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[mistasam]

What do you guys think this could be?



I took the belt off the front sprocket and it still made that rattling noise.  Sounds like something inside the motor.

[tjax]

I am no expert, but something sounds like grinding...bearings?  Is there any play in the spindle backwards and forwards?

Does anyone have something to compare this against?


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[grmarks]

To me it sounds like the rotor is hitting a single spot on the stator on each revolution. Not a bearing noise.
Definitely take it to the dealer and let him hear it.

[mistasam]

 The front sprocket isn't wobbling around, so that makes sense.  There aren't any Zero dealers in New Zealand, unfortunately.. so I'll see if an electrical place could take a look.  Thanks for your help!

[NEW2elec]

Maybe this helps though his clicking is louder and more constant you shaft key may just be starting to loosen?  I hope it's as simple a fix as his.

http://electricmotorcycleforum.com/boards/index.php?topic=4639.0

[mistasam]

Maybe this helps though his clicking is louder and more constant you shaft key may just be starting to loosen?  I hope it's as simple a fix as his.

http://electricmotorcycleforum.com/boards/index.php?topic=4639.0

Oh wow.. maybe mine is in the early stages of what happened to his.  I'm dropping it off at an electrical shop today to see if they can figure it out.  From what I could see though, my sprocket wasn't wobbling nearly as much as his.

[Burton]

Check belt tension.
Take belt off and manually turn the pulley with your hand. (don't run the motor without a load on it)
Try to move the pulley to the North South East and West when the belt is off.

Report back your findings

[mistasam]

Check belt tension.
Take belt off and manually turn the pulley with your hand. (don't run the motor without a load on it)
Try to move the pulley to the North South East and West when the belt is off.

Report back your findings

Ahh man yea I tried that last night when everything was off.  The belt tension was exactly 25kg and when the belt was off, I couldn't move the front sprocket at all.  It was super tight, and I couldn't see any wobbling.  Even moving it by hand, I could hear the noise.. so something is definitely wrong inside.

Either I take it all apart, I find a shop to take it all apart, or I wait until the motor dies and swap in a new IPM motor 

[Burton]

Ok, then it is likely NOT a bearing problem or an axle problem as both would have been very pounced with the belt off.

The only way to really figure out what is wrong would be to take it apart and look for wear locations. It is not an easy task and if you don't do it right you can mess the motor up for good. I would seek a professional if you want to explore that route.

As for waiting for it to go bad ... depending what is wrong that might be worse than getting it checked out. If something were to go so wrong the the motor were to seize up you could be asking for an accident depending when it happens.

And since you didn't feel any play in the pulley then it isn't likely that your set screws are loose either.

[mistasam]

As for waiting for it to go bad ... depending what is wrong that might be worse than getting it checked out. If something were to go so wrong the the motor were to seize up you could be asking for an accident depending when it happens.

Burton, good points.  I'll definitely try and get someone to look at it.  I feel like if I took the motor apart myself and found the issue, I wouldn't be able to fix it regardless.

Just out of curiosity (hypothetical for the time being).. is a motor swap as simple as unplugging/unbolting?

[Burton]

Depends on the MY you are swapping from. All new motors will require you "time" them for the encoder angle. If you are not familiar with DVT and programming your sevcon don't even think about doing it yourself. Really bad things can go wrong. I did make a video about doing this if I recall.

As for other requirements.

For MY13 to MY14/15 you have to turn your controller backwards because the leads for M1 M2 M3 are reversed in length.

For MY13/14/15 to MY16 I believe you have to flash your controller firmware to support the new motor. I cannot confirm this but it was hinted that this would be required for such an "upgrade."

Less you are a serious tinkerer I would leave any motor swaps to a zero certified technician.

I swapped from a MY13 to MY14 SR pretty easily.

[mistasam]

Thanks for the info!  Yea, sounds like I'd have to ship it over to Australia or something for that level of work.  Here's hoping whatever is wrong with my motor is an easy mechanical fix, like something being loose.

[tjax]

Sam,

I passed these guys the other day - might be worth a try http://www.petonemotorwinders.co.nz
 
There are plenty of specialist places like this in the area..

Best of luck..


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[mistasam]

I passed these guys the other day - might be worth a try http://www.petonemotorwinders.co.nz

Thanks man!  I'll give them a call tomorrow.  I had a chat with Astara Technologies today and may head up there  in a week or so if I can't get this thing figured out before then.