Scientific Experiences in Applied Technology

Original Research Articles

Performance and Energy Consumption Evaluation of a Yamaha 5TL Converted to BLDC Electric Propulsion

Farras Lutfi Adi , Listiyan Tri Kristanto , Muji Setiyo , Thirunavukkarasu Raja , Veeramanikandan Murugan , Sathish Dhandapani

Published
January 2, 2027

Vol. 1 No. 1 (2027): Issue in Progress
Pages e16.1-12

DOI

Open Access
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Abstract

The growing interest in electric vehicles has encouraged the conversion of conventional internal-combustion motorcycles into battery-electric motorcycles as a way to extend the service life of existing vehicles while reducing dependence on fossil fuel. This study converts a Yamaha 5TL motorcycle, originally equipped with a continuously variable transmission (CVT) and a gasoline engine, into an electric motorcycle driven by a Brushless Direct Current (BLDC) motor. The objectives were to identify the components and mechanical adjustments required for the conversion, to characterize the performance of the converted vehicle, and to compare its energy consumption and operating cost with the original gasoline-powered configuration. The conversion involved the design and fabrication of a motor-mounting bracket, modification of the fan cover, roller housing, transmission bushings and rear pulley, and installation of an electrical system consisting of a lithium battery, a miniature circuit breaker (MCB), a Juken 10 controller, and a hand throttle. Performance was evaluated through no-load bench testing and on-road testing with a 69 kg rider load over a 5.08 km distance, while energy consumption was assessed by comparing battery-capacity depletion with fuel consumption under the same test conditions. The BLDC motor was successfully integrated with the Yamaha 5TL chassis and CVT drivetrain through the fabricated bracket and the modified transmission components. Under no-load conditions, the system reached a battery voltage of 64.6 V, 100% throttle position, a 95% duty cycle, an electrical power of 788.8 W, and a maximum motor speed of about 3,243 rpm (16,215 eRPM), with controller and motor temperatures of 32.4 °C and 34 °C, respectively. On the road, the converted motorcycle attained a maximum speed of approximately 35 km/h. Energy consumption tests indicated approximately 0.0272 kWh/km for the electric configuration and approximately 0.0394 L/km for the gasoline configuration. At an electricity tariff of IDR 1,393.70/kWh and a Pertalite price of IDR 10,000/L, the corresponding energy costs were about IDR 39.25/km and IDR 400/km, respectively, indicating that the electric configuration achieved an energy-cost saving of about 90.03% under the tested conditions.

Keywords

BLDC motor; CVT transmission; Electric motorcycle conversion; Energy consumption; Yamaha 5TL

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Publication Information
Published January 2, 2027
Section Original Research Articles
Copyright Copyright (c) 2027 Farras Lutfi Adi, Listiyan Tri Kristanto Kristanto, Muji Setiyo, Thirunavukkarasu Raja, Veeramanikandan Murugan, Sathish Dhandapani (Author)
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This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.
Keywords
  • BLDC motor
  • CVT transmission
  • Electric motorcycle conversion
  • Energy consumption
  • Yamaha 5TL
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