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Electric Ride - How to Build a DC Electric Motor for a Scooter

Copyright

Electric Ride

How to Build a DC Electric Motor for a Scooter

1st edition 2015, Shakespir edition

Text by John Mccullough

eISBN 978-1-63323-398-0

[*Published by *]www.booksmango.com

E-mail: info@booksmango.com

Text & cover page Copyright© John Mccullough

No part of this book may be reproduced, copied, stored or transmitted in any form without prior written permission from the publisher

This ebook is licensed for your personal enjoyment only. It may not be re-sold or given away to other people. If you would like to share this book with another person, please purchase an additional copy for each recipient. If you are reading this book and did not purchase it, or it was not purchased for your use only, then please purchase your own copy. Thank you for respecting the hard work of this author, editors, researchers, copyright holder, publisher and contributors..

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Intro

Read First Before You Buy Parts

This motor is a 12volt system, so all your electrical parts, lights, switches and so on, will have to be 12volt. It is direct drive, so no transmission and is self charging, so no plug in.

Read first each section before you buy parts, because there are many variables to the sizes of the parts. The sizes of the parts will depend on what you buy, to make it all fit together. So why you are at the store buying parts, see how they will all fit together.

Motor Diagram

Parts List

  1. Battery, 12v, 100 amps
  2. Ignition Switch, 12v
  3. Regulator, 12v
  4. Fuse Box, 12v, 100 amps
  5. Electric Motor, 12v, 80 amps, 1 hp
  6. Alternator, 12v, 100 amps
  7. Drive Shaft, 8”-12” long, 3/4”-5/8” diameter
  8. Sealed Bearing, height- same size as inside of bearing housing, shaft hole- same size as drive shaft
  9. Bearing Housing, about 2’x2’, both outside ends threaded
  10. Pulley, height-2”, shaft hole-same size as drive shaft
  11. Centrifugal Clutch, shaft hole-same size as drive shaft
  12. Gear, 13 tooth, attaches to c. clutch
  13. Throttle Control Box, plastic, about 3’h x 3’w, length-just longer than throttle control circuit board
  14. Throttle Control Shaft
  15. Idle Screw
  16. Return Spring
  17. Longer L Bar, about 1/2” wide
  18. Flat Bar, about 1/2” wide
  19. Throttle Cable Wire
  20. Throttle Cable Housing
  21. Throttle Control Circuit Board, inside of box, 12v, 80 amps
  22. Pulley, height - 4”, shaft hole- same size as electric motor shaft
  23. Spacers, shaft hole-same size as drive shaft, wide- 1/4”- 1”, or as needed
  24. End Cap, same size as bearing housing, threaded on the inside, shaft hole- just bigger than drive shaft

Drive Shaft

Read first before you buy parts.

The drive shaft diameter will depend on the shaft hole size of the centrifugal clutch, which may be, 3/4” or 5/8”. The drive shaft length will depend on the pulley location on the drive shaft. The pulley on the drive shaft must align with the pulleys of the electric motor and alternator. The length should be about 8” to 12”. The drive shaft will have threads on both ends, just smaller in diameter than the drive shaft. This will allow the parts to slide onto the drive shaft.

The bearing housing will be about 2” in diameter and 2” long. It will have threads on both ends, on the outside of the housing.

The bearings shaft hole is the same size as the drive shaft. The bearings height will be about 2” or the right size to fit inside the bearing housing.

The end caps will be 2” or the size to screw onto the ends of the bearing housing.

They should have a hole in the center, just bigger than the drive shaft and spacer, so that they are not touching the drive shaft. You can drill holes if needed.

The spacers can be spacers, washers or pipes, to separate the parts on the drive shaft. They may be 1/4” long to 1” long, depending on the space you need.

Lay out the drive shaft and the parts, along side each other, to see how they will space out. You can use a pipe just bigger than the drive shaft to tap the parts onto the drive shaft.

You can attach 2 pipe clamps to the housing and use longer bolts to secure to your vehicle. If you need a way to adjust the chain, you can drill slots in the vehicle where the bolts attach. When you buy the alternator, you will also need the adjusting brackets, so you can adjust the belt.

Drive Shaft Assembly

  1. attach the centrifugal clutch to one end of the drive shaft, with the gear facing outward, secure with washer, lock nut and nut.
  2. slide a spacer onto the drive shaft, up against the clutch. Use the right size spacer, so there is about a 1/4” space between parts.
  3. slide the pulley onto the drive shaft and secure.
  4. place 1 bearing inside the bearing housing, so it is flush with the end of the housing.
  5. screw a end cap onto the housing, the same end as the bearing.
  6. use a spacer that will go from the pulley, through the end cap hole and against the bearing, leaving about a 1/4” space between the pulley and end cap.
  7. slide spacer onto drive shaft.
  8. slide housing, end cap first, onto drive shaft, leaving about a 1/4” space between the pulley and end cap.
  9. use a spacer that will go between the 2 bearings
  10. slide spacer onto drive shaft.
  11. slide bearing onto drive shaft and into housing, flush with the end of the housing.
  12. slide end cap onto drive shaft and screw onto housing.
  13. use a spacer that will go from the bearing to the washer, at the end of the drive shaft
  14. slide spacer onto drive shaft.
  15. place washer, lock nut and nut on end of drive shaft and secure.

Throttle Control

Read first before you buy parts.

The size of the throttle control circuit board itself, will determine the size of the box it goes in. Which should be about 3’x3”x3” and should be made of plastic, not metal. It should also have 1 side that opens and that you can close.

The length of the turning shaft, of the electric component, will determine the length of the 2 L bars. One L bar will be about the length of the turning shaft and the other L bar will be about 1/2” shorter than the other L bar.

For the return spring, I would buy a variety pack, so you can choose the right spring that works the best.

Throttle Control Assembly

  1. Drill a hole in one end of the box, just bigger than the throttle shaft.
  2. Drill a 1/8” hole in the box where you want the electrical wires to come out of.
  3. Put the throttle shaft in the box, through the hole and, secure loosely.
  4. Turn the throttle shaft to the off position and align the off position to 12:00 o clock, secure.
  5. Drill a hole in one end of the flat bar, the same size as the clamp hole.
  6. Drill a 1/16” hole at the opposite end of the flat bar, close to the top, this is for the return spring.
  7. Place the clamp onto the end of the throttle shaft and align the flat bar hole over the clamp hole, with the flat bar length closest to the box.
  8. Set the clamp at 12:00 o clock and secure.
  9. Drill 2 1/8” holes in the short end of the short L bar.
  10. Drill a 1/8” hole at the long end of the L bar, this is for the idle screw.
  11. Align the short L bar at the same height as the clamp and about 1/2” from the flat bar.
  12. Mark the 2 holes of the L bar on to the box.
  13. Drill 2 1/8” holes in the box, secure L bar to box.
  14. Drill a 1/16” hole in the short L bar, directly across from the 1/16” hole of the flat bar, this is for the return spring.
  15. Drill 2 1/8” holes in the short end of the long L bar.
  16. Drill a hole in the long end of the long L bar, just bigger than the screw end of the throttle cable.
  17. Align the long L bar directly above the clamp, about 1/8” apart.
  18. Mark the holes of the L bar onto the box.
  19. Drill 2 1/8” holes in the box and secure L bar to box.
  20. Mount throttle control box to vehicle.
  21. Place the throttle cable screw end into the long L bar hole and secure.
  22. Make a small loop at the end of the throttle cable wire, for the clamp screw.
  23. Run the throttle cable wire around the throttle shaft and attach loop end to clamp hole, between 2 washers and secure.
  24. Place tiny spring onto a self tapping screw.
  25. Screw into short L bar 1/8” hole, till it touches the flat bar.
  26. Attach return spring to both 1/16” holes, of flat bar and L bar, try different springs to get the right tension.

Author

I am John Mccullough, just a Handyman, (to have around).

To spread Gods word, the Truth, from the Bible, to the world and to help the Earth and its environment.

Please visit our website for more information and other books of interest.

www.earthlyn.puzl.com

This book is inspired by and dedicated to God, Jesus and the Holy Spirit.

To the Glory of God


Electric Ride - How to Build a DC Electric Motor for a Scooter

  • ISBN: 9781633233980
  • Author: booksmango
  • Published: 2015-11-27 14:50:10
  • Words: 1558
Electric Ride - How to Build a DC Electric Motor for a Scooter Electric Ride - How to Build a DC Electric Motor for a Scooter