How to Build an Electric Motorcycle


If you’ve been thinking about building your own electric motorcycle, you’ve likely wondered how to go about it. You’ll need to consider several factors before starting the process. These include the motor, battery storage, motor controller, On/Off switch, and wiring up the power system. Before starting, you’ll want to read as many guides and instructional materials as possible.

Battery storage

If you’re building an electric motorcycle, battery storage is an important issue. Batteries that are not stored properly can suffer from deterioration or even overheating. Store your battery away from direct sunlight. Even a small amount of sunlight will cause your battery to lose a large amount of capacity. Keeping your battery out of the sun will also prevent overheating. The average car battery can reach over 75 degrees Celsius on a hot day, so it’s important to keep your electric motorcycle battery out of the sun.

One of the first things you’ll want to consider when building an electric motorcycle is battery storage. Whether it’s lithium, carbon, or some other type of energy storage, batteries can play a major role in the performance of an electric motorcycle. When determining the right battery for your motorcycle, you’ll want to consider the capacity and weight of the battery.

Motor controller

When shopping for a motor controller for your electric motorcycle, there are some important things to consider. First of all, it should be able to monitor the voltage of the battery. If the voltage goes too high, the controller will shut down the motor. The controller should also be able to detect the temperature of the Field-Effective Transistors, or FETs. This way, you don’t have to worry about burning the motor or battery.

A motor controller can help you get the most power from your electric motorcycle. You can choose from two main types of controllers: permanent magnet motors and BLDC motors. A permanent magnet motor is simpler to install and uses a magnet to store energy. Both types of controllers change the amount of current that the motor receives. More current means more power. A permanent magnet motor controller is ideal for electric motorcycles.

On/Off switch

An on/off switch is an essential safety feature on an electric motorcycle. Even some Chinese hub motor factories sell ebikes with an integrated switch. You can add an on/off switch to your DIY electric motorcycle, but the process isn’t as simple as you might think. First, you’ll need a controller and a battery. Once you have those, you can mount the switch on the motorcycle.

Then, you’ll need a DC/DC converter, which is very small and lightweight. You’ll need one about two inches square and half-inch thick. This will save you a great deal of weight compared to a medium-sized battery. You’ll wire 48V from your drive batteries to the input end of the converter. This will replace the battery that holds 12V. The converter will have positive and negative wires.

Wiring up the power system

The first step to wiring up the power system of an electric motorcycle is to make sure the bike is grounded. Grounding is essential in all electrical components and should be done at the main chassis ground, battery negative terminal, or wiring harness ground. A multimeter is also helpful for testing wiring connections.

The next step is to wire up the ignition coils and batteries. They will be connected to the keyed power wire, ignition switch, or points. In addition, a kill switch should be installed between the coils and ignition switch. The next step involves connecting the alternator wires to the regulator/rectifier unit. The positive wire of the regulator/rectifier unit must be connected to the positive battery terminal, and the remaining wire should be connected to the battery’s ground terminal. Then, solder and heat-shrink the connections to ensure safety.

Adjusting the throttle

You can adjust the throttle by twisting the knob. Most throttles have three wires: one is the wiper, the other two are the end of the range. To figure out which wires are which, consult your dealer. Then, connect the Ohmmeter to two of them. When you twist the knob, the Ohmmeter should register a different value.

Next, you can adjust the throttle cable. The cable adjusters are usually located on the throttle grip housing. First, remove the dust cover that covers the adjuster. Loosen the locknut and adjust the cable to the proper amount of free play, usually two or three mm. Once the cable adjuster is adjusted, you can replace the dust cover and reinstall the throttle.

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