Electric Ninja

As of last weekend, the bike is running.

After countless trips to Lowes and Napa, I picked up all the stainless steel bolting hardware and fine grit sandpaper needed for a solid connection between the high voltage hardware. I also made a new ground on the bike and installed a temporary switch to turn on and off the controller without activating the 96 volt battery pack. The ignition key is then used to power up the main contactor after the controller is running.

There are some really intuitive custom gauges on the Synkromotive controller user interface which I set to monitor motor and battery current for the moment. The computer with the user interface installed can even store data logging from the controller. Overall I'm very happy with the controller and more than satisfied there are no issues with external contactor precharge circuitry.

The laptop communicates with the controller through a LAN to USB adapter:

My handmade busbar connecting the main contactor and positive battery controller terminal:

There is still a bit of tweaking expected and low voltage lighting wiring needed for a rideable status.