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Makes And Models => Zero Motorcycles Forum | 2012 and older => Topic started by: cheerad on September 26, 2017, 05:03:30 PM

Title: Zero DS 2011 wiring diagram
Post by: cheerad on September 26, 2017, 05:03:30 PM
Dear all,

I'm riding a 2011 DS for a couple of month now, and it drove quite well. Some weeks ago, the motor didn't start anymore after stopping at a traffic light for example. Sometimes it started after a couple of times switching on and off the ignition, sometimes I had to wait till the next day. I started checking everything, the motor, the connectors, reading out the MBB and the controller - no errors. I then measured the resistance of the throttle at the connectors to the controller, and realized that it is not connected directly, but through the MBB I guess. So to understand everything now and to find the error, I'm looking for a wiring diagram. My dealer doesn't have one, Zero in Europe tells me, that "we are not allowed sharing any technical details directly with customers regarding safety issues".
Can anybody help?

Thanks, Christoph
Title: Re: Zero DS 2011 wiring diagram
Post by: giacomo on September 26, 2017, 07:41:04 PM
Dear all,

I'm riding a 2011 DS for a couple of month now, and it drove quite well. Some weeks ago, the motor didn't start anymore after stopping at a traffic light for example. Sometimes it started after a couple of times switching on and off the ignition, sometimes I had to wait till the next day. I started checking everything, the motor, the connectors, reading out the MBB and the controller - no errors. I the measured the resistance of the throttle at the connectors to the controller, and realized that it is not connected directly, but through the MBB I guess. So to understand everything now and to find the error, I'm looking for a wiring diagram. My dealer doesn't have on, Zero in Europe tells me, that "we are not allowed sharing any technical details directly with customers regarding safety issues".
Can anybody help?

Thanks, Christoph
This is for a 2013, not sure how much it matches yours:
http://zeromanual.com/index.php/Unofficial_Service_Manual#Wiring_Diagram


Sent from my SM-G950U1 using Tapatalk

Title: Re: Zero DS 2011 wiring diagram
Post by: David_Walsh on September 26, 2017, 07:49:09 PM
Dear all,

I'm riding a 2011 DS for a couple of month now, and it drove quite well. Some weeks ago, the motor didn't start anymore after stopping at a traffic light for example. Sometimes it started after a couple of times switching on and off the ignition, sometimes I had to wait till the next day. I started checking everything, the motor, the connectors, reading out the MBB and the controller - no errors. I the measured the resistance of the throttle at the connectors to the controller, and realized that it is not connected directly, but through the MBB I guess. So to understand everything now and to find the error, I'm looking for a wiring diagram. My dealer doesn't have on, Zero in Europe tells me, that "we are not allowed sharing any technical details directly with customers regarding safety issues".
Can anybody help?

Thanks, Christoph
Chris, when I had a similar problem, swapping out the sensor for the updated one fixed it for me: http://electricmotorcycleforum.com/boards/index.php?topic=7289.msg60715#msg60715

Sent from my SM-N910H using Tapatalk

Title: Re: Zero DS 2011 wiring diagram
Post by: cheerad on September 26, 2017, 07:58:06 PM

This is for a 2013, not sure how much it matches yours:
http://zeromanual.com/index.php/Unofficial_Service_Manual#Wiring_Diagram


Sent from my SM-G950U1 using Tapatalk
Hi Giacomo,

unfortunately the 2013 diagram seems to be quite different to the 2011 diagram.
Title: Re: Zero DS 2011 wiring diagram
Post by: cheerad on September 26, 2017, 08:01:30 PM
Chris, when I had a similar problem, swapping out the sensor for the updated one fixed it for me: http://electricmotorcycleforum.com/boards/index.php?topic=7289.msg60715#msg60715

Sent from my SM-N910H using Tapatalk

Hi David,

I've got an Agni motor, the Lynch design. I've been through your thread already   :).
Title: Re: Zero DS 2011 wiring diagram
Post by: David_Walsh on September 26, 2017, 10:03:37 PM
Chris, when I had a similar problem, swapping out the sensor for the updated one fixed it for me: http://electricmotorcycleforum.com/boards/index.php?topic=7289.msg60715#msg60715

Sent from my SM-N910H using Tapatalk

Hi David,

I've got an Agni motor, the Lynch design. I've been through your thread already   :).
Oh, OK.
Thought Zero changed in 2010 - apologies.
I don't know too much about those models... You can probably get onto the motor terminals with a meter. See if you can measure voltage when you throttle it? If you do, then it is probably brushes that are the problem. How many miles on the bike?

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Title: Re: Zero DS 2011 wiring diagram
Post by: togo on September 26, 2017, 10:36:22 PM
... I'm looking for a wiring diagram. My dealer doesn't have one, Zero in Europe tells me, that "we are not allowed sharing any technical details directly with customers regarding safety issues".
....

I would recommend calling Zero Customer Service, getting your dealer a wiring diagram and whatever other technical info they need to fix the problem.

I had a problem with my throttle on my 2011 Zero S, it was pulling a little when stopped, I contacted Zero Customer Service, and it turned out to be the throttle itself, Zero shipped me a new one for a self-install.



Title: Re: Zero DS 2011 wiring diagram
Post by: cheerad on October 06, 2017, 02:56:01 AM
Oh, OK.
Thought Zero changed in 2010 - apologies.
I don't know too much about those models... You can probably get onto the motor terminals with a meter. See if you can measure voltage when you throttle it? If you do, then it is probably brushes that are the problem. How many miles on the bike?
The motor is running fine, if I just power up the Alltrax AXE controller with the motor connected to it. And I also used the original throttle. So the problem occurs, when everything is connected to the rest of the bike (the MBB).
Title: Re: Zero DS 2011 wiring diagram
Post by: David_Walsh on October 06, 2017, 01:45:30 PM
Oh, OK.
Thought Zero changed in 2010 - apologies.
I don't know too much about those models... You can probably get onto the motor terminals with a meter. See if you can measure voltage when you throttle it? If you do, then it is probably brushes that are the problem. How many miles on the bike?
The motor is running fine, if I just power up the Alltrax AXE controller with the motor connected to it. And I also used the original throttle. So the problem occurs, when everything is connected to the rest of the bike (the MBB).
OK, the MBB huh...? But no fault code shown by the led flashes?
My understanding is that the MBB checks MANY electrical components before it allows the throttle signal to influence the controller to spin the motor - but you should see a fault code series of flashes. I guess it may be a faulty MBB itself? This (Spanish) guy Manuel shows how to swap one out: https://youtu.be/D03DXtsEQXU
'course, you need a replacement MBB and Spanish to benefit...

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Title: Re: Zero DS 2011 wiring diagram
Post by: igorbaldo on October 18, 2017, 12:22:48 AM
I have taken the wiring diagram from my 2010 DS, which I believe is pretty much the same as the 2011. It's drawn by hand, so I will not post it now, but I will draw it in the computer an post it here, OK?
Title: Re: Zero DS 2011 wiring diagram
Post by: yokahoma on November 25, 2017, 04:17:32 AM
Here are some diagrams that might help. Technically it's for XU but I think the S and DS are similar.
Title: Re: Zero DS 2011 wiring diagram
Post by: cheerad on December 01, 2017, 10:44:54 PM
Here are some diagrams that might help. Technically it's for XU but I think the S and DS are similar.
That's cool, thanks a lot. I will check the bike tomorrow. Funny thing is, that the bike is running sometimes, and sometimes not. The contactor is not switching every time. I have ordered a male and a female 34 pin connector to build a short cable, which I can put between connector and MBB. On this cable I can then do all measurements while the whole system is up and running.
Title: Re: Zero DS 2011 wiring diagram
Post by: BrianTRice@gmail.com on December 04, 2017, 07:05:50 AM
Here are some diagrams that might help. Technically it's for XU but I think the S and DS are similar.

Are these yours, and can I post them to the unofficial service manual website? I'll link the thread for now.
Title: Re: Zero DS 2011 wiring diagram
Post by: igorbaldo on December 12, 2017, 07:24:28 AM
Hi guys,

I've finally finished drawing the schematics. Enjoy!  ;D ;D
Title: Re: Zero DS 2011 wiring diagram
Post by: Leroysparky on March 20, 2018, 07:40:21 AM
Igorbaldo,

That is great, thank you for doing that wiring diagram. I have a question for you.

So I just got my 2011 Zero XU and I got it with a dead battery. So I took about 4 days to slowly charge each of the 7 banks (2 of the cells that are stacked in series on top of one  another). I charged them at 1 amp with a car/motorcycle charger 6v. Until I got each bank to about 6.5 volts with a total of 45.5 volts. I kept those cells that I got to that voltage, using a computer power supply and a step up. After getting to the 45.5 volts I connected it back to the charger on the bike ant started charging!

So the battery is not in the best shape, with it being that low for well over a year. So with the way the battery is it will cut out around 38mph because it doesn't have enough amps to push out when I need it. (I tested it with another battery I built in parallel and it worked with out cutting out). I was also able to travel about 6 miles and then it would cut out completely with original battery.

So this brings me to the next step in my adventure. I took this pack that I made from 14 3.7v 24ah li-ion cells from a Ford C-Max. ( I did this to make it a faster build.)

So I got everything ready but I very sadly hooked up the BMS in  the exact opposite order needed and I fried my BMS.

With that can you, Igorbaldo or anyone else, tell me by chance what the voltage is going from the KSI to the MBB. The Br and B?

Thank you
Title: Re: Zero DS 2011 wiring diagram
Post by: BrianTRice@gmail.com on March 21, 2018, 12:41:20 AM
Hi guys,

I've finally finished drawing the schematics. Enjoy!  ;D ;D

Great! Do I have your permission to use/convert/share these on zeromanual.com?
Title: Re: Zero DS 2011 wiring diagram
Post by: igorbaldo on March 21, 2018, 12:46:33 AM
Great! Do I have your permission to use/convert/share these on zeromanual.com?

Yes, of course!
Title: Re: Zero DS 2011 wiring diagram
Post by: BrianTRice@gmail.com on March 21, 2018, 12:53:23 AM
Great! Do I have your permission to use/convert/share these on zeromanual.com?

Yes, of course!

Thank you! I'll make PNG images soon and link back here; later might work out something clearer.
Title: Re: Zero DS 2011 wiring diagram
Post by: igorbaldo on March 27, 2018, 08:11:07 PM
Igorbaldo,

That is great, thank you for doing that wiring diagram. I have a question for you.

So I just got my 2011 Zero XU and I got it with a dead battery. So I took about 4 days to slowly charge each of the 7 banks (2 of the cells that are stacked in series on top of one  another). I charged them at 1 amp with a car/motorcycle charger 6v. Until I got each bank to about 6.5 volts with a total of 45.5 volts. I kept those cells that I got to that voltage, using a computer power supply and a step up. After getting to the 45.5 volts I connected it back to the charger on the bike ant started charging!

So the battery is not in the best shape, with it being that low for well over a year. So with the way the battery is it will cut out around 38mph because it doesn't have enough amps to push out when I need it. (I tested it with another battery I built in parallel and it worked with out cutting out). I was also able to travel about 6 miles and then it would cut out completely with original battery.

So this brings me to the next step in my adventure. I took this pack that I made from 14 3.7v 24ah li-ion cells from a Ford C-Max. ( I did this to make it a faster build.)

So I got everything ready but I very sadly hooked up the BMS in  the exact opposite order needed and I fried my BMS.

With that can you, Igorbaldo or anyone else, tell me by chance what the voltage is going from the KSI to the MBB. The Br and B?

Thank you

You did it very well, but had a bad luck... I suppose that you're now trying to enable the MBB via the Br/B wires and run the bike without the BMS. I'm sorry, but I have not taken measures of circuit voltages, but in the near future I will take my battery apart and I will measure it for you.
Title: Re: Zero DS 2011 wiring diagram
Post by: Leroysparky on April 21, 2018, 01:16:11 AM
Thank you so much for taking the time to read this. I'm sorry I haven't gotten back sooner, but again thank you. Also it would be much appreciated if you could measure the voltage, when ever you can.

Have a great day. Thank you!
Title: Re: Zero DS 2011 wiring diagram
Post by: craigster on September 10, 2018, 06:42:21 AM
Hi guys,

I've finally finished drawing the schematics. Enjoy!  ;D ;D

This Diagram is fantastic thanks for making it! I have a question regarding the charger input connection... Red = Positive, Black = Negative, Green = charger detected, however what is the white wire? I know it says charge but what is its function? I am working on a 2010 project and am trying to make it capable of 2 quiq Q 1000w chargers. I am going to use thicker gauge wiring for the positive and negative cables and more resistant connection where the Black connects to the 3 others, however I am unsure what to do with the white. If anyone could let me know the function that would be greatly appreciated
Title: Re: Zero DS 2011 wiring diagram
Post by: igorbaldo on September 10, 2018, 07:10:39 AM
Well, the white wire connects directly to the BMS, so I suppose it's a start/stop charge feature provided by the BMS. The charger manual does not say what this wire is, it only mentions a white wire in the image below.