How to Build a 72Volt Motorcycle in the Fastest Way

In this tutorial, you will learn the 4 steps on how to perfectly build the 72-volt electric motorcycle

Here are the 4 steps to Build a 72Volt Electric Motorcycle

• Step 1. Make sure you have all the motorcycle parts.
• Step 2. Get the tools you need
• Step 3 Know how to be safe when building
• Step 4. Start building the motorcycle

Before we start

Before you start, you need to ask why you need a 72-volt electric motorcycle and know all the pros and cons of having a 72-volt electric motorcycle

So, in fact, I choose to build a 72 volt electric motorcycle mainly because of the fact that a regular motorcycle that runs on fuel requires a lot of maintenance and what I mostly don’t like is the fuel that costs a lot of money, and because of that I highly recommend for every rider to build an electric motorcycle and save thousands of dollars!

To build one motorcycle cost me $ 5000 and it took me 2 months to complete it

In addition, it is important to know that this is not an easy process and it requires a lot of searches and a lot of investment of time but in the end, it was worth it

I personally choose a 72-volt motor because it is enough for me and also considering that higher power motors will require a higher budget

Well after all these talks let’s get started

Step 1. Make sure you have all the motorcycle parts.

The first step you will need to do is first to get all the parts you need to start building your motorcycle

You can get the parts in two different ways

The Not recommended way – The first way is to buy or search for each part separately but I don’t recommend it simply because it takes a lot of time and even hard to find all the parts

The recommended way – And the second way is to just buy a very cheap motorcycle which you can take all the parts. This is the easiest and most convenient way, instead of going to look for all the parts which can be very burdensome; you can just buy a motorcycle and get the parts, in addition, if you have a close friend or relative that has a motorcycle that he doesn’t use you can approach such person and ask if you could be allowed to make use of it.

In addition, when finding the parts, it is very important that you make sure that they match your requirements

Here all the parts you need to make sure you have before you start…

Engine

The first and maybe the most important part you will need is the engine.  In fact, the engine is the heart of the motorcycle and you will have to make sure the engine is in good condition and that its weight and dimensions match the motorcycle you want to buy and as you already know by the title, I choose a 72-volt motor I got from a friend

Batteries

batteries are a very important component of your motorcycle and usually 6 batteries are great for you and of course if you have more room to put in more than 6 batteries then it will be great and at first you will have to test them to fit properly into the frame so that you can see how many batteries it can contain.

Also, when choosing batteries, it is important to make sure they are in good condition and I personally recommend you buy a new battery instead of used one

I personally was very confused about which battery I should buy until my friend who helped me build the motorcycle recommended one of the best batteries in the world that did work perfectly for me. I bought this battery from Amazon and I highly recommend this battery click here to view.

Charger

After selecting the battery, you will need to select a good charger that can charge well for 72 volts but it will have to be very tiny and not buy a very powerful charger that charge too fast because it is not good for a battery but however don’t buy a charger that charges too slowly

In addition, it is important to choose size charger that fits your requirements and the charger size. It may appear like a very simple thing but trust me you do not want to carry a heavy and big charger to the school or work, and because of this I highly recommend that you pick a small charger and not a very big charger

I personally used this charger from Amazon that fit my batteries perfectly click here to view.

Frame

The most important thing to me, and I’m sure it is equally most important to many other riders, is the frame and in general the design of the motorcycle. While the frame is what makes a bike beautiful, and I personally took the frame from a used Honda motorcycle but you can do lots of different styles which can be fun when building an electric motorcycle

Here are some tips to help you choose a good motorcycle frame

• Love the design of the frame – well I know this is a very clear tip but all you have to do is love the frame and not buy it based on other factors

• Durability and Quality – Another important factor about design is durability, because I’m sure you don’t want a clumsy simple frame that can easily break apart, so it’s important to make sure it has some durability and protection.

• Size of the frame- It is also important to make sure the frame is large enough and wide enough to accommodate all other parts like batteries and motor

Switches

It is important that you connect the ignition switch to the Slider so you can see when the motorcycle is operating and when it is switched off

Controller

In general, it is simpler more amplifier = more power but this requires a lot of money. Therefore, you will need to check how much of your budget allows you to install amplifier. Plus you will need to adjust the controller to your voltage and in addition, I personally used the 450Amp Alltrax which I think could only work efficiently with a 72 volt engine

Other equipment you will need

• DC / DC Converter
• Fuses
• Contactor
• Instruments
• Wire connectors
• Electrical tape

Step 2. Get the tools you need

This is a very short tip but very important and it is just make sure you have all the necessary tools for building a motorcycle such as

• screws
• screwdrivers
• Socket kit
• pliers
• Voltmeter
• Mill

Really very basic tools because you are still dismantling an old motorcycle and not building a new motorcycle

But if you decide to get all the parts individually, it will certainly take a lot of time and effort and will require a lot more tools and because of this, if you buy the parts individually I recommend you give all the parts to the builder and just let him do the work for a fee.

Step 3. Know how to be safe when building (only for those who build the motorcycle themselves)

If you have chosen to build the motorcycle yourself, so you will be surprised but you have to keep yourself safe when building especially when using dangerous building tools

In general, I do not recommend for anyone to build his electric motorcycle himself especially to riders who have no experience in construction and because of that, I would only recommend you build yourself just if you are building and you know how to do it

Here are all the tips you need to follow to stay safe while building your motorcycle

• Wear work gloves –it is most important is to wear work gloves. I don’t want to tell you how many people I know that built things up and got cut because they didn’t wear work gloves and because of that it is very important first to get good gloves that made from a good materials like leather or rubber and make sure they have a layer of protection that is very important especially when using dangerous tools

• Safety Goggles – Safety goggles do not have to be for all builders, but only for those who use tools such as welding machine and others that emit dangerous sparks so goggles can protect your eyes

• Hearing protection – If you are using tools that make loud noise like a drill, or grinder then you should get hearing protection like earplugs to protect your ears from the noise and believe me you don’t want to suffer from loud noise so do yourself a favor and buy earplugs that cost a few dollars

• Make sure you have protective clothing – Another thing you will need to wear is, of course, good protective clothing.  Most people just start to build without any proper protective clothing so don’t do this and instead make sure you have long pants, closed shoes, a long shirt, and a jacket to protect you in a good way

• Do not smoke or drink – The silliest thing you can do is drink or smoke while building smoke can cause fuel combustion. What can ignite fire and alcohol can make you light in the head and you can do dumb things so please do not do those things.

• Always lock shoes – What you should avoid is building without lock shoes especially if there are dangerous screws or tools on the floor that you really don’t want to tread on

Step 4. start building the motorcycle

Once you have all the parts you need and the tools, it is time to start assembling and dismantling the motorcycle

This tip only speaks to people that have found a used motorcycle and want to dismantle it and build a better electric motorcycle

On the other hand, for people that have choose the hard way and built a motorcycle from scratch, it will take a lot of time to build the motorcycle, so as I said before to these people, I would recommend to take all the parts and give a builder to build them for you

In general, I recommend that you look for a builder to build the motorcycle because he still has more experience, but if you do want to save money, so let’s get started

• Remove all unwanted parts – First remove all the parts you want to replace such as frame, motor, batteries, cables, and disassemble and to remove the parts you need using a screwdriver or mill

• Put all the unwanted parts aside – after removing all the unwanted parts it is very important to keep them clean and put them in a separate place and also clean your work environment

• Assemble your frame – Once you have removed the unwanted parts now is the time to assemble and start with the simplest thing to assemble and it is your frame to start getting some direction on what the motorcycle will look like. To assemble your frame, you need a screwdriver, in addition, I recommend you use spray color on the framing to make it more beautiful

• Start assembling all the parts – and now the final part is that it really needs some help from a friend or builder and the next thing is to start coupling the parts together like engine, battery, cables and tools and it’s really the hard part and I’m sure most riders didn’t know how to do it so instead of trying to do everything by yourself and waste time I highly recommend that you ask for help from a builder

And this is what you need to build the motorcycle successfully, just check that all parts are fastened appropriately and there are no loose ends

Summary

To summarize this guide, I have shown you 4 steps to building a 72-volt electric motorcycle

It is important to note that this guide can work on every other electric motorcycle that you will want to build and not just a 72-volt motor

In addition to any questions and opinions, you may have, please feel free to write in the comments and we will get back to you within 24 hours

Thanks for reading until next time