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[HVMoto]

My apologies for asking so many questions the past weeks and much appreciation for the assistance received so far. I now have one of my 2013 DS police bikes up and running. Rode it to work yesterday and today and it's been awesome!

My 2nd bike (bought both at auction) has been more of a challenge. In troubleshooting, it's helping me learn a lot more about the motorcycles so I'm grateful for that. I think I've read everything I could about the Main Bike Board (MBB), and in summary it appears to be an expensive piece to replace, and requires dealer service when it fails. I've also read that dealers (and perhaps Zero) really don't want to be supporting and repairing older models, and prefer new bike sales and services. I understand and respect that.

That brings me here for answers to my many questions, in particular to, but perhaps not exclusive to, the MBB.

The bike (2013 DS Police) I'm diagnosing is a non runner. No lights, no power, no obd2 function, no response when keyed on, no charging. Pack voltage is in range (~103vdc) and BMS LEDs respond to hardware or software reset. I originally suspected a failed DCDC converter but I bench tested two and both were functional (but not when installed on the bike).

I have one simple (but potentially undesirable) way of determining whether the MBB has failed. I can temporarily swap one from my working bike (or vice versa). I believe to be functional the VIN has to be set, as well as mileage, and I'm unsure what else.

Would that be catastrophic to the MBB, BMS, or other in just plugging in? I'd like to see if error codes flashed to the KOSO display, if a charge light appeared when plugged in, etc.

I also see there are MBBs on the secondary market (same model numbers on them as on my bike). Could a dealer reprovision a used MBB?

I notice there is mileage on the KOSO display when applying an external DC source and it appears mileage is stored in both the display and the MBB, which is accurate?

Since this bike is a non consumer model, it does not interact with the bluetooth app, but it does respond to the zero spy app (limited to pack soc readings). Has me wondering if the bluetooth chip is on the BMS, the MBB or both?

When the MBB is plugged in, I can read enable voltage to the DCDC and the ignition, but they appear high (near pack voltage). I was expecting low or no voltage here unless the bike is keyed on.

I read 3.3v on the OBDII port (voltage from MBB) and I've noticed the ground (pin 5) on the OBD2 shares the same common path as all the 12v accessories (black wire - side). If the MBB and low voltage DC circuits share a common ground I could see a fault causing the entire bike to be unresponsive.

Where to go from here?

[rgutt]

I probably can't help you with the MBB, but since that model year bike uses a Sevcon motor controller, have you considered gutting the bike of the MBB and letting the motor controller handle everything? You'll have to rewire the ignition and main contactor directly back to the Sevcon and probably add a direction control wire, but the unit itself is more than capable and frankly, more reliable.

You could probably even keep most of the dash data populated if you know what CAN data it needs. The Sevcon can be configured to transmit quite a bit of data over the CANbus.

[HVMoto]

Much appreciate the input. That's beyond my current abilities but I do like having options. I downloaded the Gen4 Sevcon manual to get a better understanding for potential future projects, it appears quite capable. How about communicating with the BMS and getting the battery charged? Could that be done independently from the MBB?

[TEV]

There is an adapter for charging the battery off the bike  https://electricmotorcycleforum.com/boards/index.php?topic=7116

[HVMoto]

Thanks Tev. I did read that post but good to read again. Everything looks different when you're at the point of actually having to get in and do the work. Not sure if there's a specific switch to use for the enable signal. I'll likely harvest the 4 meanwells and make something external I can use to charge either bike.