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[jmjm1]

Hi:

I have a serious problem with my 2010 ZERO DS and I do not know what can be the solution.

The bike was first launched in 2012 and has only 1,500 miles.

For months ago, I washed the bike with a water pressure machine. I let the bike dry two hours. After the bike ran for 5 miles and then the electric motor did not do work. The motor was stuck by a broken brush blocking the movement of the motor armature Agni 95R. I turned off the bike and relit three times. At first, the bike lit sounded "beep" all ok BMS. The instrument was turned on but the motor would not turn. The third time I tried to turn the motor, the bike system is turned off, and for 6 months has not been turned on again. Now when I put the ignition key to "ON" sounds "beep" of the BMS ok, but after the instrument panel no lights, nor the red light that indicates the error code lights.

I measured the voltage of the 14 cell battery pack and each shows 4.1 volts. The entire battery pack is 57.8 volts. In theory, the battery pack is 48 volts and the rated voltage is logically higher, so I think, although I am not an expert, that the problem is not with the battery pack.

I just noticed another motorcycle (motorcycle works perfectly ZERO S 2011) in the event that there is any broken or malfunctioning component normally comes power to the instrument panel and a red light to indicate the detected error code by the brain of the bike (BMM) by the number of flashes emitted.

I have also observed that in all cases there may be a problem in the system of the motorcycle, for example, a problem with the engine temperature sensor, or a problem with the throttle or low voltage battery pack, it may be that the instrument panel does not light (for low voltage battery pack, for example) but always, and in all cases, the red light on the instrument panel indicating the error code detected by the BMM. In all the above cases, if there is an error code, the contactor does not jump.

My problem is that the instrument panel does not light, but also no red light error code lights (With the DrBass help and tips I have learned to checked the voltage of the battery pack, the contactor, throttle, controller, DC-DC converter). All these components are tested and working properly. It is like if any form of energy came to the Instrument panel (Dashboard).

The motor 95 R agni is repaired. It is a pack of 8 new brushes and a new toothbrush holder with a new engine temperature sensor purchased with the kindness and help of Steve from JozzTeck. The engine now turns perfectly with an external power (12 volt battery).

I also checked on the bike to work (ZERO 2011 S), never skip the stator until the instrument is turned on, it performs the test that everything is correct and no error code lights, only then, is when the contactor jump and the controller allows to rotate the electric motor.

Based on the above observations, I conclude that we should focus on diagnosing the fault of my ZERO DS 2010, on the question of why that red light on the instrument panel, which reports the detected error is not lit, because that is the prelude everything else to work.

My thoughts on the matter, now that the problem might be broken the instrument panel, and for that reason, the red indicator light on the error code is not illuminated. The other possibility is that the BMM is broken.

I do not know if there is a method to verify the correct operation of the instrument panel. I do not know if maybe there is a fuse inside it or not. The only components that I have not known to verify are the BMM and the instrument panel.  ¿can I open the BMM without risk of damaging something inside?
I have the possibility of having an instrument panel and a BMM work right of a ZERO 2011 S. Although the two motorcycles are similar (2010 and 2011) and use the same electric motor (AGNI 95 R), the same controller (Alltrax AXE 4855 R5), the same throttle (0-5 ohms) and the same contactor (MZJ 200 D 48Volt 200 Amp), the connections are different to the input of the battery pack. On the other hand, I think the ZERO 2011 BMM is outside of the battery pack and the 2010 model is into the battery pack. Or for example, the red light that indicates excessive temperature in the electric motor, on the model 2010 ZERO model, is a light outside of the instrument panel. However, in the 2011 ZERO model, the light is into the instrument panel.

My questions are:

- I could use the instrument panel of the 2011 ZERO model to check my 2010 ZERO model to verify if the fault is in this component?

- Could I use the BMM of the 2011 ZERO model to check my 2010 ZERO model to verify if the fault is in this component?

- Is it a risk I damage components if I do these tests? or put another way, are compatible these two components between 2010 and 2011 ZERO model?

- If I open the inside of the instrument panel. What things can I look for suspect something is broken?

Please, I need your help, suggestions and opinions about my problem with the 2010 ZERO DS.

[Richard230]

The first thing I would do is to pull apart all of the wiring connectors, clean them and check for any corrosion or bent pins.  I have had more that one problem on my IC motorcycles with corroded connectors and my 2014 S suffered a very hard to locate BMS problem that was the result of a single bent pin on one of the wiring connectors.

[zap mc]

I know this is old but did you ever get it sorted and what was the problem?
For anyone reading this suffering the same problem you can”Hotwire” the Sevcon voltage reducer box on the top of the battery box by bridging across the far right red “enable “ wire to the thick red + IN wire, this will power up the bike and the dash will light up. I am yet to find out how this wire is fed and where it comes from