This page is part of the ONYX Platform Guide

This post is a practical technical reference for the ONYX 72V and 80V platforms.

It covers:

  • Platform specifications and design differences
  • Electrical system limits and operating ranges
  • Environmental protection and temperature management
  • Hardware dimensions and torque specifications
  • Riding technique and maintenance guidance

The information is organized as a structured reference to make it easy to understand the capabilities, limits, and safe operating practices of both ONYX platforms.

Platform System

Platform Differences

Feature72V ONYX80V ONYX
FrameSteel 1020 / 1026 DOMAluminum 6082-T6
Battery System72V80V
MotorQS205 V3 / V3TiCustom 80V Motor
ControllerKelly 7230Custom Controller
TiresTubeTubeless
BrakesRegen + Hydraulic FrontDual Hydraulic
DisplayCT-22Color Touch Display

Performance Levels

PlatformModekWHP
72VStock7.29.6
72VSICKO MODE2026.8
72VJAWS MODE38.952.2
80VNormal810.7
80VSports1824.1
80VHyper2229.5

Values above stock depend on controller configuration, battery capability, and system design. Modified builds can vary significantly from stock output.

Weight & Load

PlatformBikeBike without BatteryBatteryMax LoadRear Rack
72V145 lb110 lb35 lb385 lb40 lb
80V150 lb115 lb35 lb385 lb45 lb

Dimensions

PlatformLengthWidthHeight STDHeight STY
72V ONYX68" (5.67')27"40"38"
80V ONYX69" (5.75')27"40"38"

Seat Dimensions

SeatValue
Seat Size19" long × 7" wide × 4" high
Seat Foam Thickness2"
Seating Length16"
Seat Travel Adjustment3.2"
Standard Seat Height33"
Shorty Seat Height31.5"

Tire Specifications

PlatformDiameterConstructionPressure
72V23"Tube Tire32-35 PSI
80V23"Tubeless Tire32-35 PSI

Tire Usage Notes

  • Recommended brands: Michelin, Pirelli, Shinko, Continental
  • Use 2mm-3mm thick tubes for improved puncture resistance
  • Avoid tire sealants (can cause imbalance and internal rim corrosion)

Materials

Component72V ONYX80V ONYX
FrameSteel 1020 / 1026 DOMAluminum 6082-T6
Rear Swing ArmSteel 1020 / 1026 DOMAluminum 6082-T6
Battery CaseSteel 1020 / 1026 DOMAluminum 6061-T6
HandlebarsAluminum 6061-T6Aluminum 6061-T6
Front ForksSteel 1020 / 1026 DOMAluminum 7005-T6
Rear SuspensionSteel 1020 / 1026 DOMSteel 1020 / 1026 DOM
Rear RackSteel 1020 / 1026 DOMAluminum 6061-T6

Electrical System

Battery Specifications

BatteryVoltageContinuousPeak / Pulse
ONYX 45Ah72V / 80V120 A180-200 A
ONYX 41Ah72V90 A120 A
ONYX 38Ah72V80 A100 A
ONYX 23Ah72V50 A70 A

Peak: 0.5-5 seconds
Pulse: 5-30 seconds

Battery Configuration

Pack Configuration

BatteryConfiguration
ONYX 45Ah20S9P
ONYX 41Ah20S8P
ONYX 38Ah20S7P
ONYX 23Ah20S4P

Battery Operating Range

PlatformFull VoltageEmpty VoltageStorage VoltageMax Regen
72V83-84 V60 V72-79 V40 A
80V91-92 V66 V80-87 V40 A

Empty voltage and regen behavior vary under load, temperature, and controller settings. These values are best treated as reference ranges, not fixed under-throttle readings.

Battery Connectors

PlatformCharge ConnectorDischarge Connector
72VXLR / XT60 16 AWGSB50 (≤2024), QS8 (2025+) 8 AWG
80VHIGO S824B / QS9 Adapter 14 AWGQS9 6 AWG

Battery Technical Specifications

BatteryStandard ChargeLongevity Charge
ONYX 45Ah10A5A-8A
ONYX 41Ah5A3A-5A
ONYX 38Ah5A3A-5A
ONYX 23Ah5A2A-4A

Temperature and Storage Limits

All values below refer to battery pack behavior. Ambient temperature, internal cell temperature, and BMS protection thresholds are unified here to eliminate overlap.

Condition°F°C
Storage (Recommended)50°F-77°F10°C-25°C
Charge Recommended40°F-105°F4°C-40.5°C
Charge Minimum32°F0°C
Charge Maximum113°F45°C
Discharge Minimum-4°F-20°C
Discharge Maximum (System Limit)140°F60°C

Internal Battery Temperature and BMS Behavior

These values reflect actual ONYX BMS protection behavior under load.

Condition°F°C
Normal Operating Range<120°F<49°C
Elevated Temperature (Stress Zone)120°F+49°C+
BMS Cutoff (Discharge Disabled)140°F60°C
BMS Recovery (Discharge Restored)135°F57.2°C

BMS Protection Thresholds (Updated Thermal)

ProtectionTriggerRelease
Cell Over Voltage4.25V4.15V
Cell Under Voltage2.70V3.00V
Pack Over Voltage (72V)85.0V83.0V
Pack Under Voltage (72V)54.0V60.0V
Charge Over Temp55°C (131°F)45°C (113°F)
Discharge Over Temp60°C (140°F)57.2°C (135°F)

Thermal limits are BMS-enforced, not just recommended. The system has minimal buffer between maximum operating temperature and shutdown.

Cell Specifications

PackCellChemistryCapacityInternal ResistanceCycles
72V 45AhTenpower 50SGNCA~5000mAh~12-18 mΩ~700
72V 41AhKOK 45NMC~4500mAh~13-20 mΩ~700
72V 38AhLG MH1NMC~3200mAh~20-30 mΩ~500
72V 23AhPanasonic NCRPFNMC~2900mAh~25-35 mΩ~500

Battery Performance

BatteryRange
ONYX 45AhEco 120 miles / Normal 70 miles / Sport 45 miles
BatteryOutput Behavior
ONYX 45AhConstant 100A / Boost 130A (8 min) / Peak 180A (3 sec)

Detailed range and output behavior are only listed where reliable pack-specific data is available.

Range and output behavior vary with rider weight, speed, terrain, temperature, battery condition, and BMS configuration.

Battery Dimensions

BatteryLengthHeightWidthWeight
ONYX 41Ah14.09"7.28"4.9"37 lb
ONYX 23Ah13.9"5.2"4.3"25 lb

Battery Tray Measurements

Tray VersionLengthHeightWidth
v1.514.25"7.3"5.5"
v1.214.25"7.3"5.25"
v1.014.25"7.3"5.0"

Fitment Notes

  • Tray width increases across revisions: v1.0 -> v1.2 -> v1.5
  • The 41Ah battery closely matches tray length and height, with width being the primary constraint
  • The 23Ah battery provides additional clearance, improving ease of installation and airflow
  • Always verify internal clearances before installing aftermarket or modified battery packs

Controller Summary

PlatformControllerStock Power Levels0-30 mph
72VKelly 7230Eco 750W / Normal 3kW / Sport 7.2kW / Sicko 20kW~4.0 s
80VCustomEco 750W / Normal 6kW / Sport 18kW / Hyper 22kW~1.7 s

Headlight Wiring

PlatformWireFunction
72VBlackNegative
72VYellowDRL
72VBlueHigh Beam
80VBlackNegative
80VRedDaytime
80VYellowLow Beam
80VBlueHigh Beam

Left Handlebar Controls (72V Wiring Reference)

When replacing or upgrading the left handlebar controls on the 72V ONYX platform, the stock ONYX RCR control assembly should be used whenever possible.

Aftermarket controls can be used, but wire mapping must be verified and corrected. Incorrect pinout will result in non-functioning lights, turn signals, or horn behavior.

Function Overview

  • High beam switch uses a dual-position circuit
  • Turn signal uses a 3-position switch (left / neutral / right)
  • Horn is momentary
  • USB circuit (if present) is independent power

Aftermarket Control Mapping #1

FunctionPostionStock WireAftermarket Wire
High BeamOnWhiteYellow
High BeamOffGreyBlack
Turn SignalLeftGreenGreen
Turn SignalNeutralRedBlue
Turn SignalRightBlueRed
HornOnYellowPink
HornOffBrownBrown
USB(+)PurpleNone
USB(-)BlackNone

Aftermarket Control Mapping #2

FunctionPostionStock WireAftermarket Wire
High BeamOnWhiteYellow
High BeamOffGreyYellow
Turn SignalLeftGreenBlack
Turn SignalNeutralRedRed
Turn SignalRightBlueGreen
HornOnYellowYellow
HornOffBrownYellow
USB(+)PurpleNone
USB(-)BlackNone

Taillight Wiring

WireFunction
BlackGround
BlueRunning light
RedBrake light

12V System Limits

The ONYX 12V DC converter outputs 10A total.

Example load calculation:

  • 75W ÷ 12V = 6.25A draw

This leaves:

  • 3.75A remaining capacity

Guidelines:

  • Avoid exceeding 14A on a single 18 AWG wire
  • Upgrade to 15A-20A DC converter for high accessory loads

Wire current limits vary with insulation, run length, bundling, and ambient temperature. Treat 14A as an upper reference point, not a universal continuous rating.

Motor System

Electrical Characteristics and Output Profile

Category72V Motor80V Motor
Motor PlatformQS 205 Motor (variant)QS 205 Motor (variant)
Stator Size205mm class205mm class
Magnet Height50H50H
Dropout Width150mm200mm
Axle Cable Exit270° cable exit0° cable exit
Winding4T4T
RPM@ 72V 820 RPM@ 80V 930 RPM
Rated Power5000W5000W
Peak Power10-20kW10-20kW
Continuous Current100A100A
Peak Current150A150A
Torque180 Nm180 Nm
Efficiency~88-90%~88-90%
Phase Wires~10mm² (8 AWG)~10mm² (8 AWG)
Cooling CapabilityStrongStrong (same core, routing-dependent)
Weight30 lbs35 lbs
Wheel TypeCrossed spoke / rimCast mag

Core Characteristics

  • Same motor core (QS205 platform)
  • Same torque ceiling (180 Nm)
  • Same thermal limits
  • Same real power capability (10-20kW range)

Performance parity comes from shared stator geometry and magnetic structure. Winding differences affect behavior, not ceiling.

  • Dropout width (150mm vs ~200mm) -> fitment only
  • Wheel format -> spoke vs mag
  • Weight -> wider/fat configurations add mass and reduce thermal efficiency slightly

These differences are mechanical, not electrical.

  • Not more powerful
  • Not higher torque

Environmental System

IP Ratings

ComponentYearModelIPImpact
Battery202545Ah55C4
Battery202241Ah55C4
Battery201823Ah55C4
Motor2018-2022QS205 V3 / V3Ti65—
Controller2018-2025Kelly 723067—
Display2018-2025Display64—

IP ratings may vary by production year, supplier revision, or updated component design.

Ingress Protection Explanation

Solid ObjectsWater
0 No protection0 No protection
1 >50 mm objects1 Vertical drops
2 >12.5 mm objects2 Drips at 15°
3 >2.5 mm objects3 Spraying water
4 >1 mm objects4 Splashing water
5 Dust protected5 Water jets
6 Dust tight6 Powerful jets
7 Temporary immersion
8 Continuous immersion
9 High pressure jets

Thermal System

Target Operating Temperatures

Fahrenheit

ComponentGoodOkayHigh
Motor120°F150°F248°F
Controller105°F130°F176°F
Battery<120°F120°F+140°F

Celsius

ComponentGoodOkayHigh
Motor48°C65°C120°C
Controller43°C54°C80°C
Battery<49°C49°C+60°C

Motor Temperature Limits

ONYX hub motors use NdFeB neodymium magnets.

Key thresholds:

  • 120°C / 248°F ideal sustained ceiling
  • 150°C / 302°F caution zone
  • 180°C / 356°F insulation damage risk
  • 200°C / 392°F permanent demagnetization likely

Battery Temperature

Battery thermal behavior is defined by the Electrical System section above. This section summarizes real-world implications.

  • Storage: 50°F-77°F (10°C-25°C)
  • Charge Limits: 32°F-113°F (0°C-45°C)
  • Charge Recommended: 40°F-105°F (4°C-40.5°C)
  • Discharge Maximum: 140°F (60°C)
  • BMS Cutoff: 140°F (60°C)
  • BMS Recovery: 135°F (57.2°C)

Behavior Under Load

  • 120°F+ (49°C+) enters a high-stress zone
  • 140°F (60°C) triggers immediate BMS shutdown
  • Recovery occurs at 135°F (57.2°C), creating a narrow thermal band

This results in:

  • Rapid cutoff if pushed hard at high temps
  • Possible thermal cycling (cutoff -> recover -> cutoff)
  • Increased cell degradation if repeatedly operated above 49°C

Cold Weather Impact

Effect°C°F
10% range loss-130
15% range loss-228.4

Controller Temperature

Condition°C°F
Cutoff100212
High80176
Okay70158
Good50122

External controller mounting dramatically improves cooling at higher power levels.

Battery and Cell Voltage Chart

The amount of time a battery cell stays above 4.2V or below 2.5V is critical. A few seconds might be tolerable, but staying in those ranges for minutes or hours significantly increases the risk of thermal runaway above 4.2V or permanent cell damage below 2.5V.

Cell VoltsDescription
4.50vThermal Runaway Risk
4.45vThermal Runaway Risk
4.40vThermal Runaway Risk
4.35vThermal Runaway Risk
4.30vThermal Runaway Risk
4.25vOvercharge / Degradation
4.20v100% (Full Charge)
4.15vNear Full (Common BMS Limit)
4.10v
4.05v
4.00vHigh State of Charge
3.95v
3.90v~75%
3.85v
3.80v
3.75v
3.70vNominal Voltage
3.65vNominal Voltage
3.625v~50%
3.60v
3.55v
3.50v
3.45v
3.40v
3.35v
3.30v~25%
3.25v
3.20v
3.15v
3.10v
3.05v
3.00vTypical Cutoff (Not True 0%)
2.95v
2.90v
2.85v
2.80v
2.75v
2.70vDeep Discharge (Cell Stress)
2.65v
2.60v
2.55v
2.50vMinimum (Damage Threshold)

This chart is best used as a reference guide. Resting voltage, loaded voltage, BMS tuning, and battery chemistry can shift where these thresholds appear in real-world use.

Mechanical System

Brake Disc Measurements

PlatformPartMeasurement
72VRear Disc220 mm × 2 mm
80VRear Disc220 mm × 3 mm

PCD: 6 × 44 mm
Center Bore: 32 mm

Hardware & Torque Specifications (72V)

Proper torque application is critical for structural integrity and component longevity. Threadlocker is recommended where applicable.

Brakes (72V)

PartHardwareToolTorque
Front Caliper Mounting Plate TopM8 x 35mm13mm Socket30Nm
Front Caliper Mounting Plate BottomM8 x 40mm13mm Socket30Nm
Front Caliper Mounting PlateM8 x 35mm13mm Socket30Nm
Rear Brake Caliper Mount ScrewsM65mm Hex12Nm
Rear Brake Caliper Adjuster ScrewsM65mm Hex12Nm
Rear Brake Caliper Cable Stay ScrewM65mm Hex12Nm

Wheels (72V)

PartHardwareToolTorque
Front Axle NutsM12 Hex Nut19mm Socket45Nm
Rear Axle NutM16 Hex Lock Nut24mm Socket30Nm
Rear Axle Lock NutM16 Hex Lock Nut24mm Socket30Nm
Rear Axle Stay ScrewM6-1 x 16mm + M6 Hex Nut10mm + 5mm Hex12Nm

Rear axle torque values vary by axle hardware, dropout arrangement, and locking method. For high-power builds, verify final torque against the specific axle and hardware configuration in use.

Suspension (72V)

PartHardwareToolTorque
Triple Tree Fork ClampM8 x 45mm6mm Hex30Nm
Rear Swingarm Mounting HardwareM8 x 25mm + M8 Nyloc Hex Nut13mm Socket + 6mm Hex30Nm
Upper Shock NutM8 Acorn Hex Nut13mm Socket30Nm
Lower Shock NutM8 + M8 Hex Nut13mm Socket30Nm

Suspension Specifications (72V)

ComponentSpecification
Rear Suspension Standard350mm
Rear Suspension Shorty300mm
Rear Suspension Bushing15mm L × 14mm OD × 9mm ID

Pedals (72V)

PartHardwareToolTorque
Pedal Shaft Cotter Pin NutM8 x 45mm6mm Hex30Nm
Pedal ShaftM8 x 25mm + M8 Nyloc Hex Nut13mm Socket + 6mm Hex30Nm

Steering and Handlebars (72V)

PartHardwareToolTorque
Steering Stem Lock NutM20 Hex Nut30mm Socket22Nm
Steering Stem Top NutM20 Hex Cap Nut30mm Socket40Nm
Handlebar Clamp ScrewsM6 x 45mm + M6 Nyloc Nut10mm Socket + 5mm Hex12Nm
Speedometer Display MountM4 Hex Nut7mm SocketHandtight
Speedometer Display Bracket ClampM6 x 12mm + M6 Hex Nut10mm Socket + 5mm Hex12Nm
Left Control Internal Handlebar ScrewsM5 x 10mm#2 Philips Screwdriver7Nm
Left Control External Casing ScrewsM5 x 22mm#2 Philips Screwdriver7Nm
Right Control, Front Brake Banjo NutM8 Hex Nut13mm Socket12Nm
Right Control, Front Brake Mount Clamp ScrewM5 Hex Nut8mm SocketHandtight
Right Control, Throttle/Kill Switch Clamp ScrewM4 x 20mm3mm HexHandtight
Headlight Ears Clamp BoltM6-1 x 25mm10mm SocketHandtight
Headlight Side Mount BoltsM6-1 x 15mm10mm SocketHandtight

Drivetrain & Components (72V)

ComponentSpecification
Pedal Crank28T
Pedal Crank Bushing18.4mm L × 20.5mm OD × 16.4mm ID
Freewheel16T
Chain112 Links
Kickstand11"
Rim Size17" × 1.6"

Body Panel & Accessories (72V)

PartHardwareToolTorque
Body PanelsM5-0.8 x 6mm4mm Hex KeyHandtight
Seat MountsM6 Hex Nut10mm SocketHandtight
Front Fender MountsM6 x 25mm10mm Socket12Nm
Rear Fender MountsM6 x 16mm + M6 Hex Nut10mm Socket12Nm
Rear Rack Shock MountsM8 Acorn Hex Nut13mm Socket30Nm

Operation System

Riding Technique

72V ONYX Braking

The 72V platform uses regenerative braking through the left lever.

Typical braking distribution:

  • 80% regenerative braking
  • 20% front hydraulic brake
  • Rear brake used rarely

Avoid heavy regen above 83V on a full battery to prevent controller cutouts.

80V ONYX Braking

The 80V platform uses dual hydraulic disc brakes.

Recommended braking distribution:

  • 70% front brake
  • 30% rear brake

This follows standard motorcycle braking dynamics where weight transfer increases front traction during deceleration.