ElectricMotorcycleForum.com
Makes And Models => Zero Motorcycles Forum | 2012 and older => Topic started by: Doctorbass on December 12, 2013, 01:02:34 PM
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Having dead 2kWh zero battery? Looking for a working and great shape replacement battery?
I'm your man!.. These battery are becoming very rare and difficult to get even with Zero themself so i decided that it's time to make something of my (like new) 4kWh DS 2010 battery !
I am rebuilding two 2kWh battery compatible with for 2009-2011 X, XU or MX.
I got two deffective 2kWh battery with low cells that i'm rebuilding with original great shape cells coming from a perfect shape 4kWh DS 2010 battery of 2300km ( like new).
Let me know if you are looking for a like new 100% working battery very close to original capacity.
I'm looking for about 950$ each. Labor on each battery is about 20-25hours of dissassembly and testing and reassembly.
Yes i will post it in the item for sale as well..
Doc
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Zero does rebuild the older packs, but I don't think they handle very many of them. What a great community service : )
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Since I have not been able to sell my 2010 DS for $2K, I've been thinking I should do something with the battery. It has very little usage and I've always kept it plugged in so it hasn't self discharged. Too bad you are way up there in Canada, Doc.
Trikester
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Doc , might help if you add "Are you" to the start of the forum title.
It read like you are asking for those batteries instead of you wanting to sell them.
Enjoy reading about your projects and the knowledge you share.
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Doc , might help if you add "Are you" to the start of the forum title.
It read like you are asking for those batteries instead of you wanting to sell them.
Enjoy reading about your projects and the knowledge you share.
Thanks...!
Done
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interesting work. When you talk about the original capacity, I'm wondering, what real capacity is the experience. I've a 2011 XU, and whatever I do, the max charge I measured was 1.6 kWh, whereby typically when I ride the bike to a level where the engine stops, the battery charge is then in the range of 1.5kWh, and I wonder, if this is really the full capacity of a 2kWh battery, or if something is broken. Is there any experience on this, or a simple method to test, if the battery is fine?
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2011 XU was rated at 2.0 kWh maximum capacity, which is a ****** stupid metric. This is calculated in the following way:
14 cells in series * 4.2 volts/cell = 58.8 volts maximum
34 Ah (approx) * 58.8 volts maximum = 1999 Wh
You will never be able to store or draw 2 kWh out of Zero's "2 kWh" "maximum capacity" modules.
As new, in the real world you could expect to get something closer to the nominal capacity out of the battery, which is around 14 series * 3.7 volts/cell * 34 Ah = 1.76 kWh. Probably less, as typically the cell nominal capacity rating is at a C/2 or C/3 discharge rate, and your average discharge is probably closer to 2C.
1.6 kWh to charge and 1.5 kWh discharged from a 2011 battery sounds relatively healthy to me.
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thanks, this helps to understand a bit of the numbers I see on my wattmeter!
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Doc,
Do you have any of these batteries left? I have a 2011 Zero X and wouldn't mind having a spare.
Chuck
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Do you have any packs left? I an looking for one for my 2010 zero mx. Vancouver B.C Canada
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What cells are you using? The old Molicel, or the new EIG?
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I just picked up a 2010 Zero S . The battery pack is dead. Do you have any more rebuilt packs?
Thanks
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What country are you in?
Have you measured the voltage of the battery yet to see what it is?
What is the history of the bike?
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I'm in the US.
The voltage is 0. The pack has been dead for about 3 years. It's just been sitting in some guys garage, unplugged, since early 2012.
I just picked the bike up over the weekend.
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The problem you will have is putting more cells in than there are wires for the bms so there is effectively no way for the extra cells to be monitored or charged. Either you will have to fool the bms some way or use you own bms. If you take the zero bms out then you will have to ensure the rest of the bike runs without it too.
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Does anyone still work on 2009 batteries? I have five that don't work. I'm looking for repair/rebuild to make a good one.
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Nissan Leaf Cells/pack are a good replacement for original cells, few have rebuilt packs with these. They lighter, more capacity and no voltage sag under load.
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The physical size of the Nissan Leaf batteries means that you can't fit it in the same space that the old Zero battery went in.
We are still rebuilding packs Martymar, you are welcome to PM me. What country are you in? ( tell us some more detail about your project and what you want to achieve...)
If you have 5 batteries you can maybe strip them all down and harvest the decent cells to make one good one, but that will not help you if you also have 5 bikes to go along with them!
We have recently done a rebuild with EIG cells which is lighter and more powerful,than the Molicel.
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Old thread.. but has Anyone transplanted gen1 LEAF modules in a 2010 MX? Did not realize how large they were. Looking for options to get this bike running again, guessing will have to get creative with cell placement...
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It’s not possible without bi-locating the cells or modifying the chassis because they are too big to fit in the battery space.
Much easier to just fit a set of EIG cells which fit like a glove and are lighter which is what I did
If you are in the UK I have some spare.
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I've added this thread to the references section for the unofficial manual article: https://zeromanual.com/wiki/Gen1/Battery_Rebuild