SPARK’s most ambitious and advanced superbike built to date. A true blend of function and form, Zephyrus was designed and manufactured to race wheel-to-wheel against (and beat) the highest performance sport bikes on the market.
Key Performance Metrics
Zephyrus packs a serious punch, supported by the powerful Emrax 268 MV axial flux motor, a Cascadia Motion CM200DZ Inverter, and our custom built power electronics.
| Peak Torque | Peak Power Output | Continuous Power Output | Estimated Top Speed |
| 500 Nm | 210 kW | 117 kW | 200 mph |
Specs
Chassis & Aerodynamics
- Chassis
- Frame & Swingarm
- Fully custom design
- 1 of 1 prototype manufactured at TEI
- Low-pressure cast A357 Aluminum
- 43 lb frame
- 21 lb swingarm
- Subframe
- Fully custom design
- CNC machined aluminum
- Inverter Mount Points
- Frame & Swingarm
- Aerodynamics
- Fully custom carbon fiber race fairings
- Rear unibody design
- 5-panel frontend
- Optimized for minimal drag, battery pack cooling, and rider shielding
- Vacuum formed windshield
- Ram-air intake
- Carbon fiber on low density PETG skeleton
- Maximizes airflow to the battery pack
- Fully custom carbon fiber race fairings
Battery
- Battery Pack
- Samsung INR21700-50S Lithium-Ion Cylindrical Cells
- Custom 141s8p Cell Array, 1128 individual cells
- Fully designed and manufactured in-house
- Embedded thermistors for thermal monitoring
- Thermal Interface Material for maximum heat dissipation
- Specs
- 400A Peak Current
- 200A Continuous Current
- 592.2V @ 100% State of Charge
- 21.1 kWh Energy Capacity
- SIGMACLAD 60 intercell busbars
- High conductivity to minimize thermal losses
- Precision laser-cut custom profiles
- Weld projections
- Hand-welded
Powertrain
- Motor
- Emrax 268 MV Axial Flux Motor
- 92-98% Efficiency
- High power density (10 kW/kg)
- 210 kW peak power
- 500 Nm peak torque
- Inverter
- Borgwarner Portland (Cascadia Motion) CM200DZ
- 225 kW max power
- 740 A(rms) peak current
- Drivetrain
- Custom machined driveshaft & sprocket
- DID 520ERV7 X-ring racing chain – 130 link
Electronics
- Battery Management System
- Dual OrionBMS 72-S modules
- 84 battery thermistors (Thermal Expansion Module)
- High Voltage Controls
- Custom junction box controller & motherboard
- Integrated inverter precharge & discharge circuit
- Isolation monitoring (Bender ISOMETER® IR155)
- Sensors
- Linear suspension travel sensors (AiM)
- Front & rear wheel speed hall sensors
- Coolant temperature NTC
- GPS & 6-axis IMU for RTK positioning
- Rider Controls
- Dual hall-effect throttle (Domino Racing)
- Manual kill switch and safety tether
- Digital brake switch for traction/drive interlock
Software
- CAN Bus
- Fully networked vehicle
- Data logged for analysis
- Instrument Cluster
- MRS Mconn 7 Display
- QT Platform User Interface
- Embedded Controls
- Fault detection & failover
- Automated inverter precharge / discharge routines
- Analog & digital sensor measurements
- Thermal monitoring
Development Timeline
Fall 2022
- Conceptualization phase for our next bike, codename FBS begins.
Winter 2023
- Refinement of prototype designs
- Early prototype development
Fall 2023
- Completed mechanical designs
- Manufacturing begins
Winter 2024
- Frame cast & fairings completed
- Battery pack manufacturing in progress
Fall 2024
- Continuing mechanical & electrical assembly
- Battery pack sub-module welding
Winter 2025
- Battery Pack assembly completed & installed
- HV & LV wiring completed
- Zephyrus completes its maiden voyage
SPARK Electric Racing 2025 