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5 Home-Brewed Electric Powertrain Conversions

We pore over five home-made electric motorcycles based on production models.

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Lightning Yamaha Prototype

While it may look to be on the primitive side, this is the very machine that started Lightning Motorcycles. The bike was an old, abused 1999 Yamaha R1 that’d had its liter-sized inline four swapped out in 2007 for 28 90 amp-hour, 3.2 volt, 6.6 pound Lithium Iron Phosphate batteries and a 550amp 84V AC inductance system. The prototype was said to be good for more than 60 ponies and almost 70ft-lbs of torque. The 400lb protobike’s top-speed was only 100mph, while the claimed range was 80-miles at a 65mph cruising speed after a seven-hour charge.

With the full bodywork covering the two-and-a-third-dozen batteries, the YZF-based prototype doesn’t look that different from the normal bike, aside from the massive rear sprocket. A writer from the LA Times took this exact machine out for a test ride and ultimately reported back with mostly positive things to say.

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Electrified Bullet

On the surface the Royal Enfield Bullet 500 might seem like a peculiar choice for an ebike conversion, though the fact the classic model has changed so little over its decades (and decades) of production means it boasts an incredibly simple and straightforward design, minimizing the number of components that need to be removed or changed out. It’s also relatively lightweight, everything is out in the open and on display, it’s easy to source parts for, and a second-hand example can be picked up on the cheap.

What we have here is a 2005 specimen that’s undergone an amateur electric powertrain conversion, using 11 battery units—plucked from a Nissan Leaf—housed inside custom-made aluminum shell cases. Supporting the batteries are a pair of bespoke, ¾” aluminum battery bracket plates bolted to rectangular tube sections bolted to the top and bottom. Surprisingly, the installation of the electric powertrain was done entirely sans welding, with the new structural and support components bolting into the Bullet’s frame. The same brackets and rectangular tubes that carry the batteries also serve as the anchoring point for the ex-gas-powered Enfield’s motor.

The bike’s creator reports the machine’s conversion cost them just over $4,600, though the e-Bullet now yields economical $00.01-per-mile travel. They’ve also reported the scoot tips the scales at over 20lbs less than the stock 500, and that it has a charge time of eight-hours, a 44-mile range, 0-50mph time of 7.1-seconds, and a claimed top-speed just shy of 75mph.

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D-EV: The Silent Scrambler

Commissioned by Ducati Thailand owner/head honcho, Apichat Leenutaphong, who, in addition to obviously being a motorcycle enthusiast, is also an avid EV junkie, with his garage containing no less than 10 ebikes, a Nissan Leaf, and five Teslas. Another fully-electric vehicle in the “Napichat” stable started life as a Ducati Scrambler, but has since been ridded of its 803cc L-Twin and given a potent electric powertrain.

The new 33Kw (44hp) motor is paired with a 5.6kWh battery that together put 79ft-lbs of torque through the rear wheel—now via a belt-driven setup. To help compensate for the near-60-percent boost in power over the stock L-Twin, the E-Scrambler’s been fitted with a custom, machined swing-arm, lengthening the rig’s wheelbase. The rear shock was also relocated to accommodate the near swing-arm, and a hefty pair of floating discs was tacked on up front, increasing stopping power.

A new subframe was also cooked up and bolted in before being capped off with a humped leather café saddle. Out front a carbon fiber fender—borrowed off a Panigale–was slipped on, prior to a set of, what appear to be custom CNC’d rims, were also installed. A large aluminum belly-pan-esque piece was fit the bottom of the powertrain, rounding out the batteries’ boxy profile.

In total Apichat says the “D-EV”, as they’re calling it, weighs in at 364lbs—more than 60lbs less than the stock Scrambler. It’s range is reported to be a tad over 60-miles while its top-speed is an equally meh 100mph. Though it was built using a Ducati Scrambler donor, the only remaining elements that make it readily identifiable are the tank and chassis. It might not boast the most impressive specs, but Apichat has definitely got himself a mighty cool custom addition to his EV collection with this one.

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Groms and Electrons

Built by Zero Motorcycles designer, Cole Mishler, this electrified Grom is certainly one of the stranger EV conversions we’ve seen. While the idea of an electric MSX125 is nothing new—as demonstrated by all the (mostly Chinese) Grom-style ebikes on the market—none of them generated the whopping power of a Zero powertrain.

Mishler sourced the batteries, controller, 3.6kWh motor, and other bits from one of his employer’s FX models. The Zero-powered Grom makes a ridiculous 66ft-lbs of torque—more than eight times the Grommy’s stock torque, plus more than two-and-a-half-times the horsepower, aka, objectively too much. Turns out all the extra power only adds an additional 8lbs to the little Honda’s weight, though the top-speed is limited to 66mph, only a few mph’s over the stock 62mph limit.

A custom unit made by Mishler himself replaced the stock tank cover, and the new batteries now rest in bespoke supports. Finally, the factory forks on Mishler’s Grom were binned to make room for a set of trick Ohlins units while the rear shock also got an Ohlins piece. Though the little Grom only gets to around 60, it gets there damn quick, and from footage of this thing being ridden, it appears keeping the front wheel on the tarmac is an active struggle, albeit in the best way possible.

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French & Electric

Built by French outfit, Jambon-Beurre Motorcycle—the force behind the “GLORIA” concept—this mean looking all electric tracker is the result of just over six-months of labor. The rolling chassis is comprised of different sections of frames off a vintage BMW, Honda enduro, and a Suzuki DR Big. Next it was given a custom subframe and saddle, before being finished off with a (faux) tank and LED headlight cube.

Housed inside the cobbled-together-frame is an 80kW brushless motor intended for use in large military drones, spinning out an impressive 133ft-lbs of torque. The motor feeds off a custom-built 6.5kWh, 100V battery back made up of 580 lithium ion cells. Supposedly charge time is as little as 20-minutes, though range is limited to about 60-miles. Thanks to its svelte 350lb weight, the-tracker can do 0-60mph in 3.5-seconds and tops out at around 100mph.

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Apr 27, 2019 at 8:00am ET

By: Tim Huber

Though the options on the electric motorcycle market have become substantially more attractive in the last couple months alone, the existing range of production models is still fairly limited. So instead of waiting for their favorite marque to introduce an electric model of their liking, a handful of EV-minded moto-enthusiasts have opted to create their own proton and electron-powered versions of factory models, build electric-powered customs, or start their own company all together.