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[xerxesz]

I have posted this on the Facebook as well, but I am hoping, that others are reading it here

My Zero is not going anywhere. The relay switches periodically on and off. I read the Sevcon, and it says:

Code: [Select]

DEBUG:         54761  ..\src\Application\zero_mbb_module.c            : line  1906 - Restarting Sevcon to clear cutout Fault               
DEBUG:         54777  ..\src\Application\zero_mbb_module.c            : line  1108 - Disconnecting Module 00                               
DEBUG:         54796  ..\src\Application\zero_mbb_module.c            : line  1108 - Disconnecting Module 01                               
DEBUG:         55210  ..\src\Application\zero_mbb_sevcon_interface.c  : line   264 - Turning Off Sevcon                                   
DEBUG:         55382  ..\src\Application\zero_mbb_can.c               : line   779 - CAN1 ACK error                                       
DEBUG:         57232  ..\src\Application\zero_mbb_sevcon_interface.c  : line   251 - Turning On Sevcon                                     
DEBUG:         57265  ..\src\Application\zero_mbb_sevcon_interface.c  : line  2694 - Sevcon CAN Disconnected                               
DEBUG:         58239  ..\src\Application\zero_mbb_can.c               : line   704 - Initializing Sevcon CAN                               
DEBUG:         58257  ..\src\Application\zero_mbb_can.c               : line   831 - CAN1 BIT0 error                                       
DEBUG:         58270  ..\src\Application\zero_mbb_sevcon_interface.c  : line  2676 - Sevcon CAN Connected                                 
DEBUG:         58380  ..\src\Application\zero_mbb_sevcon_interface.c  : line  2928 - Precharge Complete (111 V / 113 V)                   
DEBUG:         58381  ..\src\Application\zero_mbb_sevcon_interface.c  : line   872 - Sevcon Contactor Drive OFF                           
DEBUG:         58432  ..\src\Application\zero_mbb_can.c               : line   980 - Sevcon CAN EMCY Frame, Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 01 00, Unknown
DEBUG:         58472  ..\src\Application\zero_mbb_can.c               : line   980 - Sevcon CAN EMCY Frame, Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 3E, Unknown
DEBUG:         58660  ..\src\Application\zero_mbb_sevcon_interface.c  : line   862 - Sevcon Contactor Drive ON                             
DEBUG:         58676  ..\src\Application\zero_mbb_module.c            : line  1578 - Connecting Eligible Modules                           
DEBUG:         58677  ..\src\Application\zero_mbb_module.c            : line  1171 - Connecting Module 00                                 
DEBUG:         58776  ..\src\Application\zero_mbb_can.c               : line   980 - Sevcon CAN EMCY Frame, Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x52C1, Data: 00 02 00, Encoder fault
DEBUG:         58813  ..\src\Application\zero_mbb_can.c               : line   980 - Sevcon CAN EMCY Frame, Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 10 00, Unknown
DEBUG:         59177  ..\src\Application\zero_mbb_sevcon_interface.c  : line   825 - Contactor took 487 ms to close               
Reading this, I tend to believe, that there is no connection to the motor. Logical would be the connector between the Sevcon and the motor, but there is no visible issue. I tried to move it, clean it, but no success. I also measured the 5 wires, which are going to the Sevcon (between the 2 connectors) and they are OK. The 6th is going on, so I could not check that. I am not sure, how I could check it on the motor side.
Any help/idea is highly appreciated.

br,

aron

[xerxesz]

Well:

https://photos.app.goo.gl/8TKFCAWEym2QGeyy5

I think I found it....

[Curt]

Good detective work. Will you be able to repair it without replacing a wiring harness?

[xerxesz]

Well, I have chosen a not so elegant but quick repair. I added one more connector (a single wire one) for the faulty cable. It seems to work (the bike switched on and moved fw 1m ). Replacing the whole connector would be pretty painful, most likely I should replace most of the cables since (as I can see now) the cabling is pretty much a chaos.