Kelly controller is hooked up for the elite project

This afternoon David and I were able to hook up the Kelly controller to the Honda elite.
However I kept scratching my head on this one :?
because the Kelly controller looked so much like an air filter to me???
Maybe because I am more familiar with general maintenance on vehicles?? I dunno, but I just kept thinking
of how the top part of the controller looked a lot like the fabric of a simple air filter.

So we were able to hook it up and turned the throttle and the motor turned, finally! Yay!
However the side part of the motor (I think it's a large screw or baring??)
literally flew off of where it was attached from and then the belt bounced off. That was kinda exciting lol
David ended up trying to use another method to hold the belt in place
(I already forget the name of it, David if you could help me as to remember?? thanks lol)
That idea seemed to work there are some minor adjustments that need to be made to make it fit properly.

There has been some progress on the elite. I am still puzzled on the kelly controller geez. :)

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reikiman's picture

the Kelly controller looked so much like an air filter to me What she means is the upper side of the controller has what I suspect is a heatsink. It's aluminum and ribbed in a way which would make sense for a heatsink. But this ribbing also kinda looks sorta like if you squint correctly the ribbing in an air filter.

So we were able to hook it up and turned the throttle and the motor turned, finally! Yay!
However the side part of the motor (I think it's a large screw or baring??)
literally flew off of where it was attached from and then the belt bounced off. That was kinda exciting lol

So, yeah.. the other controller I wanted to use is a 4QD UNI-8 but for some reason it wasn't working. However I was looking at the Kelly Controls site and realized their low end unit (200A max) was pretty nicely priced and I thought to give it a shot. We installed this controller yesterday and almost was able to take it on the road for a test ride.

The motor uses a belt drive and the correct sort of sprocket for a belt. However the belt isn't seating correctly centered on the sprockets. I suppose the motor needs to be more properly positioned to make the belt centered on the sprocket.

I spun up the controller a bit reving the motor up and down. It's clear this controller is going to overdrive the motor by a bit. Craig told me the motor is rated for 48v and 4000watts, which would be just shy of 100A, but the controller is rated for 200A. So, yeah, I'll need to fiddle with the settings to tone down the controller a bit. Cranked all the way up the bike and/or motor was doing some interesting-sounding vibrations and noise.

But while testing the motor at speed... the sprocket kinda fell apart. This sprocket is built with two walls and the belt ought to be centered between the walls. However the belt was resting partly on one of the walls. That wall came off the sprocket - I believe it's glued on and must have came undone. In any case once the wall came off the sprocket the belt flew off and started flopping around pretty dramatically.

Needless to say we didn't take it out for a test ride ;)

Hmmm wondering when I get to work on the elite again :?

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