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Author Topic: SAFETY ISSUE: my front fork is breaking apart after only 4000kms  (Read 1563 times)

Le Z Turbo

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I noticed a oil leak on the front fork, left side. I thought of a oil seal leak but a member of the forum told me he had the problem coming the lower part of the fork. Indeed as shown on my other post, the fork is leaking between the lower tube and the forged part retaining the wheel and the front brake.
But as I was investigating I discovered that the tube is free to rotate !!! I don't know if my front wheel is still retained by the left side of the fork !!!! I'M GOING TO DIE !!!

I made this small video:
I'm not the first one to have this issue.... Check your fork, I think the oil starting to leak is a good symptom. I think it's coming from the part retaining the brake caliper getting hot, then cold, then hot again at each breaking, cold, hot, etc....

Problem is my dealer in France stop making Zero, he is trying to reach the french representative by phone but nobody want to answer him. My rear shock is out leaking since 3 months, I had to replace it with a longer lengh, lower stroke DNM one. I'm a little on my own on these issues now, I'm feeling a bit lonely.

A little help from Zero or someone knowing how to fix the fork would be appreciated !!!

Also may I insisted that the only trouble with my bike are these suspensions and that I really enjoy this bike a lot. Maybe the 2014 have better suspension parts.
Laurent
« Last Edit: June 30, 2014, 08:14:16 PM by Le Z Turbo »
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firepower

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Re: SAFETY ISSUE: my front fork is breaking apart after only 4000kms
« Reply #1 on: June 30, 2014, 05:19:00 PM »

Contact aaronzeromoto
@aaronzeromoto
Zero Motorcycles
Director of Customer Experience
send him a PM he should be able to help you.
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Le Z Turbo

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Re: SAFETY ISSUE: my front fork is breaking apart after only 4000kms
« Reply #2 on: June 30, 2014, 05:43:24 PM »

Doing that right away, thanks !
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Richard230

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Re: SAFETY ISSUE: my front fork is breaking apart after only 4000kms
« Reply #3 on: June 30, 2014, 08:21:19 PM »

Having owned a 2012 S (which has the same fork as the 2013 S, I believe) and now a 2014 S, I can confirm that the larger 2014 S front suspension is a big improvement in performance compared with their smaller previous version.  Hopefully, they will also turn out to be more robust and more reliable.
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Richard's motorcycle collection:  2018 16.6 kWh Zero S, 2016 BMW R1200RS, 2011 Royal Enfield Bullet 500 Classic, 2009 BMW F650GS, 2005 Triumph T-100 Bonneville, 2002 Yamaha FZ1 (FZS1000N) and a 1978 Honda Kick 'N Go Senior.

CliC

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Re: SAFETY ISSUE: my front fork is breaking apart after only 4000kms
« Reply #4 on: June 30, 2014, 08:47:31 PM »

The front forks have been the only real problem with my 2012 DS. I realize why Zero went with what they did, but i suspect a few Empulse owners didn't mind paying more for some higher-end components. Now that Zero has their powertrain sorted, I hope they focus on the other parts of the bike a bit more, especially if the 2014s have suspension reliability issues (beefier forks, but same supplier).
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Le Z Turbo

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Re: SAFETY ISSUE: my front fork is breaking apart after only 4000kms
« Reply #5 on: June 30, 2014, 10:41:48 PM »

Mine is a 2013 DS, maybe the 2014 won't suffer the same flaws ? And are the 2014's suspensions adaptable the 2013 frame ? I don't think so, new steering tube with different bearing size I think.
Laurent
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BSDThw

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Re: SAFETY ISSUE: my front fork is breaking apart after only 4000kms
« Reply #6 on: June 30, 2014, 11:19:33 PM »

Some weeks ago I saw a 2013 FX with a 2014 FX fork. I don't know if there is additional work to do but I can ask.
Also they use the DS fork in a FX supermoto to have the correct brake holder. It seems everything should be exchangeable.
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frodus

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Re: SAFETY ISSUE: my front fork is breaking apart after only 4000kms
« Reply #7 on: June 30, 2014, 11:48:01 PM »

The front forks have been the only real problem with my 2012 DS. I realize why Zero went with what they did, but i suspect a few Empulse owners didn't mind paying more for some higher-end components. Now that Zero has their powertrain sorted, I hope they focus on the other parts of the bike a bit more, especially if the 2014s have suspension reliability issues (beefier forks, but same supplier).

FWIW: I will say that the higher quality componentry definitely swayed me towards purchasing my Brammo Empulse.

lolachampcar

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Re: SAFETY ISSUE: my front fork is breaking apart after only 4000kms
« Reply #8 on: July 01, 2014, 12:27:01 AM »

I suspected the problem had to do with the brake caliper's fatigue cycling the lower fork leg casting until it failed.

You can see how this casting is removed 4:45 into this video-


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kingcharles

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Re: SAFETY ISSUE: my front fork is breaking apart after only 4000kms
« Reply #9 on: July 01, 2014, 12:47:22 AM »

The front forks have been the only real problem with my 2012 DS. I realize why Zero went with what they did, but i suspect a few Empulse owners didn't mind paying more for some higher-end components. Now that Zero has their powertrain sorted, I hope they focus on the other parts of the bike a bit more, especially if the 2014s have suspension reliability issues (beefier forks, but same supplier).

FWIW: I will say that the higher quality componentry definitely swayed me towards purchasing my Brammo Empulse.
+1
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lolachampcar

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Re: SAFETY ISSUE: my front fork is breaking apart after only 4000kms
« Reply #10 on: July 01, 2014, 04:41:59 PM »

The only problem I see with the Bramo comments is that Zero has a much better chance of being around in a few years.  Resale was a concern for me which is why I went with Zero (knowing they were using crap pit bike suspension).
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frodus

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Re: SAFETY ISSUE: my front fork is breaking apart after only 4000kms
« Reply #11 on: July 01, 2014, 10:29:23 PM »

I don't think they're going away. Brammo has gotten grants from Oregon, secured several rounds of investors and is selling bikes all over the world. I think both motorcycle companies have a high liklihood they'll be around in the coming years.

I will say that having the Brembo/Sachs/Marzocchi/Parker parts, I'll have a very high liklihood of being able to find parts when I need them, and a low liklihood that they'll have issues. With Fast Ace/Nissin/J-Juan, I'm not so sure that will be the case.




peter

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Re: SAFETY ISSUE: my front fork is breaking apart after only 4000kms
« Reply #12 on: July 02, 2014, 03:16:24 AM »

If I had to bet a carton of beer (OAMOB)* on which company will survive, I'd put my beer on the one without the string of dissatisfied customers, and without the problem with component failures.

And Laurent, thanks for the video.
Peter

*Old Australian Measure Of Betting
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lolachampcar

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Re: SAFETY ISSUE: my front fork is breaking apart after only 4000kms
« Reply #13 on: July 02, 2014, 04:02:42 AM »

I hope they do indeed both make it.  I suspect there is plenty of room for several good options.

Now if Mission would just start shipping................


This is going a bit off topic, but does anyone have a feel for the relative production volume between Bramo and Zero.  I had the impression Zero was way ahead but then that is simply an impression and not based on any facts.  If Zero does have more product in the field, I would expect them to have more activity on the problem front.
« Last Edit: July 02, 2014, 04:04:42 AM by lolachampcar »
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Richard230

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Re: SAFETY ISSUE: my front fork is breaking apart after only 4000kms
« Reply #14 on: July 02, 2014, 04:08:21 AM »

If either company stops producing motorcycles, I think it will only be because they were bought out by a major IC motorcycle manufacturer who plans to use their technology to market their own electric motorcycle.  It seems to me that Polaris would be the most likely purchaser of Brammo and I don't have a clue who might be interested in Zero.  Perhaps Kawasaki or Suzuki, or a Chinese firm.  Maybe Aprilia, but certainly not BMW or KTM, who have their own ideas how EV's should be designed.  Honda and Yamaha seem to have their own EV development programs and likely would need Zero to jump start their electric motorcycles.

As far as Zero's suspension choice goes, I really think they should consider switching to Showa components.
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Richard's motorcycle collection:  2018 16.6 kWh Zero S, 2016 BMW R1200RS, 2011 Royal Enfield Bullet 500 Classic, 2009 BMW F650GS, 2005 Triumph T-100 Bonneville, 2002 Yamaha FZ1 (FZS1000N) and a 1978 Honda Kick 'N Go Senior.
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