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Build-Your-Own-Electric-Motorcycle Build Your Own Electric Motorcycle TAB Green Guru Guides Consulting Editor: Seth Leitman Renewable Energies for Your Home: Real-World Solutions for Green Conversions by Russel Gehrke Build Your Own Plug-In Hybrid Electric Vehicle by Seth Leitman Build Your Own Electric Motorcycle by Carl Vogel Build Your Own Electric Motorcycle Carl Vogel New York Chicago San Francisco Lisbon London Madrid Mexico City Milan New Delhi San Juan Seoul Singapore Sydney Toronto Copyright © 2009 by The McGraw-Hill Companies, Inc. All rights reserved. Except as permitted under the United States Copyright Act of 1976, no part of this publication may be reproduced or distributed in any form or by any means, or stored in a database or retrieval system, without the prior written permission of the publisher. ISBN: 978-0-07-162294-3 MHID: 0-07-162294-2 The material in this eBook also appears in the print version of this title: ISBN: 978-0-07-162293-6, MHID: 0-07-162293-4. All trademarks are trademarks of their respective owners. Rather than put a trademark symbol after every occurrence of a trademarked name, we use names in an editorial fashion only, and to the benefit of the trademark owner, with no intention of infringement of the trademark. Where such designations appear in this book, they have been printed with initial caps. McGraw-Hill eBooks are available at special quantity discounts to use as premiums and sales promotions, or for use in corporate training programs. To contact a representative please e-mail us at [email protected]. Information contained in this work has been obtained by The McGraw-Hill Companies, Inc. (“McGraw-Hill”) from sources believed to be reliable. However, neither McGraw-Hill nor its authors guarantee the accuracy or completeness of any information published herein, and neither McGraw-Hill nor its authors shall be responsible for any errors, omissions, or dam- ages arising out of use of this information. This work is published with the understanding that McGraw-Hill and its authors are supplying information but are not attempting to render engineering or other professional services. If such services are required, the assistance of an appropriate professional should be sought. TERMS OF USE This is a copyrighted work and The McGraw-Hill Companies, Inc. (“McGraw-Hill”) and its licensors reserve all rights in and to the work. Use of this work is subject to these terms. Except as permitted under the Copyright Act of 1976 and the right to store and retrieve one copy of the work, you may not decompile, disassemble, reverse engineer, reproduce, modify, create deriv- ative works based upon, transmit, distribute, disseminate, sell, publish or sublicense the work or any part of it without McGraw- Hill’s prior consent. You may use the work for your own noncommercial and personal use; any other use of the work is strict- ly prohibited. Your right to use the work may be terminated if you fail to comply with these terms. THE WORK IS PROVIDED “AS IS.” McGRAW-HILL AND ITS LICENSORS MAKE NO GUARANTEES OR WAR- RANTIES AS TO THE ACCURACY, ADEQUACY OR COMPLETENESS OF OR RESULTS TO BE OBTAINED FROM USING THE WORK, INCLUDING ANY INFORMATION THAT CAN BE ACCESSED THROUGH THE WORK VIA HYPERLINK OR OTHERWISE, AND EXPRESSLY DISCLAIM ANY WARRANTY, EXPRESS OR IMPLIED, INCLUD- ING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. McGraw-Hill and its licensors do not warrant or guarantee that the functions contained in the work will meet your requirements or that its operation will be uninterrupted or error free. Neither McGraw-Hill nor its licensors shall be liable to you or anyone else for any inaccuracy, error or omission, regardless of cause, in the work or for any damages resulting therefrom. McGraw-Hill has no responsibility for the content of any information accessed through the work. Under no circum- stances shall McGraw-Hill and/or its licensors be liable for any indirect, incidental, special, punitive, consequential or similar damages that result from the use of or inability to use the work, even if any of them has been advised of the possibility of such damages. This limitation of liability shall apply to any claim or cause whatsoever whether such claim or cause arises in contract, tort or otherwise. About the Author Carl Vogel is the president of Vogelbilt Corporation, a research, engineering, and development company for alternative fuels and alternative-fueled vehicles. Vogelbilt is in the process of building renewable fueling stations in the New York City area. These stations will function on a platform of sustainability, using wind and solar energy and cogeneration to stay mostly off the grid. Some of the proposed alternative fuels that would be available at the stations are electric, E85, CNG, biodiesel, and hydrogen. Mr. Vogel is also the president of the Long Island chapter of the Electrical Automotive Association (www.LIEAA.org). Previously, he worked at Festo Corporation and Curtis Instruments, planning and designing robotic and programmable logic controller applications for computer-integrated manufacturing (CIM). While at Curtis Instruments Mr. Vogel worked on battery chargers and solid-state motor controllers for electric vehicles. He has also taught at Farmingdale State College, expanding electric vehicle and fuel cell operations R&D on campus. This page intentionally left blank Contents Preface . xv Acknowledgments . xvii 1 Why You Need to Get an Electric Motorcycle Today! ............. 1 Convert That Motorcycle! . 3 What Is an Electric Motorcycle? . 4 Electric Motors . 5 Batteries . 6 Controllers . 6 Electric Motorcycles Are Fun to Drive . 6 Electric Motorcycles Save Money . 7 Operating Costs . 7 Purchase Costs . 7 Safety First . 7 Electric Motorcycle Myths: Dispelling the Rumors . 8 Myth 1: Electric Motorcycles Can’t Go Fast Enough . 8 Myth 2: Electric Motorcycles Have Limited Range . 8 Myth 3: Electric Motorcycles Are Not Convenient . 9 Myth 4: Electric Motorcycles Are Expensive . 10 Disadvantages . 10 Time to Purchase/Build . 10 Repairs . 11 My Passion . 11 Coolfuel Roadtrip . 12 2 Electric Motorcycles Save the Environment and Energy .......... 17 Why Do Electric Motorcycles Save the Environment? . 17 Environmental Benefits . 18 Save the Environment and Save Some Money Too! . 19 Energy Efficiency . 20 Electricity Generation: How Is It Made? . 20 Steam Turbines Are the Leader . 22 Natural Gas . 22 Petroleum . 22 Nuclear Power . 22 Hydropower . 22 Geothermal Power . 23 Solar Power . 23 Wind Power . 23 Biomass . 23 Efficiencies of Power Plants . ................................. 23 U.S. Transportation Depends on Oil . 24 vii viii Contents Contents ix Emission Facts . 25 Further Economic and Competitive Matters . 26 Economic Benefits . 26 Summary . 27 EPA Testing Procedures for Electric Motorcycles . 29 3 History of the Electric Motorcycle ............................. 31 Steam First! . 31 Copeland Steam Motorcycle . 31 Early 1900s . 35 The Early 1940s . 36 1970s–1990s . 36 Late 1990s . 36 Vogelbilt Corporation’s Electra Cruiser Was in Coolfuel Roadtrip . 36 Latest News . 38 The Idea . 38 The Prototype . 38 Future Plans . 40 The KillaCycle—Bill Dube Breaks NEDRA Records . 40 E-mail from Bill Dube . 41 New World Record at Bandimere— 7.89 Seconds (Also 174 mph!) . 43 Ducati Project . 43 Vectrix Corporation . 45 The Vectrix VX-1 . 45 Summary . 47 4 Current Electric Motorcycles on the Market .................... 49 Electric Motorcycles: Cool and Green . 49 Eva Håkansson’s Electrocat Electric Motorcycle . 49 KillaCycle and KillaCycle LSR Electric Motorcycles . 50 Zero Motorcycles . 51 Brammo Motorsports . 53 Voltzilla: DIY Electric Motorcycle by Russ Gries . 56 Electric Motorcycle Conversions: Easier Than You Think . 56 KTM “Race Ready” Enduro Electric Motorcycle . 56 Honda and Yamaha to Make Electric Motorcycles in 2010–2011 . 57 EVT America . 57 Summary . 61 5 Geometry: A Basic Lesson on Rake, Trail, and Suspension . ..... 63 Rake . 63 Trail . 66 Fork Angle . 68 Fork Length . 68 Fork Dive . 69 viii Contents Contents ix Travel . 70 Spring Rate . 71 Rear Suspension . 72 Rear Suspension Styles . 72 Twin-Shock Regular H Swingarm . 75 Monoshock Regular H Swingarm . 75 Hybrid Twin-Shock H Swingarm . 75 Monolever Suspension . 76 Conclusion . 77 6 Frame and Design ........................................... 79 Choosing a Frame and Planning Your Design . 79 Selecting a Frame Dos and Don’ts . 81 Optimize Your EV . 83 Standard Measurements and Formulas . 83 EV Weight . 84 Remove All Unessential Weight . 84 During Conversion . 84 Weight and Acceleration . 85 Weight and Climbing . 85 Weight Affects Speed . 87 Weight Affects Range . 88 Remove the Weight But Keep Your Balance . 88 Remember the 30 Percent Rule . 89 Streamline Your EV . 89 Aerodynamic Drag Force Defined . 90 Choose the Lowest Coefficient of Drag . 90 Frontal Area . 92 Relative Wind Contributes to Aerodynamic Drag . 92 Aerodynamic Drag Force Data You Can Use . 93 Wheel Well and Underbody Airflow . 93 Roll with the Road . 93 Rolling Resistance Defined . 94 Pay Attention to Your Tires . 95 Use Radial Tires . 97 Use High Tire Inflation Pressures . 97 Brake Drag and Rolling Resistance . 97 Rolling-Resistance Force Data You Can Use . 97 Less Is More with Drivetrains . 97 Drivetrains ............................................ 98 Difference in Motor versus Engine Specifications . 99 Going through the Gears . 101 Manual Transmission versus Chain or Shaft Drive . 102 Drivetrains and Fluids . 104 Design Your.
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