How to convert old petrol bike to geared electric bike || INDIA’S FIRST FOUR GEARED ELECTRIC BIKE


hi, guys, I am Shalin and all of you are welcome to tech tube 360 and he is my friend Tejas. Hi Guys Today’s video is going to be very special because we have made India’s first four geared electric vehicle for which we were working on for the past six months and finally, this project is completed today Friends we have selected Bajaj Boxer bike form scrap We have selected Geared bike to convert because of the known disadvantage of electric vehicles of poor traction on load and slopes so for that reason, we have got a Geared bike As Tejas said We have got this vehicle from the scrap there are two advantages one is you are stopping a new vehicle from entering already populated Indian Roads secondly, your scrap value vehicle is converted to zero emissions eco-friendly vehicle you can expect an increase in life for another 12 to 15 years which was totally a scrap value vehicle yet another thing is that in electric vehicles, there is nothing that wears out easily so life expectancy is almost 15 years or more after conversion. So friends today’s video is going to be very interesting please watch till the end you will really enjoy watching this video Music!!! So, friends, we have got a Bajaj boxer bike for this conversion We have taken apart the entire engine and what are the modifications in the engine that I will show you step by step so let’s get started So these are some of the components that we don’t need like Engine head and block assembly it’s cover we don’t need an oil pump original crankshaft and connecting rod and piston not needed the timing chain is not required Kick is also not required no magneto required and its stator assembly too removed No need for an engine Block Air filter box carburetor connecting pipe not required No need for silencer too !!!! All this weight we are saving from our electric bike now I will show you what all modification we need to do in the engine and all those components that are required for engine modification and let’s see those parts So, friends, this is e-rikshaw motor If you know then there is a gear on this shaft that gear directly fits into the rear differential gearbox but as we are not using the differential box so we modified this motor shaft to So we opened up the motor and and turned the worm gear from the motor shaft made shaft found and filed one part of the shaft to a flat part for gear which will not slip on the shaft once it’s fixed by the grub screw So this was a motor modification This is the customized gear this gear will be fixed on this shaft tightened by L&key grub screws The motor will then rotate the gear and This smaller gear will fit on the customized shaft will show you that in a while this gear will be fitted on the customized shaft which will in turn spin the smaller gear at the bottom and the shaft through transmission will send the power to wheels And This is that customized shaft on which we will be This smaller gear which I showed you will be fixed here and finally through the gearbox, it will drive our rear wheel For Mounting the motor on to the engine this is the customized plate which is very thick almost 12mm thick these holes are drilled to match studs on the gearbox and at this adjacent side motor will be mounted So friends lets go ahead with engine assembly So as you can see all the parts lying in the tray So we will start our assembly So, friends, this is basically our bike In this, we have changed the throttle to as you can see to hall throttle and it’s matching grip on left side For battery, we have removed the tank from here we have welded an iron strip at the bottom i don’t know if you guys are able to see Ya I am talking about this strip on that this battery bay is fixed which will four batteries of 12v each which will power our bike 12v 20amp/Hr batteries and we will cover this later the hall throttle cable was short so we elongated it till controller here and the controller is fixed at empty space of air filter this is the controller connection plate here all the three phases are wired as you can see blue-green and yellow phase wires this is controller enable wire which will be connected to the key ignition switch in the wiring As you can see the entire engine is removed as we were to work on the making it electric So the primary modification in the bike as seen is done silencer too removed we will place the assembled engine in its place remains to be done I apologize for the surrounding noises but as this is an industrial area please excuse me so we will work on the engine after placing the engine at its place will show you wiring and connections So, friends, we will place batteries in the battery bay we will place all four one by one as you can see to connect all in series we will place them alternate positive and negative connections made with battery series wires isn’t that nice and perfect the tray which we have made holds the batteries perfectly we ill do connections in series so we will get 12v X 4=48v as our controller and motor are 48v rated Speeding up a bit to keep the video length under the limit Form these two leads we will draw the output Here thick wires which can carry 18 to 25 amps will be connected So these are our output tabs So as you can see the battery stand in fixed nice and snug let me just show you a top view After seat, the battery bay starts Music!!! Installing gearbox whilst the electric engine Music !! Music !! Music !! Speed 6X Friends thank for watching the video till the end what do you think about our electric vehicle which is eco-friendly maintenance free and green vehicle do let me know in the comment section below if you enjoyed watching the video please do give it a like do share this video if you have not subscribed to my channel please do subscribe to techtube360 and hit that notification bell icon so that you will be getting instant updates of our forthcoming videos and I will see you in my next video till then bye take care JAI HIND 🙂

100 comments on “How to convert old petrol bike to geared electric bike || INDIA’S FIRST FOUR GEARED ELECTRIC BIKE”

  1. WILDCRAFT says:

    Share your contact information . On email: [email protected]

  2. KHAN sports says:

    How much speed for this electric bike

  3. jignesh khatri says:

    Mare 48v 900 w motor thi loading cart banavvu Che to ketla ah ni battery lagadu ane kayu charger vapru ? Please help me.

  4. KASHISSH DEMBLA says:

    Sir ye bike sirf 40 ke speed tak he jati h kya

  5. Krishna Yadav says:

    I want convart Yamaha Crux convart karneke leye ayega oil leak prabulam

  6. B J says:

    In any case, a vehicle having electric motor of more than 250 watt and /or speed above 25 KMs per hour is within the ambit of Motor Vehicles Act. RTO may have a say in the matter of any conversion. Please correct if I am wrong.

  7. Viraj wadatkar says:

    What is the total modification price and another bike cab run ??🤔🤔

  8. Sakariya chirag says:

    Bhai tamara fon no aapo

  9. Sakariya chirag says:

    Hu Rajkot ma chu

  10. Krishna MK technical says:

    सर जी कितने किलोमीटर चलती है एक बार चार्ज में

  11. kirankumar angadi says:

    Brilliant concept

  12. All in raj says:

    નવા વીડિયો ક્યારે આવશે

  13. Narasimhan Srinivasan says:

    hi, your effort is wonderful. I have an old Hero Honda CD 100 SS motorcycle that I haven't used for nearly 2 years. Can I convert it into an electric bike, it is a geared 4 stroke bike. Kindly help.. indicate what will be the cost, I live in Sahibabad, District Ghaziabad (Delhi NCR, only 2 kms. from Dilshad Garden).. my email i.d. is [email protected], if you write to me, I will convey my mobile numbers to you.

  14. jilani Shaik says:

    So goodi

  15. Selva Raj says:

    Nice Iam Allready Thinking, This My Next Project.

  16. Nitin Gite says:

    1st time maine gear wali electric bike dekhi…Good job keep it up..

  17. Shiv Lakhan says:

    Sir mere ko v banawana hi

  18. Sunu Das says:

    Go 🇮🇳 go No1 position 🤗

  19. Sanjay Karkar says:

    Ha mozzzxzzzz. Great

  20. Tarun Agarwal says:

    I like the bike conversion.. your efforts to make environment and pocket green..
    I need to know why you have added gear box? As I feel if the motor power goes directly to rear wheel gearless, it could give more power and more Kms per charge.
    Thank you

  21. Pranav Sharma says:

    How many distance it will cover in a single charging ?? I mean how much is the battery life ??

  22. Ali Musavir says:

    Saeen very good work

  23. Bharat Keshri says:

    7908089898 सर आप मुझे फ़ोन करे मुझे भी ये सब समान चाहिये मेरे पास यही गाड़ी है

  24. Brain Kida says:

    What's top speed of it?

  25. manish mewada says:

    shandaar

  26. mohammedjaveedFirst Name miyya says:

    Electric bike technique good total cost motor material where you buy I am also interested making this type please help me same thing reply me
    My mobile 9980065547

  27. Pardeep Kumar says:

    Good

  28. Vishal Sonawane says:

    Sir but Brek kaise lgega

  29. mk jh says:

    What is the power of the motor? How many Kilowatt?

  30. Shah Alam says:

    Aisi bike hamen bhi chahie

  31. mk jh says:

    What is the maximum speed attained by the bike? I saw the Car speedometer was showing 40 kmph. Can this bike attain a speed above 60 kmph?

  32. Vimal saha says:

    मेरे पास एक यामाहा 350 है।उसको मैं इलेक्ट्रिक में कन्वर्ट करना चाहता हूँ।कैसे करूं। मोबाइल नंबर है
    8081049957 .

  33. Satyapal Singh says:

    Sir m aap se milna chata hu ,aapka name and whatsapp no chaheye,or aap kaha se belong karte ho , Esme kuch or bhe modified bhe ho sakta h

  34. Sanjay Rawal says:

    Good job.. pls batao kharcha kya aaega..

  35. Yasin Juneja says:

    Xcd Bajaj ko electronic karoge
    Our price kya hogi

  36. SACHIN BORTWAR says:

    Sir aapne jo invention kiya hai vo bahut hi badhiya bahot achha hai,
    Muze bhi aisa hi karna hai apni bike me
    Aapki help chahiye,
    Mere paas hero honda super splendor bike hai us me aisa ho sakata hai kya ?,
    My no. 8888755667 muze aapse baat karni hai.

  37. Yash Raj says:

    8923795556 bhai plz call ye bike leni he muje

  38. BABU K says:

    Great! Will you do the same for my KB 100 BIKE?

  39. seeusoon007 says:

    Have you ever noticed how many mileage you get with 1 charge . And how many hour required to charge battery. Plus up hills performance?

  40. Jayesh Basantani says:

    Can we Do the same with Activa .. if you are interested in opening your branch ahmedabad, contact Me.

  41. seam Bhai says:

    Top speed kitna hai

  42. Muhammad Azeem says:

    Lol bakwas setup rare rim ma motor lag jati chain ki zarorat Nahi Hoti phr ya Acha Nahi bss Jo chain use kia

  43. Srinivas Kodati says:

    Could you say us your number we are trying to do that

  44. saroj kumar singh says:

    Superbike

  45. saroj kumar singh says:

    Can u convert old scooter too??

  46. nachiket joshi says:

    Vaah bhai vaa
    Bike banavddavu hoi to kro cho ?

  47. Ashok S says:

    Dear good work….. India needs practical electrical bike like this… but companies are concentrating on premium bikes… we need a electric scooter like Activa… practical reliable and comfortable…. no need touch screen GPS…. need good range and better charging….

  48. Sachin R says:

    Hello Sir, really appreciate your efforts, your techniques are wonderful. I have query related to this, since you have removed piston head and used only gearbox from main engine, so do it required oil for lubricant of gears and the moving parts?

  49. Basudev Mishra says:

    Main apne bike.ko ebike pe convert karana chahata hun please contact& mob no send kijiya..

  50. manjunath vankadari says:

    congratulations guys you have done it.you and your team efforts will definatly will be rewaeded.kindly let me know if you guys planning to do activa scooter,my vehicle ready tobe sent from bangalore.

  51. Nadra Kiosk Center says:

    Assalamualikum
    Apki Video Bohat Bohat Achi lgi so a cute Bike & is bike per kitna Khrcha Aya or ye kitni CC Power ki Bike hy
    Kiyon k mery pas Honda ki 1987 madel ki 70cc Bike hy or us per 12000 rupies khrcha kiya hy jis min jo tabdeel kiya hy wo usny Unit Khtam ker k CDI sysem kyahy baqi Bike bahir purani hi legti hy
    Aap sy nihayet Guzarish hy k mujhy acha sa mashwara dein taky m apni bike ko acha bana skon
    All Very Thanks

  52. Masood Ahmed says:

    It's remarkable,but the chain running underneath the"tank"at high speed without a guard is hazardous! Otherwise ok!

  53. Manikandan Thampi says:

    what about battery life

  54. Tech Tube 360 says:

    I have a great video recommendation for all those people who believe in free energy have a look at link below and don't waste your time watching free energy videos on YouTube as I want to save your time watching lies
    https://youtu.be/15V0gUXUPko

  55. Ketan Bachkaniwala says:

    I have a old Karizma bike, I want to convert the bike to electric. What components i.e which watts motor do I require and which capacity Battery do I require
    Please advice

  56. ahmed lakadia says:

    I want this bike

  57. lancer Games says:

    How much motor kit please

  58. Koustubh Javheri says:

    बहुत ही मिनिमम कॉस्ट में हम अपने एक्जिस्टिंग व्हीकल को इलेक्ट्रिक में कन्वर्ट कर सकते हैं बहुत ही अच्छा प्रयास है.

  59. Education Katta says:

    please share your contact details or address

  60. bhavin ganatra says:

    wah gj3 gujarati creative

  61. Vimala Ugesh says:

    Wasted my favourite 2 stroke bike

  62. Sunny Singh says:

    Did you add engine oil or not?

  63. Sam says:

    भाई तुंमने विडिओ भि अच्छा बनाया और bike उससे 10 गुना अच्छि बनाई

  64. Doctor Sai says:

    The very thought of taking a scrap vehicle is ingenious

  65. ADHIYAMAN R says:

    Evalavu Neeram ya starting la irunthu peesuvinga

  66. Doctor Sai says:

    With all th existing components, won't it be a bit heavy?

  67. Aniket Varshney says:

    Congratulations! Great Initiative. Really helpful! Keep up the good work.

  68. Tanaji Dhane says:

    Crank shaft se pura weight na nikale ply wheel ki tarah kaam karega aap ko kya lagta hai ??

  69. Latu Kolita says:

    Nice… Kitna kharsa huwa hai.. pls bataye….

  70. ram mohan says:

    I am from Bangalore
    Awesome can you please convert my bike also to EV bike.

  71. Anuj Rathee says:

    i think they even not on full throttle

  72. Pankaj Saha says:

    Charge kaise karenge

  73. photo studio says:

    U number plz…
    [email protected]

  74. Bhavin Kavaiya says:

    I'm from Rajkot and I've also Bajaj Boxer riding since 2002. What will the cost of converting battery bike?

  75. Ritul Vasani says:

    Ye 100% Gujarati hai..

  76. Shaheed Khan says:

    Kitna kharcha aayega bike ko banwane me

  77. Shubham Parmar says:

    Bhai mujhe apna WhatsApp no send kar do

  78. Martin Strange says:

    Wonder about insurance? registering as electric here in the UK is something that could be done, if it is cost effective then I would do it. Great vid. It needs a 2000 watt motor though.

  79. Solanki Divyarajsinh says:

    What is highest speed of bike?

  80. Md Qadeer says:

    Sir ji maine complete video dekha bohat badiya kaam karke dikhaya hai aapne kya hero honda super splender ko bhi aisa bana sakte hai sir

  81. MR. KING says:

    EK BAAR CHARGE HONE PAR KITNE KILOMETRES CHALTI HAI

  82. Ganesh Mhamane says:

    Charging kise karenge?

  83. akash2038 says:

    Impressive
    I want to learn this
    Can you please help me? ?

  84. kishor koli says:

    भाई बेटरी चार्ज कैसे होगीं?

  85. Biju K A says:

    ഇലക്ട്രിക് മോട്ടോർ ബൈക്കുകൾ റോഡ് കീഴടക്കുന്നു ബുക്കിങ് ആമസോണിൽ തുടങ്ങീട്ടുണ്ട് Geekay Pegaz DIY 48 V 550 Watt BLDC Electric Pedal Rickshaw Motor Kit with Gear Set (Multicolour)

  86. edward peter says:

    Good work bhai save people from pollution we r INDIANS

  87. DAYANAND KASLE says:

    We can control motor speed and torque without gear box and save mechanical loss

  88. SUNIL AGGARWAL says:

    Same video for hero splendor

  89. SUNIL AGGARWAL says:

    I want your address

  90. SUNIL AGGARWAL says:

    I want to convert my hero splendor bike into electric bike that's why I want your address

  91. Avinash Khartade says:

    ओल्ड बाईक को इलेक्ट्रीक बाईक मे कन्वर्ट करणे का खर्चा कितना आयेगा…. और कहा बनवाके मिलेगा? अॅड्रेस

  92. Shiv Narayan sahu says:

    You send me your postal address and mobile number.

  93. Pedro Barchuk says:

    Traducción.
    Este video es muy especial ya que hice una bicicleta eléctrica que también es la primera bicicleta eléctrica de la India con cuatro marchas. La idea detrás de hacer la bicicleta eléctrica con engranaje era hacer una bicicleta de cercanías o una bicicleta de calle con una bicicleta de calle económica, verde y de cero emisiones que pueda transportar fácilmente a cualquier persona, dos personas y pueda navegar a una velocidad decente. No se queda en ninguna parte en el tráfico rápido de la ciudad. También puede transportar cargas mientras sube más de 35 grados de pendientes. Hemos hecho que todas las cosas anteriores sean ciertas y que funcionen en la bicicleta. La bicicleta donante que tomamos estaba en muy mal estado. Este proyecto tardó seis meses en completarse ya que queríamos que todos los criterios anteriores estuvieran presentes en nuestra bicicleta. Cómo lo hicimos y qué modificaciones se hacen para hacer esta bicicleta está todo bien descrito en este video. Básicamente, tomamos Bajaj Boxer y usamos solo el cuadro y la caja de cambios de la bicicleta. Para usar la caja de cambios de cuatro velocidades en una bicicleta eléctrica, tuvimos que reemplazar el cigüeñal principal por uno personalizado. Además, se fabricó una placa gruesa del motor para montar el motor en la caja de engranajes y convertirlo en un motor eléctrico completo con cuatro engranajes. Este proyecto salió realmente muy bien e incluso más que mis expectativas. Espero que te haya encantado ver este video. Muchos de mis amigos me han preguntado que las siguientes son razones 1) Mejor torque en motores de menor potencia. 2) los vehículos eléctricos suelen estar maldecidos por una baja tracción en la subida o subida de una pendiente que se elimina en esto. 3) en general, los amperios menores se extraen de la batería debido a los engranajes que mejoran la vida útil de la batería y la eficiencia de todo el sistema 4) una mayor capacidad de carga debido a los engranajes 5) Acabo de usar un motor de 1000 vatios que produce apenas 2000 rpm en el eje pero aún , Logré lograr un equilibrio entre rendimiento y potencia solo debido a un sistema de engranajes, así que espero que haya despejado todas sus dudas sobre el uso de la caja de cambios. Gracias por su tiempo e interés. 👍🙏✌️ Sub Nota: subtítulos en inglés disponibles, active los subtítulos en su youtube para esa pregunta frecuente: ¿Cuál es la velocidad máxima? Respuesta: 47.5 km / h en cuarta marcha ¿Cuál es el rango? Respuesta: 50 km / h. ¿Cuál es la capacidad de la batería? Respuesta: 48v 24Ah

  94. Vishal Maan says:

    Bhai ji aapis m lto betrry use kro

  95. Jayanthan Kumar says:

    Need to use engine oil for gears?

  96. Prasad Acharekar says:

    Finally someone is here who made what i was trying to say … Thanks for your support.. it really supports my project too … But right now I'm thinking for ac motors and vfd control and inverter system

  97. Mahak Sayyad says:

    kitna cost aya he janab

  98. jatin sharma says:

    isme kitna kharcha aaya?

  99. Omprakash Vishnoi says:

    Max speed? How many km range in single charge? Charging time?

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