Connecting to The Kelly Controller

Before diving in, take some time to practice connecting to the ONYX RCR Kelly controller. You can do this using either an Android Phone or Tablet, ensuring you have the necessary app installed. A Windows Laptop: You’ll need the appropriate software, a USB-to-RS232 cable, and a JST SM 4-pin adapter.

ONYX RCR Stock Kelly Controller

Purchase options:

  • 72v
  • 300a
  • Waterproof
  • Field Weakening
  • Hall Sensor
  • Waterproof Connector
  • Bluetooth Adapter

Top Speed

The information provided here will not increase the top speed. Instead, it focuses entirely on improving torque and acceleration.

Increasing Acceleration

Enhancing the torque and acceleration of the Onyx RCR can make the bike challenging to handle when pushed to its limits. With experience and gradual adjustments to power levels, what initially feels unpredictable becomes manageable. The Onyx RCR, like any bike with a gyroscopic effect, naturally wants to travel straight. Proper application of acceleration is key, as improper handling can lead to issues like speed wobbles, which can often be mitigated by keeping a light grip on the handlebars and avoiding excessive weight on them.

Important Precautions

  • Never walk beside the bike when it’s powered on. Accidental throttle activation can cause the bike to lurch forward uncontrollably.
  • Familiarize yourself with emergency motor cut-offs. Learn to use the regen brake, kill switch, and throttle-off techniques effectively. At full power, the bike demands precision and offers no room for error. Without a tight throttle control, one mistake can lead to immediate consequences.

Mastering High Power

Once you’ve honed your skills with the increased power settings, the bike becomes a thrilling and powerful machine. Mastery of control at higher power levels allows you to experience its full potential. Interestingly, even at 100% power, you can achieve the same range as stock settings—provided you throttle carefully and efficiently.

However, as power increases, many riders unconsciously adjust their throttle habits, often leading to faster battery depletion. Maintaining disciplined throttle control is crucial to balance performance and efficiency.

Requirements Checklist

The Onyx RCR comes set at 35% of its power potential, delivering 7800 watts. Before increasing the power, it’s essential to address both thermal management and the rider’s experience handling the bike. Incremental power adjustments are recommended to allow the rider to adapt to the increased performance as settings are dialed up.

Preparing the Onyx RCR with the following requirements is crucial before modifying the controller settings. Increased power generates more heat in both the controller and motor, so effective cooling measures are necessary. While adding vents to the side panels or installing a fan can improve controller cooling, relocating the controller outside the bike offers the best results.

Preparation Steps

Rear Axle

  • Tighten the rear axle nuts as securely as possible.
  • Apply thread locker to ensure they remain firmly in place.
  • Upgrade to the latest rear axle plates designed by Ryan Dean.

Controller Cooling

  • Ideally, relocate the Kelly controller to the exterior of the bike for optimal cooling.
  • If relocation isn’t feasible, add vents to the side panels to improve airflow and reduce heat buildup.

Once these steps are completed, you can safely begin increasing the controller settings to unlock the bike’s full potential.

  • Statorade
  • Hubsinks
  • Chain Tensioner
  • OSE 8 connector
  • Threadlocker
  • Controller Relocation
  • Thicker Motor Stays
  • Double Velcro Battery Strap

Battery Compatibility

All modifications detailed here are compatible with the stock Onyx 23Ah and 41Ah batteries, as well as any Lite Speed Bikes battery. The more powerful the battery, the greater the potential power output:

  • Amorge Batteries (Molicel P45B, P50B, Samsung 50S): Over 20,000 watts.
  • Onyx 41Ah Battery: Up to 17,000 watts.
  • Onyx 23Ah Battery: Up to 11,000 watts.

Battery Connector Upgrade

The stock Onyx SB50 connector is rated for 50 amps, which is insufficient for the output of the Onyx 23Ah and 41Ah batteries, as well as Lite Speed Bikes batteries, especially after increasing the “Bat Current Limit” setting on the controller from 55A to 100A.

To ensure safe and efficient power delivery:

  • Replace the stock SB50 connector on both the bike and the Onyx batteries (23Ah and 41Ah) with an OSE 8 connector rated for 200 amps.
  • All Amorge batteries come equipped with OSE 8 connectors and include an OSE 8 replacment battery cable, providing an easy path to upgrade the stock battery’s connector.

This upgrade is essential to handle the increased current safely and to maximize performance.

v1.5 Battery Connector Fuse

The Onyx RCR 1.5 comes equipped with an inline (red wire) 100-amp fuse:

  • Onyx 23Ah Battery: Capped at 55A with a peak of 70A, unlikely to trigger the fuse unless there’s a short.
  • Onyx 41Ah Battery: Capped at 80A with a peak of 90A, which has a slight chance of triggering the fuse.
  • Amorge Batteries: Capped at 100A with peaks of 150A, likely to trigger the fuse.
  • NAB Battery: Capped at 150A with peaks of 400A, will definitely trigger the fuse.

Recommendation

If using the Onyx 41Ah battery, Amorge, or NAB battery, remove the fuse before increasing the power settings.

  • Inline fuses cannot be reset, so you would need to carry spares if you choose to keep it.
  • To remove the fuse, either solder the line together or replace it completely.

Both Amorge and NAB batteries and the Onyx 23Ah and 41Ah batteries have built-in protection mechanisms, as does the controller, which should be sufficient. If you prefer an inline protection mechanism, consider using a legitimate breaker, like the ones found in Sur Ron bikes.

Operating Max Temperatures

During hot summer days (above 85°F ambient), the Onyx RCR controller and motor can experience thermal limitations:

  • Controller: Reduces power output (“limp mode”) when it reaches 248°F (120°C).
  • Motor: Hits limp mode when it reaches 212°F (100°C).

These thermal behaviors are normal and are designed to protect the components from overheating.

Used Battery Balancing

Onyx RCR batteries with fewer than 300 full charge cycles should follow the battery balancing method outlined above. Unbalanced batteries can cause the battery management system (BMS) to cut off the battery prematurely, especially when the charge is low. Regular balancing ensures optimal performance and prevents early cut-offs.

Side Panel Vents

Installing side panel vents can significantly reduce controller temperatures. On a hot 90°F (32.3°C) day, these vents can lower controller temperatures from 194°F (90°C) to 167°F (75°C) during moderate riding at speeds above 20 mph.

Controller Placement Modification

The stock Kelly KLS7230S controller performs well but is poorly positioned inside the Onyx RCR’s body, causing it to reach peak temperatures too easily during hard use on hills or hot days. Relocating the controller outside the bike resolves this issue by improving airflow and heat dissipation.

Controller Upgrade Options

If you’re upgrading your Onyx controller, the following are currently the only worthwhile replacement options.

  • FarDriver 72680, 84680, and 96680
  • Sabvoton 72200 and 96150
  • ASI BAC 8000
  • Kelly KLS7275H 500A
  • Thermo Nucular 24F

Stock Controller Relocation Instructions

  • Relocating the stock Kelly controller requires extending the power wires (not the phase wires) to mount it externally.
  • The Kelly controller is already water-sealed, making it suitable for outdoor placement and capable of handling exposure to the elements.

Adjusting Kelly Controller Settings

  • Change Output Power
  • Set “Current Percent” from 50 to 75 for 75% total output (setting it to 100 will max out the power).

Remove Battery Amp Limit

  • Adjust “Bat Current Limit” from 55 to 100 to remove the battery amp restriction.

Disengage Full-Time Regen

  • Tap the arrow in the top-right corner and set “RLS_TPS Brk Per%” from 1 to 0 to disengage full-time active regenerative braking for a true free-spinning wheel.

Adjust Acceleration Time

  • Set “Accel Time” from 5 to 4. This controls how quickly the bike delivers full power.
  • A lower value (e.g., 1) will result in extreme acceleration, such as a wheelie, which requires advanced handling skills.
  • Mastering this setting takes practice, as it greatly affects bike control.

Refine Torque and Speed Settings

  • Change “Torque Speed KP” to 4000.
  • Change “Torque Speed KI” to 110.
  • Set “Speed Err Limit” to 1100.

Save Changes

  • Once all fields are updated, tap “Write”.
  • You’ll receive a confirmation message that the changes were written successfully.

Commit Changes

  • Turn off your Onyx RCR using the kill switch for 5 seconds.
  • Turn it back on to finalize the changes in the controller.

Kelly Controller Mode Settings

The Accel Time setting is a critical factor across all modes. The stock setting of 5 delivers full power in 5 seconds. Adjusting it to 4 shortens the time to 4 seconds, offering a more responsive ride.

  • The lower the Accel Time value, the more instantaneous and aggressive the bike’s acceleration becomes.
  • Riders can customize the Accel Time to match their preferences and riding style.

Take your time experimenting with different Accel Time values to find the one that best suits your comfort and control level.

Torque Mode (65% - 9kw)

  • Current Percent: 65
  • Bat Current Limit: 100
  • RLS_TPS Brk Per%: 0
  • Accel Time: 4
  • Torque Speed KP: 4000
  • Torque Speed KI: 110
  • Speed Err Limit: 1100

Champ Mode (75% - 12kw)

  • Current Percent: 75
  • Bat Current Limit: 100
  • RLS_TPS Brk Per%: 0
  • Accel Time: 3
  • Torque Speed KP: 4000
  • Torque Speed KI: 110
  • Speed Err Limit: 1100

Plaid Mode (85% - 15kw)

  • Current Percent: 85
  • Bat Current Limit: 100
  • RLS_TPS Brk Per%: 0
  • Accel Time: 2
  • Torque Speed KP: 4000
  • Torque Speed KI: 110
  • Speed Err Limit: 1100

Sicko Mode (100% - 20kw)

  • Current Percent: 100
  • Bat Current Limit: 100
  • RLS_TPS Brk Per%: 0
  • Accel Time: 1
  • Torque Speed KP: 4000
  • Torque Speed KI: 110
  • Speed Err Limit: 1100