Millennial Motors - DIY Electric Motorcycles for the Home Mechanic

A few pre-matched components were available, but they still required a custom battery pack, management system, and comprehensive integration—all tasks left to the end user. This inspired the concept of a model-specific, turn-key electric drivetrain kit that could empower both home and professional builders to create electric motorcycles without needing extensive expertise in electric drivetrains. The kit would be designed to integrate seamlessly, with OEM-like fit and function, offering an approachable pathway to electric conversions.

The initial goal was to develop a modular, turn-key electric drivetrain prototype that could serve as a platform for testing drivetrain functionality, programming, gearing, and electrical isolation. This prototype, while not yet customer-ready, had to maintain high voltage isolation for safety, seamlessly integrate with the motorcycle’s 12V wiring, and reuse as much of the existing bike as possible. Additionally, the testbed had to deliver compelling power and range to assess whether this concept was viable for broader applications and feasible for assembly by home mechanics.

The resulting drivetrain included a fully isolated battery pack, with a safety shutoff switch to protect users during assembly. Once assembled, the switch enabled the system for operation, and the bike functioned using a standard ignition key. A display was added to indicate critical information, including speed, mileage, and battery life. The powertrain centered on a PMAC drive motor by Parker GVM, similar to that found in later Brammo electric motorcycles, paired with a Sevcon Gen4 Size 6 controller, a sin/cos encoder, regenerative braking, and peak power delivery of 550A. The selected gearing fit the bike’s geometry without requiring a separate gearbox, balancing low-end torque with a top speed of around 140 km/h. With a full charge, the prototype achieved a 120 km range in city driving. Importantly, the weight and weight distribution closely matched that of the original motorcycle within 2%—ultimately weighing 10 pounds less—allowing for an unmodified suspension setup. The bike successfully passed an out-of-province inspection, affirming that the design met all legal and safety requirements.

Far from ordinary, the prototype had an industrial, "Mad Max" aesthetic that drew attention. It was displayed at The One Motorcycle Show 2020 in Portland, where it won a trophy for its distinctive design, solidifying its place among an impressive array of custom motorcycles. Beyond its appearance, the prototype achieved its primary objective: it functioned as a two-year testbed for daily use, providing invaluable insights for fine-tuning the drivetrain and highlighting necessary design improvements before taking it to market.