Customer Case Study

Electric Motorcycle Battery Project

Custom Lithium Battery Pack for Electric Motorcycles, Delivery Fleets and Cargo Vehicles

RYDBATT developed a custom electric motorcycle lithium battery pack for a B2B mobility customer serving the urban delivery and logistics fleet market. The project was designed for high-frequency daily riding, frequent charging, outdoor use and long-term fleet operation, and is built on the same 60V and 72V platforms that RYDBATT publishes on the electric motorcycle battery category.

This case shows how RYDBATT helped the customer move from standard lead-acid and unstable replacement batteries to a more reliable lithium battery solution with better discharge stability, smart BMS protection, sealed aluminium housing and project-based customization - supported by a published product line covering 48V, 60V and 72V platforms from 1440Wh to 3600Wh.

The customer was an electric mobility distributor serving delivery motorcycle operators and local logistics fleets in an overseas market. Their main customers used electric motorcycles and electric scooters for food delivery, parcel delivery and short-distance urban transportation, and had previously run the same platforms on 72V 60Ah lead-acid packs of roughly 38 kg.

Before working with RYDBATT, the customer faced several problems with their existing battery supply:

• Nominal capacity did not translate into stable usable range across a full working day
• Voltage sag appeared quickly under hill-climb and loaded riding conditions
• Lead-acid cases were open to electrolyte top-up and terminal corrosion in outdoor service
• Service life of 300–500 lead-acid cycles meant frequent replacement and rising after-sales complaints
• The customer needed one battery partner able to cover 48V, 60V and 72V platforms instead of several suppliers
• Existing suppliers could not support flexible customization for connectors, protocol, casing dimensions and private-label packaging

The customer wanted a battery pack that could support high-frequency charging and discharging, stable power output, safer operation and better long-term performance for delivery motorcycles and logistics fleet applications - ideally at roughly half the weight of the lead-acid pack it replaced, with telemetry for fleet management.

RYDBATT designed a custom electric motorcycle lithium battery pack based on the customer's vehicle system, controller current, target riding range, installation space and fleet operating conditions.

Cell Selection

RYDBATT selected grade-A lithium iron phosphate (LiFePO4 / LFP) cells for the whole published RYDM range, chosen for electric motorcycle traction duty where thermal stability, cycle life and daily deep cycling matter more than absolute cell weight. Cell configurations run from 20S6P at 60V 30Ah (5.0Ah cells, 6 in parallel) through 20S2P at 60V 50Ah, 23S2P at 72V 30Ah and 23S1P at 72V 50Ah, with 20S9P at 72V 22Ah on the 18650-based platform. Charge cut-off is set at 3.65V per cell and discharge cut-off at 2.80V per cell, so the pack works with standard 72V controllers.
 

Smart BMS Design

The battery pack used a smart BMS with protection functions including overcharge protection, over-discharge protection, overcurrent protection, short-circuit protection, temperature monitoring and cell balancing. State-of-charge accuracy is held within ±3%, with continuous and peak limits matched to the controller rating and the target riding load.

For fleet operation, CAN and RS485 communication ship as standard on the 60V and 72V platforms, with Bluetooth monitoring for smartphone or dashboard use and GPS tracking available as an option. Data available to the controller typically includes state of charge, pack voltage, current, cell voltage, temperature and fault flags.

Heavy-Duty Sealed Housing

RYDBATT designed a sealed aluminium alloy case to improve structural strength during delivery use while keeping the pack light. The RYDM6030 weighs 15 kg for 1800Wh - roughly 120Wh/kg at pack level - against about 38 kg for a comparable 72V 60Ah lead-acid pack. Casing dimensions, mounting position, connector direction and IP67 sealing were all taken from the customer's battery compartment.

Connector and Charger Matching

Charging and discharging connectors were customized according to the customer's electric motorcycle system - pin assignment, cable length and gauge are matched to the vehicle-side interface, and the published platform uses an M23 2+1+5-core female socket with dust cap. RYDBATT also matched the charger specification with the battery voltage, BMS setting and charging current requirements.

Project-Based Customization

The final battery solution supported:

• 48V / 60V / 72V / 73V voltage options
• 20Ah–50Ah standard range from 1440Wh to 3600Wh, project-based capacity design
• Smart BMS protection with cell balancing and ±3% SOC accuracy
• CAN and RS485 standard, Bluetooth monitoring and optional GPS tracking
• Sealed aluminium alloy, engineering plastic or stainless steel casing
• Connector, harness and charging current customization, charger matching
• Label, logo, barcode, user manual and packaging customization
• OEM/ODM production for fleet and distributor projects, with UL, CE and CB available

Before sample approval and mass production, RYDBATT carried out a complete testing and validation process to verify battery performance, safety and batch consistency. Published packs are rated for 1,500–2,000 cycles at 80% depth of discharge on the NCM platform and roughly 2,000+ cycles on the LFP platform, with a 2-year or 1,500-cycle warranty whichever comes first.

After sample testing and customer-side vehicle verification, the electric motorcycle battery pack passed the required performance checks and was approved for mass production.

The customer received a more stable lithium battery solution for delivery motorcycles and logistics fleet use. Compared with the previous lead-acid supply, the new battery pack helped improve discharge stability, reduce after-sales complaints and support better product consistency for fleet customers - at roughly half the pack weight and around four to six times the cycle life class.

✓Samples passed customer testing

✓Battery pack entered batch production

✓Stable delivery for B2B fleet application

✓After-sales complaints were reduced compared with previous supply

✓Customer placed repeat orders after initial shipment

✓Product line expanded from one battery configuration to multiple voltage, capacity and housing options

✓The customer started promoting the battery for delivery motorcycles, electric scooters and logistics fleet projects

Electric motorcycle batteries for delivery and logistics use must perform under more demanding conditions than ordinary consumer batteries. Riders may charge and discharge the battery every day, ride in outdoor environments, carry heavier loads and require stable output during long working hours. The published comparison is blunt about the chemistry gap: lead-acid gives 300–500 cycles, Li-ion 800–2,000, and LiFePO4 2,000+.

For this type of B2B project, the key is not only battery capacity. The battery must match the vehicle system, controller current, charger, connector, casing space, waterproof requirement and fleet management needs. Voltage alone is not a specification: 48V suits smaller motorcycles and scooters, 60V is a middle tier for moderate performance and range, and 72V is the high-performance platform for faster speeds and longer rides.

RYDBATT's project-based battery development helped the customer build a more reliable electric motorcycle battery product line for high-frequency urban mobility use.

The project draws on a product line that is already in production and published on the RYDBATT electric motorcycle battery category. The models below are the platforms most often specified for two-wheel and light-vehicle duty, with the figures taken directly from the published technical specifications.

Source: ryderelectronics.com/electric-motorcycle-battery/ - specifications as published at time of writing.
 

The pack delivered for this project follows the RYDM6030 platform, which is the configuration most often specified for delivery and logistics duty where weight, range and charging turnaround all matter at once.

The published RYDM7230 comparison against a typical 72V 60Ah lead-acid pack is the clearest way to size the upgrade for a fleet buyer. Note that capacity is not directly comparable and the charger must change with the chemistry.

The platform is engineered for two-wheel and light-vehicle platforms that need more than a small commuter pack. Each duty below is matched to a specific published attribute rather than a generic claim.

Voltage is the first decision on any electric motorcycle project, and it is a performance decision rather than a compatibility one. All three platforms below are in production.

Three chemistries are relevant to electric motorcycles. The published cycle-life figures explain most of the total-cost argument for a B2B fleet buyer.

The published platform is already open for adaptation, so a project-specific pack usually changes dimensions, interface or protocol rather than the whole product.

The following terms are the published defaults for the electric motorcycle battery category and are confirmed again in the quotation for each project.