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« on: September 11, 2018, 09:30:47 AM »
Since shadow moved this to the discussion portion I thought I would update the project for removing the 2010 Main bike board (mbb) and wiring direct. Prior to the mbb going out I would get 57.9-58 volts from a charge and 25 miles @ 45 mph average. Given I still have life left in the battery I thought it was worth salvaging. I wanted as many functions as I could keep, basically only lost all the safety interlocks that were controlled by the mbb. The stock D.C. Converter was used to go from 48volts to 12 volts (13.5 actual)so I have all the 12v stock functions like green system light, headlight hi/low, turn signals, speedometer, tripometer, horn, stock 5k throttle assembly, kill switch, and key assembly. I could not find the feed for the fuel gauge so I mounted a volt gauge where the warning blinker light used to be (that was controlled by the mbb as well). I was able to utilize the stock charger with all stock wiring and maintain all functions of the battery management system (BMS). I get the beep for acceptable voltage on start up and it will alert me if I turn power on while the charger is plugged in. It will beep when it hits the low voltage point which is around 44.1 volts on my battery pack. The mbb controlled the safety shutdowns so I don't have the low voltage pulsing feedback through the motor or the motor shutdown for high temperature and maximum low voltage (volt gauge used instead) also no way to keep the current sensor which fed into the mbb. Since the 2010 has the constant on fan and I was able to wire that up, I am not concerned about the motor getting hot enough to overheat.
I utilized this forum to gather as much info as possible but there was a lot of time spent tracing wire with the ohm function and volt meter. I will include pictures and as much reference material as I can over the next week or so. Pics of when I started and will add mods as I can. I need to finish up the modified wiring harness.
