Removing the Cover and Accessing the Motor
I'm going to let Steven take it from here. We're going to pull the motor out, everything's unbolted, ready to go. Apparently, it was too heavy, Rich said something about he got his manicure done and didn't want to tamper with his fingers. You don't touch that kind of thing, yeah, yeah, Sean, you're guessing what this weighs? Think straight up, hundred pounds, 100 and change, give it a lift, stephen. No, no, nope, well, that will work too.
Yeah, beautiful, all right here comes the transmission, shut it, forget it, steven did a fantastic job not only pulling the motor but cleaning and organizing everything. That was a subtle hint that I need to clean the shop, but he did it for me instead. This is the transmission to the Harley-Davidson, this thing is massive. Forgive me here, I'm not used to working with these large transmissions, I'm used to sport bikes, like my CBR 600 RR, 1000 RR, F4i, other things like that, but this is just a complete monster.
The engine is no isn't exactly small either, but Steven went ahead and actually cleaned the inside, got all the grease and dirt out, and started doing some grinding on the frame a little bit, just to clean it up. We have to start making mounts to house the motor. Speaking of motor, this is the motor we're going to use, it's a 20 kilowatt with 50 kilowatt peak motor by Golden. This is the same motor that was installed in the City EL, that went over 60 miles an hour, this one is considerably larger, more powerful, more torque, and it has an option for liquid cooling, which I'm not sure if we're going to need to use that in this bike yet.
What I want to start doing now is thinking about where I'm going to place the controller. Now the controller is the thing that controls the motor, the problem is a little bit on the larger side, and I'm running out of spaces to put that in the bike. I really would like to put it in the middle here, unfortunately, this is where the 12-volt battery will be located, as well as miscellaneous other wiring. Ideally, I'd like to put it in the actual gas tank, which is the fuel tank for the bike. And if I can put the controller right there, that would be absolutely magic.
Because once we put the motor in the inside, we have to figure out where the batteries are going to go as well. What I'm going to do now is find a clever way to cut this gas tank open to see if I could fit that controller inside. I can't put the controller underneath here because the battery is going to be stacked up pretty high. Hmm, all right, here's the hole that was cut; it's a nice big section at the bottom.
What I'm noticing now is I don't think I could actually fit this in the way I want it to, ideally you'd want it up and down like this. What I'm noticing is because the tank is tapered, it gets thinner and thinner and it goes to the bottom. What I'm going to do, I'm going to have it width-wise, so it'll be side to side like that. Put this in the tank first, there you go, now that that's here, and it's resting on top.
I can easily fit the rest of the tank; exactly where it needs to be. Now, you're probably thinking to yourself, wait a second, Rich, that's kind of high, that's a high-voltage cable going to the top, what are you gonna do about that? That's okay because Harley-Davidson like they always do build things to excess.
Watch this; put this on top there, you go. There's plenty of room for this now. Now what I'm going to do, I'm going to cut around this so there's more room cut some of this excess fat out of here at the side. I'm probably gonna end up cutting it all around here to open this up a little bit and then we're all set.
The motor is going to sit about here; these cables still easily reach to the controller now you're probably thinking about cooling, it's actually okay because this is still open. I'll probably add a fan or two here and it's getting air cooled by front airflow from the bike. This is looking pretty damn good so far.
Let me get the seat action, see what I'm up against; you know, I never liked Harley's but this one's actually starting to grow on me a little bit that there it's actually not that bad-looking once that tank is painted black, obviously it won't be bad, typical Harley behavior.