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[Arlo]

After working on this for a while now its safe to post some videos. here is one I finishes last night.

[TheRan]

Dope, both the bike and the dyno. Looks like a blast to ride. What's the battery and controller, stock Zero and just reprogrammed? What's the reasoning for the jackshaft?

[Arlo]

Dope, both the bike and the dyno. Looks like a blast to ride. What's the battery and controller, stock Zero and just reprogrammed? What's the reasoning for the jackshaft?

Its more or less a 2018 Zero SR motor and controller.  The battery is a newer longbrick (FX battery or 1/2 a monolith)

The Jackshaft is for 2 reasons.  #1 is to run realistic gearing.  I have 3 CRF sprockets and 1 industrial sprocket machined to accept the 520 chain.
So I wanted to gear down as far as I could with OEM gears.  This is also nice to I don't have a HUGE rear sprocket to hit rocks and add unspring weight to the rear wheel its also a sprocket I can get at any motorcycle supply store. 

The second reason is because you can't slide the motor back far enough to put the motor sprocket in a good place to keep the chain from whipping around.  OEM ICE MX bikes run the sprocket as close to the swing arm pivot as they can to prevent it from changing its slack to much as the rear suspension travels.

[TheRan]

Dope, both the bike and the dyno. Looks like a blast to ride. What's the battery and controller, stock Zero and just reprogrammed? What's the reasoning for the jackshaft?

Its more or less a 2018 Zero SR motor and controller.  The battery is a newer longbrick (FX battery or 1/2 a monolith)

The Jackshaft is for 2 reasons.  #1 is to run realistic gearing.  I have 3 CRF sprockets and 1 industrial sprocket machined to accept the 520 chain.
So I wanted to gear down as far as I could with OEM gears.  This is also nice to I don't have a HUGE rear sprocket to hit rocks and add unspring weight to the rear wheel its also a sprocket I can get at any motorcycle supply store. 

The second reason is because you can't slide the motor back far enough to put the motor sprocket in a good place to keep the chain from whipping around.  OEM ICE MX bikes run the sprocket as close to the swing arm pivot as they can to prevent it from changing its slack to much as the rear suspension travels.

7.2kW/h? Cool to see that it's capable of that sort of power without blowing up. Zero limits the 7.2 bikes to about 44hp and you need to step up to a 14.4 to get 59hp.

I didn't look too closely so it looked like the jackshaft had the same sprocket size on each end. Is it something you made from scratch or was it made from the stock engine? I notice it goes between the swingarm like I've seen some dirtbike engines do. What is the final gear ratio?

[Arlo]

Dope, both the bike and the dyno. Looks like a blast to ride. What's the battery and controller, stock Zero and just reprogrammed? What's the reasoning for the jackshaft?

Its more or less a 2018 Zero SR motor and controller.  The battery is a newer longbrick (FX battery or 1/2 a monolith)

The Jackshaft is for 2 reasons.  #1 is to run realistic gearing.  I have 3 CRF sprockets and 1 industrial sprocket machined to accept the 520 chain.
So I wanted to gear down as far as I could with OEM gears.  This is also nice to I don't have a HUGE rear sprocket to hit rocks and add unspring weight to the rear wheel its also a sprocket I can get at any motorcycle supply store. 

The second reason is because you can't slide the motor back far enough to put the motor sprocket in a good place to keep the chain from whipping around.  OEM ICE MX bikes run the sprocket as close to the swing arm pivot as they can to prevent it from changing its slack to much as the rear suspension travels.

7.2kW/h? Cool to see that it's capable of that sort of power without blowing up. Zero limits the 7.2 bikes to about 44hp and you need to step up to a 14.4 to get 59hp.

I didn't look too closely so it looked like the jackshaft had the same sprocket size on each end. Is it something you made from scratch or was it made from the stock engine? I notice it goes between the swingarm like I've seen some dirtbike engines do. What is the final gear ratio?

Lol not worried about blowing up.  The pack will produce what it can until current cutbacks kick in.  A OEM FX is a smaller motor.  Its also a lower temp magnet motor and a surface mount magnet motor.  This is a SR IPM motor.   The pack is a usable 6.5kwh (Zeros number is a sales spoof number)  It is good for up to 640 amps its usable AH is 64ah and at 10c burst for 10 seconds you can see as much as 640 amps out of it. The right side of the jackshaft is 14 teeth and the left side is 12 teeth. Both machined to use OEM Honda 450 mx sprockets

[TheRan]

I was talking about the S/DS btw, they sell a 14.4 model as well as the 7.2 here in Europe. Same motor and controller but different power outputs. Zero say it's a 550A controller so in theory there's more to give even with the smaller battery.

When you say current cutbacks is that some sort of active protection in the battery pack? I'm not all that knowledgeable on this stuff, I just pick up things mostly from what I've read on here and haven't heard that before.

[Arlo]

I was talking about the S/DS btw, they sell a 14.4 model as well as the 7.2 here in Europe. Same motor and controller but different power outputs. Zero say it's a 550A controller so in theory there's more to give even with the smaller battery.

When you say current cutbacks is that some sort of active protection in the battery pack? I'm not all that knowledgeable on this stuff, I just pick up things mostly from what I've read on here and haven't heard that before.

Oh I see.  Well the way Zero does it is the BMS sends info to the MBB and the MBB sends a max allowable current to the controller.  So I will have to make myself some sort of MBB most likely and I will program it with limits I want.   But the controller it self also has Low voltage cutbacks so when the battery sags to 88 or 89volts it starts to reduce power and at 84v it does not allow any power.  So this is another level of protection.  And if you cells are to weak they will sag to a point the controller will cut back either way.

[Crissa]

It looks really nice, too!  Clean run cabling is always sexy

-Crissa

[Curt]

That's damn impressive, essentially building your own Alta equivalent, and running your own dyno, the Arduino stuff, etc.

When it's done I'd like to see a complete tour of the bike and your maiden voyage in the dirt!

(Tell your wife I said it was worth waking her up for this)

[Arlo]

That's damn impressive, essentially building your own Alta equivalent, and running your own dyno, the Arduino stuff, etc.

When it's done I'd like to see a complete tour of the bike and your maiden voyage in the dirt!

(Tell your wife I said it was worth waking her up for this)

Thank you for the kind words.
Yes this is the first test ride before working on the dyno and it was at 48hp in this video! 

[Arlo]

Here is the latest update.  Just about done.

[Crissa]

Looking good!

-Crissa