As gasoline prices rise and environmental awareness grows, converting a gasoline-powered motorcycle into an electric one is becoming a popular and rewarding DIY project. Whether you’re an EV enthusiast, a professional builder, or simply love tinkering with bikes, this guide will walk you through how to convert your motorcycle from gas to electric power in 2025 using modern kits and components.
Why Convert a Gasoline Motorcycle to Electric?
- ✅ Reduce emissions and support a cleaner environment
- ✅ Lower operating costs—no more oil changes or gas
- ✅ Improve performance with instant torque
- ✅ Quiet and smooth riding experience
- ✅ Customize and upgrade as you wish
What You’ll Need for the Conversion
To convert your gasoline motorcycle to electric, you’ll need the following components:
- Electric Motor: Brushless DC (BLDC) motor or PMSM motor. We recommend CMVTE’s 3kW–10kW BLDC air-cooled motors.
- Motor Controller: Matched to your motor voltage and amperage.
- Lithium Battery Pack: Typically 48V–96V depending on desired speed and range.
- Battery Management System (BMS): For safe battery charging and discharging.
- Throttle: Handlebar twist throttle compatible with your controller.
- DC/DC Converter: To step down high voltage for lights and accessories.
- Charger: Matched to battery voltage and chemistry (Li-ion or LiFePO4).
- Mounting Hardware: Metal brackets, motor mounts, welding tools (if needed).
- Wiring, Fuses, Connectors: For secure and safe electrical connections.
Step-by-Step Conversion Guide
Step 1: Choose the Right Motorcycle
Start with a small to mid-size motorcycle—preferably under 500cc—with a strong chassis and lightweight frame. Examples include the Honda CB series, Yamaha SR, or any old street bike with enough room for battery and motor mounting.
Step 2: Strip the Gas Components
Remove the following:
- Gasoline engine
- Exhaust system
- Fuel tank
- Cooling system (if water-cooled)
- ECU and wiring harness
This frees up space and reduces weight, preparing the frame for the new EV components.
Step 3: Mount the Electric Motor
Use a strong steel bracket or custom-built mount to secure the electric motor to the frame. Ideally, the motor should align with the existing chain or belt drive for efficient transmission. Some use the original gearbox; others opt for direct drive.
CMVTE Tip: Our air-cooled BLDC motors are compact and mount easily to most frames with basic welding or bracket mods.
Step 4: Install the Battery Pack
Determine the optimal location for battery installation—usually within the frame’s triangle or replacing the gas tank. Ensure it’s well-balanced and protected from vibration and moisture. Use anti-vibration mounts and steel casing if needed.
Step 5: Connect the Controller and Wiring
Wire the controller to the motor, battery, throttle, BMS, and other components. Follow wiring diagrams closely. Include fuses or breakers for overcurrent protection.
Ensure connectors are waterproof and neatly organized to prevent short circuits or vibration damage.
Step 6: Add Supporting Components
- Install the DC-DC converter for 12V lighting
- Reconnect headlights, indicators, brake lights
- Mount throttle to the handlebar and calibrate input
- Optional: Add digital dashboard for battery voltage/speed
Step 7: Test the System
Before riding, do the following:
- Test throttle response with wheels off the ground
- Check brake compatibility with regen (if used)
- Verify BMS operation and charger functionality
- Ensure all lights and indicators are working
Step 8: Ride and Fine-Tune
Take your first test ride in an open area. Observe:
- Throttle smoothness
- Motor temperature after a few kilometers
- Battery voltage drop during acceleration
Adjust controller parameters as needed (torque curve, regen braking strength, speed limits).
How Much Does It Cost?
The total cost depends on the components and quality you choose. Here’s an approximate breakdown:
| Component | Estimated Cost (USD) |
|---|---|
| Motor + Controller (CMVTE) | $300 – $800 |
| Battery Pack | $400 – $900 |
| Throttle, DC/DC, Charger | $100 – $200 |
| Wiring & Misc. | $100 – $200 |
| Total | $900 – $2100 |
Is It Legal to Ride an Electric Motorcycle Conversion?
Legal regulations vary by country and region. In many places, you’ll need to:
- Register your EV-converted bike
- Pass safety or emissions inspections
- Update insurance records
Check with your local Department of Transportation or Vehicle Authority before converting for on-road use.
Recommended Conversion Kits from CMVTE
At CMVTE, we offer plug-and-play conversion kits with:
- Air-cooled brushless DC motors (3kW, 5kW, 8kW options)
- Smart controller with app integration
- Matching throttles, chargers, and BMS
- Technical support and wiring diagrams
Contact us for custom kit quotes or technical consultation.
Final Thoughts
Converting a gasoline motorcycle to electric is not only eco-friendly—it’s exciting, educational, and rewarding. With careful planning and the right components, you can build a powerful, silent, and futuristic machine that turns heads and respects the planet.
Whether you’re aiming for a daily commuter or a custom show bike, start your EV journey today with CMVTE.
FAQs
- How fast can an electric motorcycle conversion go?
- Depending on motor and battery setup, speeds can reach 60–100 km/h or more.
- How long does it take to convert a motorcycle to electric?
- Most conversions take 1–2 weeks of part-time work.
- Is it hard to install an EV motor?
- Basic mechanical and wiring skills are sufficient. CMVTE provides diagrams and support.
