Design and Manufacturing:
Four key items had to be designed and mounted on to the motorcycle frame. The two of greatest importance were the motor plate and the battery trays. The other two items were the charging system and the contactor and controller mounts.
The motor plate was designed to mount to the original gasoline motor mounts. A large hole was drilled in the motor plate to allow the drive shaft of the electric motor to pass through it. Holes were drilled in the plate at the locations that allowed for the electric motor to be properly positioned when mounted to the motor plate.
The battery trays were designed to be slightly larger than the dimensions of the battery. This allowed for the batteries to be easily placed in the trays. The trays were mounted directly to the frame of the motorcycle by welding. Extra care was taken to ensure that the batteries were centered in the motorcycle frame to help maintain the balance of the motorcycle. Thin rubber sheets were place on the top, bottom, and sides of each battery to reduce vibrations and to ensure that the battery terminals do not come in contact with the frame. Preventing contact between the terminals and frame is key to preventing short circuiting and possible injury to the rider. Removable straps were added to the battery trays to make sure the batteries do not slide out of the trays.
The charging system was mounted in the area that the gas tank of the motorcycle used to be. The bottom portion of the gas tank was removed. A retractable extensions cord was mounted inside the gas tank. The plug comes out of the gas cover which can be plugged into any traditional 3 prong receptacle. The battery charger was mounted directly to the frame above the battery trays. This was an ideal location considering the locations of the batteries and the power cord.
The contactor and motor controller were mounted below the seat near the motor plate. This location was chosen because the components fit nicely. The position relative to the batteries and motor was convenient.