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[winfried]

When noticed a strange noise from below when start driving, I first thought on the rear break, but
when did a closer look I saw a metal ring between belt-drive and motor, which is part of the belt drive sprocket, I think, loose (see photo)

So before I start dismantling the bike I ask for your advice:

- Is it dangerous to drive with this for small distances (eg. to my shop) ?

- Can I fix the sprocket myself or do I need an exchange ?
 
- Any special tools, skills if I remove it and fix it again myself ?

mfg winfried

[Richard230]

That is the first time I have seen a cog wheel fall apart.  I have no idea how to answer your questions.  Hopefully someone else can be more helpful.

[BrianTRice@gmail.com]

The front sprocket isn't easy to change. Terry weighed in once, as recorded here:

https://zeromanual.com/index.php/Unofficial_Service_Manual#Front_Sprocket_Removal_.2F_Swap

The 2013 XU's power and torque output are pretty low (through a Gen2 Size 2 controller) so you may be able to limp, but I think we'd all be guessing at this point.

[winfried]

Thanks for advice.

The front sprocket isn't easy to change. Terry weighed in once, as recorded here:

https://zeromanual.com/index.php/Unofficial_Service_Manual#Front_Sprocket_Removal_.2F_Swap

The 2013 XU's power and torque output are pretty low (through a Gen2 Size 2 controller) so you may be able to limp, but I think we'd all be guessing at this point.

 I read the the manual and decided to fix in a motorcycle workshop, since they have higher quality tools (to remove the motor), but I have to convince the mechanic at the workshop to do this, since they do not repair electric motorcycles normally, so I print out this part of the manual, since my zero dealer is out of battery range.

In the meantime I fixated the loose side part of the sprocket to the motor with a metal tape and some silicon glue, so I can drive safely within the city, since I hope the side part is not essential.

Does anyone know how the side part  is fixated on the sprocket, I guess spot-welded, maybe we can repair the sprocket ?

---

PS: since I am not native English, in the manual as tools are listed:  "27mm socket, 3mm Allen key, 10mm Allen key socket "

What is the difference between (or German translation of)  a socket, an Allen key and and Allen key socket ?

[Erasmo]

Imbus.

[rayivers]

Does anyone know how the side part  is fixated on the sprocket, I guess spot-welded, maybe we can repair the sprocket ?

The side plate on the 2014 1"-shaft pulley/sprocket is spot-welded on.

A socket (holds in inside diameter) is for nuts.  An Allen key is usually a handheld L-shaped hex rod for hex-I.D.-head screws/bolts (holds in outside diameter).  An Allen socket mounts the hex rod in a square-drive adaptor for use with a ratchet wrench etc.

[winfried]

Thanks for the info,

So I ask if at the workshop they can spot-weld it again, maybe it was not spot welded good enough, since I saw a welding point outside not inside.

mfg
 winfried

[rayivers]

Mine has 4 large spot welds on the motor side.  You might want to do 6 or 8 small welds, for greater reliability and also to distribute the welding heat.

[winfried]

Now I got time and take courage to do the repair myself, and after some troubles unscrewing and  organizing the right tools, I got the sprocket to be replaced by a new one. The old one was too ruined to be fixed.
First trying without removing the motor didn't succeed, since the sprocket stuck to hard, so I build out the motor.

Afterwards  as a first power up, the XU looked fine, but after the first small  throttle the wheel turned a little and then the sevcon controller resets until it gets on again, seeing green light flashing than green stays and hearing the contactor in the sevcon clicking off and on. It stays reseting periodically ... but if the motor is turned to a certain angle, the sevcon stays on until I turn the motor again to another position.

So what I messed up ?

It checked all the connectors to motor including the black multicore, and I am sure I connected the phases in right order (since I made a foto before).

I could get out the error log via mobile and there is the repeating sequence below:

Code: [Select]

04506     11/19/2018 10:46:11   Sevcon CAN Link Up
 04507     11/19/2018 10:46:12   DEBUG: Sevcon Contactor Drive OFF
 04508     11/19/2018 10:46:12   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 01 00, Unknown
 04509     11/19/2018 10:46:12   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 2E, Unknown
 04510     11/19/2018 10:46:12   DEBUG: Sevcon Contactor Drive ON.
 04511     11/19/2018 10:46:12   Module 00 Closing Contactor  vmod: 114.130V, maxsys: 114.132V, minsys: 114.132V, diff: 0.000V, vcap:  0.000V, prechg: 0%
 04512     11/19/2018 10:46:12   DEBUG: Module 00 FETs are now Closed
 04513     11/19/2018 10:46:12   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x52C1, Data: 00 02 00, Unknown
 04514     11/19/2018 10:46:12   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 10 00, Unknown
 04515     11/19/2018 10:46:12   Contactor took 595 ms to close
 04516     11/19/2018 10:46:12   0x3e 0x66 0x9a 0x01 0x00 0x23 0xba 0x01 0x00 0x28 0x9a 0x01 0x00 0x11 0xbd 0x01 0x00 0xe9 0x99 0x01 0x00 0x11 0xbd 0x01 0x00 0xab 0x99 0x01 0x00 0x11 0xbd 0x01 0x00 0xab 0x99 0x01 0x00 0x11 0xbd 0x01 0x00 0x6c 0x99 0x01 0x00 0x11 0xbd 0x01 0x00 0x2e 0x99 0x01 0x00 0xd3 0xbc 0x01 0x00 0x2e 0x99 0x01 0x00 0x11 0xbd 0x01 0x00 0x7c 0xc0 0x01 0x00 0xd3 0xbc 0x01 0x00 0x7c 0xc0 0x01 0x00 0xd3 0xbc 0x01 0x00 ???
 04517     11/19/2018 10:46:17   Restarting Sevcon to clear cutout fault
 04518     11/19/2018 10:46:17   Module 00 Opening Contactor  vmod: 114.110V, batt curr:   0A
 04519     11/19/2018 10:46:17   Module 01 Opening Contactor  vmod:   0.000V, batt curr:   0A
 04520     11/19/2018 10:46:18   Sevcon Turned Off
 04521     11/19/2018 10:46:18   DEBUG: Module 00 FETs are now Open
 04522     11/19/2018 10:46:20   Sevcon Turned On
 04523     11/19/2018 10:46:20   Sevcon CAN Link Down

What can I test next ? Like if the motor is out of phase or the sensors not working ?
Anyhow I cannot decode the log line 04516, which seems to be the error.

Any hints are appreciated.

mfg
 winfried

[gregoryjward]

This is little better than a guess, but it sounds like there is some issue with the motor's encoder/sensor connection.  See the unofficial Zero manual https://zeromanual.com/wiki/Unofficial_Service_Manual#Z-Force_Motor.  There are also some helpful hints about aligning the motor after reinstallation.  The main thing I'm suggesting is that you double-check all your wiring connections are firm and have the proper polarity.

[winfried]

thanks for the guess, It is now my guess too, after studying some forum threads and manual und your post.

But I cannot figure out how to correctly measure this and adjust without software for calibration.
I phoned my dealer and he said there is a special software needed to do the adjustment and store it in the controller, so I visit my dealer tomorrow, maybe he can retrieve the failure with the zero software.

Hopefully the encoder has not been wrecked by my harsh re-movement of the sprocket, it stuck quite hard it was loctited and since the motor screws has not been in place, the front has been twisted.

PS: I checked the polarity and cables twice.