Electric tricycle conversion kit:keep the original frame, replace only the drivetrain
Converting a petrol tricycle is not a matter of pulling the engine and dropping in a battery. The kit has to solve four things: motor torque that survives a loaded gradient, a controller current limit aligned with what the pack can deliver, a harness that reaches the ignition and lighting without cutting the factory loom, and a bracket that bolts into the original chassis holes instead of being welded on. This page lists the full bill of materials, the displacement-to-configuration mapping, the retrofit-versus-replace cost routes and the five-step workflow.
verifiedConversion times, weights and energy figures come from recorded conversion bays; the signed specification sheet shipped with your container governs.
Four figures that define a kit deployment
Specification notice:The figures above are engineering reference values. They may differ with production batch, configuration and actual duty cycle, and the percentages for life, efficiency, availability and coverage are engineering estimates and bench references. Contact us for the detailed specification sheet.
Conversion kit bill of materials: standard and optional
Standard items ship in one crate and are everything needed to complete the build. Optional items follow the vehicle type and the operating model. Each row states what happens if the part is missing.
| Component | Standard / optional | Specification | What it does and how it is sized | If it is missing |
|---|---|---|---|---|
| Drive motor | Standard | 2.5kW hub motor, or 3.5–5.0kW mid-drive PMSM (4.2–9.5kW peak) | Replaces the engine and transmission; full torque from low rpm so a loaded start does not roll back | No drive at all |
| Vector FOC controller | Standard | Fully potted IP67, electronic brake energy recovery, upper-computer calibration | Sets launch torque, top speed and gradient ability; the current limit must match motor and pack | Weak launch, cut-out under load, or a burnt motor |
| Motive battery pack | Standard | LiFePO4 48V / 60V / 72V, steel case with potted BMS bay, IP67 | Supplies range and loaded peak current; capacity is sized on daily distance and payload | Blank instrument, no power |
| DC-DC step-down module | Standard | Independent 12V supply, isolated from the main circuit by dual fuses | Feeds headlight, horn, indicators and instrument cluster | Lighting assembly and cluster burn out at switch-on |
| Instrument cluster / LCD | Standard | Voltage, SOC, speed and gear display, versioned by platform voltage | Drops into the original instrument position; SOC must be calibrated to the BMS | No usable state of charge, unmanaged shift distance |
| Plug-and-play harness | Standard | Pre-formed modular flame-retardant loom, ignition-lock relay, keyed IP67 connectors | Plugs into the factory ignition assembly, headlight and brake-light switch without touching the original loom | Hand-spliced joints, heat build-up and short-circuit risk |
| Adapter bracket / stamped mount | Standard | 3mm galvanised heavy-duty bracket, grade 10.9 bolts and anti-vibration pads, vibration verified to 3G | Locks into the original chassis bolt holes — no cutting, no welding | Pack cannot be secured, or the factory safety structure is compromised |
| Dedicated CC-CV charger | Optional | Matched to the platform voltage, 10–40A, with BMS handshake | LiFePO4 requires constant-current/constant-voltage charging; a lead-acid charger must never be reused | Pack never fully charges, or trips straight into protection |
| Quick-release / swap structure | Optional | Quick-release handle or a BMS version that handshakes with swap cabinets, with anti-theft positioning | Lets double-shift fleets swap instead of charge, cutting vehicle downtime | Shift distance limited by charging time |
| Calibration and training | Optional | Payload and wheel-diameter parameters written in, plus multilingual video tutorials and a 3D assembly manual | Covers hall self-learning, cluster SOC calibration and the 5km loaded road test | Uncalibrated parameters, visible speed and SOC error |
The kit does not include tyres, brake shoes, body panels or local registration. Those follow the condition of the vehicle and destination regulations. For the all-in configuration with the pack included, see /conversion-kit-with-battery/.
Specification notice:The figures above are engineering reference values. They may differ with production batch, configuration and actual duty cycle, and the percentages for life, efficiency, availability and coverage are engineering estimates and bench references. Contact us for the detailed specification sheet.
Displacement mapped to motor power and battery configuration
Original displacement sets the everyday payload and the expected top speed, which sets motor rating. Daily distance and route gradient set battery capacity. Size the two separately rather than guessing both at once.
| Original displacement / vehicle | Recommended motor | Battery voltage and capacity | Vehicle examples | Top speed (loaded) | Target range | Standard conversion time |
|---|---|---|---|---|---|---|
| 100cc class (light two-wheeler / mini shuttle three-wheeler) | 2.5kW hub motor · 4.2kW peak | 72V 45Ah (3.24 kWh), quick-release carry handle | Light commercial 110cc–150cc delivery two-wheelers, mini shuttle tricycles | 70 km/h | 85 – 100 km | 25 minutes |
| 125 – 150cc (3+1 passenger) | 3.5kW PMSM · 6kW peak | 60V 105Ah (6.3 kWh), flame-retardant aluminium case | Bajaj Compact RE 3+1 passenger | 50 km/h | 110 – 130 km | 35 minutes |
| 150 – 175cc (wide-body passenger) | 4.2kW vector sine-wave · 7.5kW peak | 72V 120Ah (8.64 kWh), automotive blade cells | Bajaj Maxima / TVS King wide-body passenger | 55 km/h | 135 – 150 km | 40 minutes |
| 200cc class (1 tonne cargo / heavy open bed) | 5.0kW high-torque integrated differential · 9.5kW peak | 72V 150Ah (10.8 kWh), dual-module cold-rolled steel | Piaggio Ape, heavy open-bed cargo tricycles | 45 km/h (800kg payload) | 95 – 115 km | 45 minutes |
These are factory-calibrated values for four mainstream platforms, with a 1:8.6 reduction ratio as standard to build loaded torque. For non-standard vehicles we offer 3D chassis reverse-scanning and custom stamped brackets. Range moves with payload, gradient, tyre pressure and riding style.
Specification notice:The figures above are engineering reference values. They may differ with production batch, configuration and actual duty cycle, and the percentages for life, efficiency, availability and coverage are engineering estimates and bench references. Contact us for the detailed specification sheet.
Retrofit or replace: what each route costs and returns
Route one: buy a new electric tricycle
Whole-vehicle purchase- cancelSpend profileOne-off vehicle purchaseBody, bed and drivetrain bought together, all at the start
- cancelExisting vehicleFrame, bed, brakes and tyres are effectively written off
- cancelLead timeVehicle build plus sea freight and clearance — longer than a crate of parts
- cancelRegistrationRuns through whole-vehicle type approval and new registration; destination law governs
- cancelRoute fitVoltage platform and payload fixed at the factory and cannot follow the route
- cancelLocal serviceDependent on the OEM dealer network; parts and technicians rebuilt from zero
Route two: retrofit the existing frame
Kit conversion- check_circleSpend profileKit plus labourPriced FOB / CIF from destination port, payload, daily distance and motor rating
- check_circleExisting vehicleFrame and body stay in serviceOnly the drivetrain is replaced, so bed, brakes and tyres keep their value
- check_circleLead timeSamples in 3 – 5 daysAbout 180 three-wheeler packs per 20GP, 320+ per 40HQ, shipped with the container
- check_circleRegistrationFiled through the local conversion or change-of-particulars process; destination law governs
- check_circleRoute fitMotor rating and pack capacity calibrated to your payload and gradients
- check_circleReturn6 – 8 months paybackCost per km falls 68–72% and servicing spend collapses
- check_circleConversion time35 – 45 min per vehicleTwo experienced technicians, released only against a signed handover sheet after a 5km loaded test
Five steps, 35 – 45 minutes per vehicle
Two experienced technicians follow the standard sequence with no frame cutting and no welding. A 5km loaded road test and a signed handover sheet close every build.
- 01oil_barrel
Drivetrain removal and ballast assessment
Drain residual fuel and remove the tank, carburettor, exhaust, ageing two- or four-stroke engine and recoil starter. Measure static front and rear axle load and clean the installation bay.
Note: 48–65kg of removed mass - 02handyman
Bolt the anti-vibration stamped bracket
The 3mm galvanised heavy-duty bracket locks into the original chassis bolt holes (factory threads align exactly). The LiFePO4 pack drops in and is secured with double anti-release clamps.
Note: vibration tested to 3G - 03settings
Couple motor to differential axle
Install a 3kW–5kW mid-drive PMSM or an integrated differential on the rear axle housing. Align the driveshaft flange (deviation < 0.5°), grease, and secure the torque arm.
Note: 1:8.6 reduction ratio as standard for loaded torque - 04power
Plug in the smart BMS and vehicle harness
Connect the high-current main terminals, then plug the smart BMS into throttle, gear selector and brake cut-off in one action. An integrated pre-charge resistor prevents arcing.
Note: dual fuses plus independent 12V step-down supply - 05speed
Upper-computer calibration and road test
Connect the controller over Bluetooth or a handheld tool and write the payload and wheel-diameter parameters. Verify hall self-learning and cluster SOC accuracy, then run a 5km loaded acceleration, braking and hill-hold test.
Note: released only against a signed handover checklist
Registration and compliance: destination law governs
Conversion and change of particulars
A retrofit changes the drivetrain, and most markets require it to be filed through a local conversion or change-of-particulars process, with type approval in some. Whether the original frame may be kept and which tests apply is governed by destination law. We supply the technical dossier and drawings to support your filing, but we do not replace local approval.
Lithium shipping documents
Transport requires UN38.3, MSDS and a dangerous-goods packing certificate (Class 9), all shipped with the container. Market access depends on the destination: India AIS-156 Phase 2, Indonesia SNI, South Africa NRCS LOA, Nigeria SONCAP, Kenya PVoC / KEBS, Tanzania TBS PVoC, Egypt GOEIC / ACID, Thailand TISI, Vietnam QCVN 91, Sri Lanka SLS 1656, Pakistan CPFTA / Form E.
Operating licence and insurance
A converted commercial vehicle must be reported to the transport authority and the insurer. The interface between kit warranty and vehicle warranty is written into the quotation so responsibility is clear if a claim is made.
Three pages to read next
Kit with battery included
Exactly what is in the crate and what is not, the three build packages and the document set that ships with it.
See the kit with batteryarrow_forwardGlobal retrofit engineering guide
Workshop-floor records, the logic behind the weld-free bracket holes, and tropical heat and monsoon wading countermeasures.
Open the guidearrow_forwardPassenger three-wheeler packs
An ultra-slim under-seat chassis that removes the dead lead-acid weight the original vehicle carried.
See the three-wheeler rangearrow_forwardElectric tricycle conversion kit questions
What exactly has to be replaced?expand_more
What does it cost with the battery included?expand_more
Can I keep the original frame?expand_more
How long does one vehicle take?expand_more
How fast will it go afterwards?expand_more
Will it be road legal where I operate?expand_more
Does one kit fit every displacement?expand_more
How is the kit warranted?expand_more
Get a kit list and quotation for your vehicle
Send the original brand and chassis model, displacement, everyday payload, daily distance and destination port. We will size the kit, return FOB / CIF pricing and container scheduling, and attach the shipping document list.
- Kit configuration advice and pricing within 24 hours on working days
- Sample kits available to prove bracket holes and harness length before you commit to a container
- Chassis and market-access documents are strictly confidential; NDA available first
Specification notice:The figures above are engineering reference values. They may differ with production batch, configuration and actual duty cycle, and the percentages for life, efficiency, availability and coverage are engineering estimates and bench references. Contact us for the detailed specification sheet.
The chassis details and conversion plans you submit are used only for kit selection and remain strictly confidential.