motor maybe 250rpm or so. Somehow size matters. The bigger the slower. Therefore I can imagine that the medium-sized Zero motor is safe at 6k rpm, probably usable at 7k and may explode at 10krpm....

The motor of my BMW i3 revs more than 11,000 rpm. That motor is bigger and stronger than the Zero motor.

That motor also has the magnets slotted into a core on the rotor, so that they are not just relying on adhesive and wrapping to contain them.
I imagine that the IPM motor probably could do more RPM than it does now, but thats just a theory to me. I havent done it. I wouldnt try it on the older motor simply from looking at it... Frankly im suprised it can sustain 6000RPM as a production motor with zero issues (as far as I know). It doesnt look like a design intended for that kind of sustained RPM.

[Doug S]

Keep in mind that the faster the motor turns, the less time the windings have to build up to maximum current -- in fact, as I understand it, the Zero motor field starts to weaken a ways before "redline". So even if the motor can take higher operating speeds mechanically, I'd be surprised if it can achieve them electrically. The available torque (and horsepower) rolls off so fast after the onset of field-weakening that the motor really CAN'T operate at higher speeds. You start losing torque just as you need it the most.

[Doctorbass]

The other option is that you can order the  Hybrid 75-7 motor witch is made for 66V to replace the defective 2012 me0913 motor. this motor does not turn faster, it is still limited to 6000rpm, however you wont need the field weakening even at up to 6000rpm.

The regular 75-7 have 6 turn in teh winding and the hybrid 66V version is 4 turns.

I had one with my size 6  on my 2012 powertrain.  it worked nicely.

If you dont already have the SR my suggestion would be to upgrade to teh SR controller and go with a lower gear ratio and to use the. this way you will get up to 190kmh easy

Doc

[Killroy]

Thank you, Terry.

I just bought myself a 2016 KTM 1190 Adventure (next to my Zero and 5 Honda CB750s), so my wife will divorce when I spend more €€€ for a new 2017 SR 

Get you wife a motorcycle license, WAF-problem solved

I tried, but she refused. At the other hand, I am afraid that I fall asleep when I ride with her 

Make her watch the "For Us" Video