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[MicheldeL]

Unfortunately a not so happy reason for joining the forum today (have been reading for a while since I bought a second hand Zero DS MY13 in July, thank you all for sharing years’ worth of experiences!)

My Zero DS shut down completely on the highway last week for two mornings in a row! This was an extremely dangerous situation as I had almost no place to safely come to a stop. I have attached the motorcycle logs after downloading from my Zero through the app below for anyone who believes they have an idea what we’re looking at.

The occurence:
After having a bit of a 'stuttering engine' for a few seconds, there is suddenly no throttle response at all anymore while driving on the highway at approx 100+ km/h. The throttle no longer responded at all and the "exclamation mark triangle" indicator flashed (not the temperature indicator, as I had not driven or accelerate extremely fast/hard). After coming to a full stop the motor seemed to restart (the tachometer swung fully down to zero) after which I could resume my drive to work without any further issues.

Made an appointment at the local Zero dealer here in Amsterdam to have it checked out. Took a week before I could swing by, but they did a read-out and came to the conclusion something is wrong in the electro motor and it needs to be fully replaced (their estimated cost: 1300 euro for the motor, 300 euro for the labor). They came to this conclusion after contact with Zero HQ (possibly European HQ, didn’t ask specifically), who also confirmed nothing is wrong with the battery pack after doing a full scan.

The interesting thing is, that this has only occurred when I drive off with having a battery charge <65%. If the bike is charged to 100% at my work and I drive home, I’ve never had an issue with the engine.

Anyone else ever have a similar experience on the highway or have further experience with the electromotor to determine whether it wouldn’t be possible to simply replace a relatively small part instead of the full engine?

Bike: Zero DS MY13 (9.4KwH, battery pack replaced under warranty in 2016, original had 8.5KwH)

Code: [Select]

05026                       0   DEBUG: Reset: Power-On, External
 05027                       0   Power On                   Key Switch
 05028                       0   Key On
 05029                       0   Module 00 Opening Contactor  vmod:   0.000V, batt curr:   0A
 05030                       0   Module 01 Opening Contactor  vmod:   0.000V, batt curr:   0A
 05031                       0   CAN0 ACK error. count=1
 05032                       1   DEBUG: Module scheme changed from None mode to Running mode
 05033                       1   Module 00 CAN Link Up
 05034                       1   Module 00 Registered       serial: ,  vmod: 105.821V
 05035     09/17/2018 22:47:15   Sevcon Turned On
 05036     09/17/2018 22:47:16   Sevcon CAN Link Up
 05037     09/17/2018 22:47:16   DEBUG: Sevcon Contactor Drive ON.
 05038     09/17/2018 22:47:16   Module 00 Closing Contactor  vmod: 105.816V, maxsys: 105.840V, minsys: 105.840V, diff: 0.000V, vcap:  0.000V, prechg: 0%
 05039     09/17/2018 22:47:17   Contactor took 63 ms to close
 05040     09/17/2018 22:47:17   DEBUG: Module 00 Contactor is now Closed
 05041     09/17/2018 22:47:17   INFO:  Enabling Charger 1
 05042     09/17/2018 22:47:17   INFO:  Enabling Charger 2
 05043     09/17/2018 22:47:17   0x3e 0x25 0xdf 0x00 0x00 0x99 0x9c 0x01 0x00 0xa8 0xde 0x00 0x00 0x99 0x9c 0x01 0x00 0x69 0xde 0x00 0x00 0x99 0x9c 0x01 0x00 0x43 0x0e 0x01 0x00 0x5e 0x91 0x01 0x00 0x7d 0x77 0x01 0x00 0x5a 0x9c 0x01 0x00 0x4a 0x75 0x01 0x00 0x99 0x9c 0x01 0x00 0x12 0x74 0x01 0x00 0x99 0x9c 0x01 0x00 0xd9 0x72 0x01 0x00 0x1c 0x9c 0x01 0x00 0x87 0x9f 0x01 0x00 0xdd 0x9b 0x01 0x00 0xc5 0x9f 0x01 0x00 0x1c 0x9c 0x01 0x00 ???
 05044     09/17/2018 22:47:23   Riding                     PackTemp: h 19C, l 17C, PackSOC: 65%, Vpack:105.775V, MotAmps:   0, BattAmps:   2, Mods: 10, MotTemp:  20C, CtrlTemp:  15C, AmbTemp:   0C, MotRPM:   0, Odo:    0km
 05045     09/17/2018 22:47:23   Batt Dischg Cur Limited    101 A (14%), MinCell: 3774mV, MaxPackTemp: 19C
 05046     09/17/2018 22:48:23   Riding                     PackTemp: h 19C, l 17C, PackSOC: 65%, Vpack:105.090V, MotAmps:  54, BattAmps:  14, Mods: 10, MotTemp:  22C, CtrlTemp:  17C, AmbTemp:   0C, MotRPM: 868, Odo:    0km
 05047     09/17/2018 22:48:23   Batt Dischg Cur Limited    553 A (80%), MinCell: 3750mV, MaxPackTemp: 19C
 05048     09/17/2018 22:49:23   Riding                     PackTemp: h 19C, l 17C, PackSOC: 64%, Vpack:105.306V, MotAmps:   0, BattAmps:   1, Mods: 10, MotTemp:  24C, CtrlTemp:  18C, AmbTemp:   0C, MotRPM:   0, Odo:    0km
 05049     09/17/2018 22:49:23   Batt Dischg Cur Limited    658 A (95%), MinCell: 3757mV, MaxPackTemp: 19C
 05050     09/17/2018 22:50:23   Riding                     PackTemp: h 19C, l 17C, PackSOC: 64%, Vpack:105.425V, MotAmps: -31, BattAmps:  -7, Mods: 10, MotTemp:  27C, CtrlTemp:  19C, AmbTemp:   0C, MotRPM:1238, Odo:    0km
 05051     09/17/2018 22:50:23   Batt Dischg Cur Limited    673 A (97%), MinCell: 3762mV, MaxPackTemp: 19C
 05052     09/17/2018 22:51:23   Riding                     PackTemp: h 19C, l 17C, PackSOC: 64%, Vpack:103.628V, MotAmps:  58, BattAmps:  27, Mods: 10, MotTemp:  28C, CtrlTemp:  20C, AmbTemp:   0C, MotRPM:1966, Odo:    0km
 05053     09/17/2018 22:52:23   Riding                     PackTemp: h 19C, l 18C, PackSOC: 64%, Vpack:104.191V, MotAmps:   0, BattAmps:   1, Mods: 10, MotTemp:  35C, CtrlTemp:  24C, AmbTemp:   0C, MotRPM:   0, Odo:    0km
 05054     09/17/2018 22:52:23   Batt Dischg Cur Limited    602 A (87%), MinCell: 3719mV, MaxPackTemp: 19C
 05055     09/17/2018 22:53:23   Riding                     PackTemp: h 19C, l 18C, PackSOC: 62%, Vpack:104.264V, MotAmps:   0, BattAmps:   0, Mods: 10, MotTemp:  37C, CtrlTemp:  25C, AmbTemp:   0C, MotRPM:   0, Odo:    0km
 05056     09/17/2018 22:53:23   Batt Dischg Cur Limited    620 A (89%), MinCell: 3721mV, MaxPackTemp: 19C
 05057     09/17/2018 22:54:23   Riding                     PackTemp: h 19C, l 18C, PackSOC: 61%, Vpack:102.532V, MotAmps:  52, BattAmps:  30, Mods: 10, MotTemp:  43C, CtrlTemp:  28C, AmbTemp:   0C, MotRPM:2377, Odo:    0km
 05058     09/17/2018 22:54:23   Batt Dischg Cur Limited    611 A (88%), MinCell: 3624mV, MaxPackTemp: 19C
 05059     09/17/2018 22:55:23   Riding                     PackTemp: h 19C, l 18C, PackSOC: 61%, Vpack:103.500V, MotAmps:  30, BattAmps:   6, Mods: 10, MotTemp:  40C, CtrlTemp:  27C, AmbTemp:   0C, MotRPM:2170, Odo:    0km
 05060     09/17/2018 22:55:23   Batt Dischg Cur Limited    649 A (94%), MinCell: 3654mV, MaxPackTemp: 19C
 05061     09/17/2018 22:56:23   Riding                     PackTemp: h 20C, l 18C, PackSOC: 60%, Vpack:103.934V, MotAmps: -31, BattAmps: -20, Mods: 10, MotTemp:  44C, CtrlTemp:  29C, AmbTemp:   0C, MotRPM:2299, Odo:    0km
 05062     09/17/2018 22:56:23   Batt Dischg Cur Limited    567 A (82%), MinCell: 3710mV, MaxPackTemp: 20C
 05063     09/17/2018 22:57:16   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 01 00, Unknown
 05064     09/17/2018 22:57:18   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 00, Unknown
 05065     09/17/2018 22:57:18   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 02 00, Unknown
 05066     09/17/2018 22:57:23   Riding                     PackTemp: h 20C, l 19C, PackSOC: 58%, Vpack: 98.495V, MotAmps: 102, BattAmps: 109, Mods: 10, MotTemp:  51C, CtrlTemp:  34C, AmbTemp:   0C, MotRPM:3969, Odo:    0km
 05067     09/17/2018 22:57:23   Batt Dischg Cur Limited    471 A (68%), MinCell: 3474mV, MaxPackTemp: 20C
 05068     09/17/2018 22:57:28   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 B6, Unknown
 05069     09/17/2018 22:57:28   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 01 00, Unknown
 05070     09/17/2018 22:57:38   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 99, Unknown
 05071     09/17/2018 22:57:52   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 01 00, Unknown
 05072     09/17/2018 22:57:53   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 3E, Unknown
 05073     09/17/2018 22:57:53   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 02 00, Unknown
 05074     09/17/2018 22:57:56   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 B0, Unknown
 05075     09/17/2018 22:57:56   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 03 00, Unknown
 05076     09/17/2018 22:57:58   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 99, Unknown
 05077     09/17/2018 22:57:58   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 04 00, Unknown
 05078     09/17/2018 22:58:01   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 5B, Unknown
 05079     09/17/2018 22:58:01   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 05 00, Unknown
 05080     09/17/2018 22:58:11   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 00, Unknown
 05081     09/17/2018 22:58:11   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 04 00, Unknown
 05082     09/17/2018 22:58:18   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 99, Unknown
 05083     09/17/2018 22:58:18   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 05 00, Unknown
 05084     09/17/2018 22:58:18   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 68, Unknown
 05085     09/17/2018 22:58:18   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 0A 00, Unknown
 05086     09/17/2018 22:58:18   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 08, Unknown
 05087     09/17/2018 22:58:18   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 0B 00, Unknown
 05088     09/17/2018 22:58:18   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 68, Unknown
 05089     09/17/2018 22:58:18   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 0F 00, Unknown
 05090     09/17/2018 22:58:18   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 99, Unknown
 05091     09/17/2018 22:58:18   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 10 00, Unknown
 05092     09/17/2018 22:58:18   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x52C1, Data: 00 02 00, Unknown
 05093     09/17/2018 22:58:23   Restarting Sevcon to clear cutout fault
 05094     09/17/2018 22:58:23   Module 00 Opening Contactor  vmod: 103.034V, batt curr:   0A
 05095     09/17/2018 22:58:23   Module 01 Opening Contactor  vmod:   0.000V, batt curr:   0A
 05096     09/17/2018 22:58:24   Sevcon Turned Off
 05097     09/17/2018 22:58:24   DEBUG: Module 00 Contactor is now Open
 05098     09/17/2018 22:58:24   Riding                     PackTemp: h 20C, l 19C, PackSOC: 58%, Vpack:103.046V, MotAmps:   0, BattAmps:   0, Mods: 00, MotTemp:  56C, CtrlTemp:  35C, AmbTemp:   0C, MotRPM: 998, Odo:    0km
 05099     09/17/2018 22:58:24   CAN1 ACK error. count=1
 05100     09/17/2018 22:58:26   Sevcon Turned On
 05101     09/17/2018 22:58:26   Sevcon CAN Link Down
 05102     09/17/2018 22:58:27   Sevcon CAN Link Up
 05103     09/17/2018 22:58:27   DEBUG: Sevcon Contactor Drive OFF
 05104     09/17/2018 22:58:27   DEBUG: Sevcon Contactor Drive ON.
 05105     09/17/2018 22:58:27   Module 00 Closing Contactor  vmod: 103.098V, maxsys: 103.073V, minsys: 103.073V, diff: 0.000V, vcap:  0.000V, prechg: 0%
 05106     09/17/2018 22:58:27   DEBUG: Module 00 Contactor is now Closed
 05107     09/17/2018 22:58:27   Contactor took 128 ms to close
 05108     09/17/2018 22:58:27   0x3e 0x82 0x8b 0x01 0x00 0xa2 0x90 0x01 0x00 0x43 0x8b 0x01 0x00 0xa2 0x90 0x01 0x00 0x43 0x8b 0x01 0x00 0xa2 0x90 0x01 0x00 0x43 0x8b 0x01 0x00 0xa2 0x90 0x01 0x00 0xc6 0x8a 0x01 0x00 0xa2 0x90 0x01 0x00 0x88 0x8a 0x01 0x00 0x64 0x90 0x01 0x00 0x88 0x8a 0x01 0x00 0x64 0x90 0x01 0x00 0x88 0x8a 0x01 0x00 0x64 0x90 0x01 0x00 0x8a 0x94 0x01 0x00 0x64 0x90 0x01 0x00 0x8a 0x94 0x01 0x00 0x64 0x90 0x01 0x00 ???
 05109     09/17/2018 22:59:24   Riding                     PackTemp: h 21C, l 20C, PackSOC: 56%, Vpack: 98.154V, MotAmps:  80, BattAmps:  86, Mods: 10, MotTemp:  57C, CtrlTemp:  35C, AmbTemp:   0C, MotRPM:4206, Odo:    0km
 05110     09/17/2018 22:59:24   Batt Dischg Cur Limited    398 A (57%), MinCell: 3481mV, MaxPackTemp: 21C

[domingo3]

  I recall reading here on the forums that there were one or two others that experienced shutdowns on the highway, but don't recall if the details were the same.  If someone else doesn't recall, it may be useful to do a search.

  I've chronicled my experiences here.  With two different motors, I experienced an extreme momentary regen when on the highway at full throttle.  I am not certain, but I think that it correlated to an error that is in your logs as well, Sevcon Error Code: 0x46C3.  I believe it's a someone generic code, though.  Fortunately for me, the motor was replaced under warranty.  After two motor replacements, Zero still didn't know what the problem was and they replaced the entire bike.  I'm still not convinced it was the motor at all.

  If you get the motor replaced, I'd ask what the warranty is on the replacement motor and if they issue any credit if it's later determined to not be the source of your problem.

[ctrlburn]

Other thread shared error code and symptom.
"Sudden Deceleration at highway speed"
http://electricmotorcycleforum.com/boards/index.php?topic=6567.msg51820#msg51820



2013 S Just over 30,000 miles.  Sudden stutter resistance at variety of throttle positions in both ECO and SPORT.

My Zero is currently in the shop needing that same new motor.

Don't put too much on the battery level. Here is a sample of mine at nearly a full charge and lower:


 04601     09/21/2018 05:00:22   Riding                     PackTemp: h 34C, l 33C, PackSOC: 98%, Vpack:114.716V, MotAmps:  92, BattAmps:   9, Mods: 10, MotTemp:  42C, CtrlTemp:  27C, AmbTemp:   0C, MotRPM: 302, Odo:    0km
 04602     09/21/2018 05:01:15   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 01 00, Unknown
 04603     09/21/2018 05:01:15   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 4E, Unknown
 04604     09/21/2018 05:01:15   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 02 00, Unknown
 04605     09/21/2018 05:01:15   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 80, Unknown
 04606     09/21/2018 05:01:15   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 03 00, Unknown
 04607     09/21/2018 05:01:16   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 3E, Unknown
 04608     09/21/2018 05:01:16   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 04 00, Unknown
 04609     09/21/2018 05:01:17   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 99, Unknown
 04610     09/21/2018 05:01:17   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 05 00, Unknown
 04611     09/21/2018 05:01:18   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 99, Unknown
 04612     09/21/2018 05:01:18   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 06 00, Unknown
 04613     09/21/2018 05:01:19   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 7A, Unknown
 04614     09/21/2018 05:01:19   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 07 00, Unknown
 04615     09/21/2018 05:01:20   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 99, Unknown
 04616     09/21/2018 05:01:20   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 08 00, Unknown
 04617     09/21/2018 05:01:22   Riding                     PackTemp: h 34C, l 33C, PackSOC: 97%, Vpack:112.762V, MotAmps: 134, BattAmps:  97, Mods: 10, MotTemp:  46C, CtrlTemp:  30C, AmbTemp:   0C, MotRPM:3173, Odo:    0km



 05177     09/21/2018 15:19:42   Riding                     PackTemp: h 24C, l 23C, PackSOC: 38%, Vpack:100.546V, MotAmps: -31, BattAmps: -22, Mods: 10, MotTemp:  57C, CtrlTemp:  25C, AmbTemp:   0C, MotRPM:2800, Odo:    0km
 05178     09/21/2018 15:19:42   Batt Dischg Cur Limited    472 A (68%), MinCell: 3585mV, MaxPackTemp: 24C
 05179     09/21/2018 15:20:17   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 01 00, Unknown
 05180     09/21/2018 15:20:19   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 01, Unknown
 05181     09/21/2018 15:20:19   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 02 00, Unknown
 05182     09/21/2018 15:20:29   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 99, Unknown
 05183     09/21/2018 15:20:29   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 01 00, Unknown
 05184     09/21/2018 15:20:39   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 99, Unknown
 05185     09/21/2018 15:20:42   Riding                     PackTemp: h 24C, l 24C, PackSOC: 37%, Vpack: 98.656V, MotAmps:  74, BattAmps:  61, Mods: 10, MotTemp:  58C, CtrlTemp:  25C, AmbTemp:   0C, MotRPM:3218, Odo:    0km
 05186     09/21/2018 15:20:42   Batt Dischg Cur Limited    489 A (70%), MinCell: 3515mV, MaxPackTemp: 24C
 05187     09/21/2018 15:21:43   Riding                     PackTemp: h 24C, l 24C, PackSOC: 37%, Vpack:100.389V, MotAmps: -40, BattAmps: -12, Mods: 10, MotTemp:  57C, CtrlTemp:  24C, AmbTemp:   0C, MotRPM:1451, Odo:    0km
 05188     09/21/2018 15:21:43   Batt Dischg Cur Limited    473 A (68%), MinCell: 3555mV, MaxPackTemp: 24C
 05189     09/21/2018 15:22:43   Riding                     PackTemp: h 24C, l 24C, PackSOC: 37%, Vpack:100.548V, MotAmps:   0, BattAmps:   1, Mods: 10, MotTemp:  55C, CtrlTemp:  23C, AmbTemp:   0C, MotRPM:   0, Odo:    0km
 05190     09/21/2018 15:22:43   Batt Dischg Cur Limited    504 A (73%), MinCell: 3587mV, MaxPackTemp: 24C
 05191     09/21/2018 15:22:58   0x37 

[MicheldeL]

  I recall reading here on the forums that there were one or two others that experienced shutdowns on the highway, but don't recall if the details were the same.  If someone else doesn't recall, it may be useful to do a search.

  I've chronicled my experiences here.  With two different motors, I experienced an extreme momentary regen when on the highway at full throttle.  I am not certain, but I think that it correlated to an error that is in your logs as well, Sevcon Error Code: 0x46C3.  I believe it's a someone generic code, though.  Fortunately for me, the motor was replaced under warranty.  After two motor replacements, Zero still didn't know what the problem was and they replaced the entire bike.  I'm still not convinced it was the motor at all.

  If you get the motor replaced, I'd ask what the warranty is on the replacement motor and if they issue any credit if it's later determined to not be the source of your problem.

Thanks Domingo, just went through your own topic http://electricmotorcycleforum.com/boards/index.php?topic=6567.0 (which I didn't find before). Very worrying that the problem wasn't resolved by replacing the motor (twice!).

One work-around that seems to have prevented this from re-occuring is starting my trip @full charge (most of my one-way trips are <40% battery use and I can usually charge at almost every destination).
Going to try the tip of setting Custom (or ECO on the <2015 models) to 95% max torque as most of my symptoms have materialized under Wide-Open-Throttle.

Will keep you all posted. Appreciate any further input anyone could give!

[qorw]

Dude, sell it quickly, you will only regret owning one, like I do!

See my post about failed firmware update causing major nightmares on my 2014 Zero DS. If you read my post about failed firmware update in Nov 2017 and that my Zero DS is still there (10 months now) waiting for a buy-back since even their replacement battery does not charge fully and the dash flashes in error from time to time, you will know to STAY AWAY from this brand.
And as if things could not get worse, THEY JUST DID; I heard this week that the reason the buy-back from Zero is not happening is because the local dealer just went belly up. So now my Zero DS and the Thousands of dollars Zero paid the dealer for the buy back  ARE ALL LOCKED UP IN A LIQUIDATION CASE!!! 
Everyone is going to loose big time here, the only ones smiling are the liquidation lawyers.
PS I am trying to work through Zero Amsterdam too, not much luck there..... lots of "I'm sorries" but no real customer satisfying action.

[domingo3]

To be clear about my case, I only experienced this issue with the first and third motor. I had the second motor for about a year and had other problems with that. I
Our cases may be related, but I never experienced a full shutdown like you have.
  I also only had this happen at full throttle. If I wasn't under warranty, I would have considered trying out the 95% torque solution - way cheaper than getting the motor replaced.  Did you notice if the lights stayed on when this happened?  If you ever ride in the dark, you should carry or wear something with battery lights just in case.

[Auriga]

Hmm. Zero uses BLDC motors on their bikes, and their drive control requires an encoder to correctly align the current's phase to produce an optimal driving torque. If that encoder  becomes loose or breaks or cracks or slips, or develops a fault, that would cause a lot of the stuttering some of you are mentioning. It sounds like ctrlburn experienced this.

0x46c3 sounds like a generic errorcode for a fault in the controller/motor feedback loop, which could be caused by a bunch of things. Trying to pull more current than the batteries can provide, a motor failure, or a motor controller issue. Keeping a motor moving in a system like this is complicated. The amount of available current is affected by battery temperature, motor temperature, battery configuration, battery impedance, current motor status, rotor position, current ramp, and motor state, among other things.

domingo3, I suspect you ran into an edge case, where something happened that acted unexpectedly in that feedback loop. It sounds pretty rare if it only happened to you and a couple others intermittently under specific conditions

michaeldel, I don't think you're going to get a different or cheaper resolution. I'd have them check the encoder/motor alignment, but if it's not that, it'll probably be a motor or controller. 

[MicheldeL]

To be clear about my case, I only experienced this issue with the first and third motor. I had the second motor for about a year and had other problems with that. I
Our cases may be related, but I never experienced a full shutdown like you have.
  I also only had this happen at full throttle. If I wasn't under warranty, I would have considered trying out the 95% torque solution - way cheaper than getting the motor replaced.  Did you notice if the lights stayed on when this happened?  If you ever ride in the dark, you should carry or wear something with battery lights just in case.

Thanks for the nuance on the motor replacements Domingo3. The <95% torque 'trick' didn't do much for me. My last shutdown now also happened at waaay less than 95% throttle. Had a full shutdown on the highway yesterday morning again, with below log (failure occuring as of 09/30/2018 23:02:00.

Luckily I now know how it presents itself, so at first 'hick-up' I move to the most right lane so I can weave onto the side ramp when the motor shuts down completely. Still not a very pleasant experience!). One difference now was that the electromotor didn't reboot itself automatically after coming to a full stop, but I have to turn off my Zero and turn it back on myself using the ignition key.

Am in contact now with the dealer to have a new electromotor ordered such that they can replace asap as it is becoming undrivable (previous work-around of managing throttle to max 80% and leaving with fully charged battery now doesn't seem to be foolproof anymore). Will continue to drive it 'as-is' as I rely on the bike for my daily work commute.

Code: [Select]

00161     09/30/2018 22:50:02   Sevcon Turned On
 00162     09/30/2018 22:50:03   Sevcon CAN Link Up
 00163     09/30/2018 22:50:03   DEBUG: Sevcon Contactor Drive ON.
 00164     09/30/2018 22:50:03   Module 00 Closing Contactor  vmod: 116.248V, maxsys: 116.266V, minsys: 116.266V, diff: 0.000V, vcap:  0.000V, prechg: 0%
 00165     09/30/2018 22:50:03   Contactor took 104 ms to close
 00166     09/30/2018 22:50:03   DEBUG: Module 00 Contactor is now Closed
 00167     09/30/2018 22:50:03   INFO:  Enabling Charger 1
 00168     09/30/2018 22:50:03   INFO:  Enabling Charger 2
 00169     09/30/2018 22:50:03   0x3e 0xb2 0x3a 0x01 0x00 0x5e 0xc5 0x01 0x00 0x35 0x3a 0x01 0x00 0x5e 0xc5 0x01 0x00 0x0a 0x56 0x01 0x00 0x56 0xbc 0x01 0x00 0x54 0x9d 0x01 0x00 0x5e 0xc5 0x01 0x00 0x5a 0x9c 0x01 0x00 0x5e 0xc5 0x01 0x00 0xdd 0x9b 0x01 0x00 0x20 0xc5 0x01 0x00 0x9f 0x9b 0x01 0x00 0x5e 0xc5 0x01 0x00 0x60 0x9b 0x01 0x00 0x5e 0xc5 0x01 0x00 0x4c 0xc8 0x01 0x00 0xe1 0xc4 0x01 0x00 0x8b 0xc8 0x01 0x00 0xe1 0xc4 0x01 0x00 ???
 00170     09/30/2018 22:50:10   Riding                     PackTemp: h 20C, l 17C, PackSOC:100%, Vpack:116.212V, MotAmps:   0, BattAmps:   2, Mods: 10, MotTemp:  18C, CtrlTemp:  14C, AmbTemp:   0C, MotRPM:   0, Odo:    0km
 00171     09/30/2018 22:50:10   Batt Dischg Cur Limited    101 A (14%), MinCell: 4149mV, MaxPackTemp: 20C
 00172     09/30/2018 22:51:10   Riding                     PackTemp: h 20C, l 17C, PackSOC:100%, Vpack:115.414V, MotAmps:  50, BattAmps:  15, Mods: 10, MotTemp:  20C, CtrlTemp:  17C, AmbTemp:   0C, MotRPM:1079, Odo:    0km
 00173     09/30/2018 22:51:10   Batt Dischg Cur Limited    553 A (80%), MinCell: 4115mV, MaxPackTemp: 20C
 00174     09/30/2018 22:52:10   Riding                     PackTemp: h 20C, l 17C, PackSOC:100%, Vpack:114.484V, MotAmps:  65, BattAmps:  28, Mods: 10, MotTemp:  23C, CtrlTemp:  18C, AmbTemp:   0C, MotRPM:1836, Odo:    0km
 00175     09/30/2018 22:52:10   Batt Dischg Cur Limited    658 A (95%), MinCell: 4087mV, MaxPackTemp: 20C
 00176     09/30/2018 22:53:10   Riding                     PackTemp: h 20C, l 18C, PackSOC:100%, Vpack:113.913V, MotAmps:  76, BattAmps:  38, Mods: 10, MotTemp:  25C, CtrlTemp:  17C, AmbTemp:   0C, MotRPM:2153, Odo:    0km
 00177     09/30/2018 22:54:10   Riding                     PackTemp: h 20C, l 18C, PackSOC: 98%, Vpack:115.103V, MotAmps:   0, BattAmps:   1, Mods: 10, MotTemp:  27C, CtrlTemp:  19C, AmbTemp:   0C, MotRPM:1595, Odo:    0km
 00178     09/30/2018 22:55:10   Riding                     PackTemp: h 20C, l 18C, PackSOC: 98%, Vpack:114.318V, MotAmps:  40, BattAmps:  17, Mods: 10, MotTemp:  27C, CtrlTemp:  17C, AmbTemp:   0C, MotRPM:1815, Odo:    0km
 00179     09/30/2018 22:56:10   Riding                     PackTemp: h 20C, l 18C, PackSOC: 97%, Vpack:111.477V, MotAmps: 100, BattAmps:  74, Mods: 10, MotTemp:  28C, CtrlTemp:  18C, AmbTemp:   0C, MotRPM:3222, Odo:    0km
 00180     09/30/2018 22:57:10   Riding                     PackTemp: h 20C, l 18C, PackSOC: 97%, Vpack:114.393V, MotAmps:  49, BattAmps:  12, Mods: 10, MotTemp:  29C, CtrlTemp:  17C, AmbTemp:   0C, MotRPM: 810, Odo:    0km
 00181     09/30/2018 22:58:10   Riding                     PackTemp: h 20C, l 18C, PackSOC: 96%, Vpack:114.501V, MotAmps: -40, BattAmps: -24, Mods: 10, MotTemp:  32C, CtrlTemp:  18C, AmbTemp:   0C, MotRPM:2695, Odo:    0km
 00182     09/30/2018 22:59:10   Riding                     PackTemp: h 20C, l 18C, PackSOC: 96%, Vpack:111.364V, MotAmps: 123, BattAmps:  66, Mods: 10, MotTemp:  33C, CtrlTemp:  18C, AmbTemp:   0C, MotRPM:2260, Odo:    0km
 00183     09/30/2018 23:00:10   Riding                     PackTemp: h 20C, l 18C, PackSOC: 94%, Vpack:110.945V, MotAmps:  63, BattAmps:  61, Mods: 10, MotTemp:  36C, CtrlTemp:  18C, AmbTemp:   0C, MotRPM:3394, Odo:    0km
 00184     09/30/2018 23:01:10   Riding                     PackTemp: h 21C, l 18C, PackSOC: 92%, Vpack:105.516V, MotAmps: 143, BattAmps: 148, Mods: 10, MotTemp:  40C, CtrlTemp:  19C, AmbTemp:   0C, MotRPM:4362, Odo:    0km
 00185     09/30/2018 23:02:00   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 01 00, Unknown
 00186     09/30/2018 23:02:02   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 99, Unknown
 00187     09/30/2018 23:02:02   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 02 00, Unknown
 00188     09/30/2018 23:02:02   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 99, Unknown
 00189     09/30/2018 23:02:02   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 0B 00, Unknown
 00190     09/30/2018 23:02:02   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 4E, Unknown
 00191     09/30/2018 23:02:02   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x54C2, Data: 00 10 01, Unknown
 00192     09/30/2018 23:02:02   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x52C2, Data: 00 10 01, Unknown
 00193     09/30/2018 23:02:02   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 0E 00, Unknown
 00194     09/30/2018 23:02:07   Restarting Sevcon to clear cutout fault
 00195     09/30/2018 23:02:07   Module 00 Opening Contactor  vmod: 110.285V, batt curr:   0A
 00196     09/30/2018 23:02:07   Module 01 Opening Contactor  vmod:   0.000V, batt curr:   0A
 00197     09/30/2018 23:02:08   Sevcon Turned Off
 00198     09/30/2018 23:02:08   DEBUG: Module 00 Contactor is now Open
 00199     09/30/2018 23:02:08   SEVCON CAN EMCY Frame      Error Code: 0x3100, Error Reg: 0x44, Sevcon Error Code: 0x45C5, Data: 07 07 00, Unknown
 00200     09/30/2018 23:02:08   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x04, Sevcon Error Code: 0x46C3, Data: C2 54 5E, Unknown
 00201     09/30/2018 23:02:08   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x44, Sevcon Error Code: 0x46C3, Data: 1F 0F 00, Unknown
 00202     09/30/2018 23:02:08   SEVCON CAN EMCY Frame      Error Code: 0x2000, Error Reg: 0x46, Sevcon Error Code: 0x54C1, Data: 00 10 03, Unknown
 00203     09/30/2018 23:02:08   CAN1 ACK error. count=2
 00204     09/30/2018 23:02:08   INFO: Bmvolts:37875, Cmvolts:126750, Amps:0, RPM:2922
 00205     09/30/2018 23:02:10   Sevcon Turned On
 00206     09/30/2018 23:02:10   Riding                     PackTemp: h 22C, l 19C, PackSOC: 89%, Vpack:110.410V, MotAmps:   0, BattAmps:   0, Mods: 00, MotTemp:  47C, CtrlTemp:  22C, AmbTemp:   0C, MotRPM:2922, Odo:    0km
 00207     09/30/2018 23:02:10   Sevcon CAN Link Down
 00208     09/30/2018 23:02:11   SEVCON CAN EMCY Frame      Error Code: 0x3100, Error Reg: 0x04, Sevcon Error Code: 0x45C5, Data: 07 07 00, Unknown
 00209     09/30/2018 23:02:11   SEVCON CAN EMCY Frame      Error Code: 0x2000, Error Reg: 0x06, Sevcon Error Code: 0x54C1, Data: 00 00 02, Unknown
 00210     09/30/2018 23:02:11   Sevcon CAN Link Up
 00211     09/30/2018 23:02:11   INFO: Bmvolts:110000, Cmvolts:123875, Amps:0, RPM:0
 00212     09/30/2018 23:02:11   DEBUG: Sevcon Contactor Drive OFF
 00213     09/30/2018 23:02:11   SEVCON CAN EMCY Frame      Error Code: 0x3100, Error Reg: 0x06, Sevcon Error Code: 0x45C8, Data: 07 BB 78, Unknown
 00214     09/30/2018 23:02:11   INFO: Bmvolts:109937, Cmvolts:123687, Amps:0, RPM:0
 00215     09/30/2018 23:02:13   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x02, Sevcon Error Code: 0x45C8, Data: C1 54 16, Unknown
 00216     09/30/2018 23:02:13   INFO: Bmvolts:110062, Cmvolts:122687, Amps:0, RPM:0
 00217     09/30/2018 23:02:13   Contactor Welded
 00218     09/30/2018 23:02:13   INFO:  Disabling Charger 1
 00219     09/30/2018 23:02:13   INFO:  Disabling Charger 2
 00220     09/30/2018 23:02:13   Module 00 Opening Contactor  vmod: 110.594V, batt curr:   0A
 00221     09/30/2018 23:02:13   Module 01 Opening Contactor  vmod:   0.000V, batt curr:   0A
 00222     09/30/2018 23:02:15   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x02, Sevcon Error Code: 0x45C5, Data: C1 54 11, Unknown
 00223     09/30/2018 23:02:15   INFO: Bmvolts:110187, Cmvolts:118062, Amps:0, RPM:0
 00224                       0   DEBUG: Reset: Power-On, External
 00225                       0   Power On                   Key Switch
 00226                       0   Key On
 00227                       0   Module 00 Opening Contactor  vmod:   0.000V, batt curr:   0A
 00228                       0   Module 01 Opening Contactor  vmod:   0.000V, batt curr:   0A
 00229                       0   Module 00 CAN Link Up
 00230                       0   Module 00 Registered       serial: ,  vmod: 111.084V
 00231     09/30/2018 23:02:23   Module 00 CAN Link Down
 00232     09/30/2018 23:02:23   Module 00 CAN Link Up
 00233     09/30/2018 23:02:23   DEBUG: Module scheme changed from None mode to Running mode
 00234     09/30/2018 23:02:24   Sevcon Turned On
 00235     09/30/2018 23:02:25   Sevcon CAN Link Up
 00236     09/30/2018 23:02:26   DEBUG: Sevcon Contactor Drive ON.
 00237     09/30/2018 23:02:26   Module 00 Closing Contactor  vmod: 111.175V, maxsys: 111.195V, minsys: 111.195V, diff: 0.000V, vcap:  0.000V, prechg: 0%
 00238     09/30/2018 23:02:26   Contactor took 108 ms to close
 00239     09/30/2018 23:02:26   DEBUG: Module 00 Contactor is now Closed
 00240     09/30/2018 23:02:26   INFO:  Enabling Charger 1
 00241     09/30/2018 23:02:26   INFO:  Enabling Charger 2
 00242     09/30/2018 23:02:26   0x3e 0xcb 0x9e 0x01 0x00 0x1b 0xb1 0x01 0x00 0x6c 0x99 0x01 0x00 0x1b 0xb1 0x01 0x00 0xdb 0x91 0x01 0x00 0x1b 0xb1 0x01 0x00 0xdb 0x91 0x01 0x00 0xdc 0xb0 0x01 0x00 0xdb 0x91 0x01 0x00 0x1b 0xb1 0x01 0x00 0xdb 0x91 0x01 0x00 0x1b 0xb1 0x01 0x00 0xdb 0x91 0x01 0x00 0x1b 0xb1 0x01 0x00 0xdb 0x91 0x01 0x00 0x1b 0xb1 0x01 0x00 0x47 0xb4 0x01 0x00 0x9e 0xb0 0x01 0x00 0x86 0xb4 0x01 0x00 0x9e 0xb0 0x01 0x00 ???
 00243     09/30/2018 23:02:32   Riding                     PackTemp: h 22C, l 19C, PackSOC: 89%, Vpack:111.354V, MotAmps:   0, BattAmps:   2, Mods: 10, MotTemp:  45C, CtrlTemp:  19C, AmbTemp:   0C, MotRPM:   0, Odo:    0km
 00244     09/30/2018 23:02:32   Batt Dischg Cur Limited    101 A (14%), MinCell: 3973mV, MaxPackTemp: 22C
 00245     09/30/2018 23:03:32   Riding                     PackTemp: h 23C, l 20C, PackSOC: 86%, Vpack:101.102V, MotAmps: 155, BattAmps: 208, Mods: 10, MotTemp:  55C, CtrlTemp:  26C, AmbTemp:   0C, MotRPM:5144, Odo:    0km
 00246     09/30/2018 23:03:32   Batt Dischg Cur Limited    553 A (80%), MinCell: 3595mV, MaxPackTemp: 23C
 00247     09/30/2018 23:04:32   Riding                     PackTemp: h 24C, l 21C, PackSOC: 84%, Vpack:106.855V, MotAmps:  62, BattAmps:  61, Mods: 10, MotTemp:  54C, CtrlTemp:  23C, AmbTemp:   0C, MotRPM:4025, Odo:    0km
 00248     09/30/2018 23:04:32   Batt Dischg Cur Limited    656 A (95%), MinCell: 3792mV, MaxPackTemp: 24C
 00249     09/30/2018 23:05:32   Riding                     PackTemp: h 24C, l 22C, PackSOC: 84%, Vpack:107.366V, MotAmps: 121, BattAmps:  78, Mods: 10, MotTemp:  50C, CtrlTemp:  21C, AmbTemp:   0C, MotRPM:2760, Odo:    0km
 00250     09/30/2018 23:05:32   Batt Dischg Cur Limited    679 A (98%), MinCell: 3824mV, MaxPackTemp: 24C
 00251     09/30/2018 23:06:32   Riding                     PackTemp: h 24C, l 22C, PackSOC: 84%, Vpack:109.102V, MotAmps:  12, BattAmps:   9, Mods: 10, MotTemp:  50C, CtrlTemp:  21C, AmbTemp:   0C, MotRPM:2925, Odo:    0km
 00252     09/30/2018 23:07:32   Riding                     PackTemp: h 24C, l 22C, PackSOC: 82%, Vpack:110.321V, MotAmps: -40, BattAmps: -12, Mods: 10, MotTemp:  49C, CtrlTemp:  20C, AmbTemp:   0C, MotRPM:1585, Odo:    0km
 00253     09/30/2018 23:08:32   Riding                     PackTemp: h 25C, l 22C, PackSOC: 82%, Vpack:110.117V, MotAmps: -31, BattAmps: -17, Mods: 10, MotTemp:  49C, CtrlTemp:  21C, AmbTemp:   0C, MotRPM:2426, Odo:    0km
 00254     09/30/2018 23:09:32   Riding                     PackTemp: h 25C, l 22C, PackSOC: 81%, Vpack:108.347V, MotAmps:  51, BattAmps:  33, Mods: 10, MotTemp:  49C, CtrlTemp:  21C, AmbTemp:   0C, MotRPM:2673, Odo:    0km
 00255     09/30/2018 23:10:32   Riding                     PackTemp: h 25C, l 22C, PackSOC: 80%, Vpack:105.279V, MotAmps: 117, BattAmps: 106, Mods: 10, MotTemp:  50C, CtrlTemp:  21C, AmbTemp:   0C, MotRPM:3793, Odo:    0km
 00256     09/30/2018 23:11:32   Riding                     PackTemp: h 25C, l 23C, PackSOC: 78%, Vpack:105.256V, MotAmps:  55, BattAmps:  55, Mods: 10, MotTemp:  53C, CtrlTemp:  22C, AmbTemp:   0C, MotRPM:4446, Odo:    0km
 00257     09/30/2018 23:12:32   Riding                     PackTemp: h 25C, l 23C, PackSOC: 76%, Vpack:103.703V, MotAmps:  55, BattAmps:  65, Mods: 10, MotTemp:  57C, CtrlTemp:  24C, AmbTemp:   0C, MotRPM:4707, Odo:    0km
 00258     09/30/2018 23:12:32   Batt Dischg Cur Limited    647 A (93%), MinCell: 3642mV, MaxPackTemp: 25C
 00259     09/30/2018 23:13:13   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 01 00, Unknown
 00260     09/30/2018 23:13:22   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 68, Unknown
 00261     09/30/2018 23:13:22   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 02 00, Unknown
 00262     09/30/2018 23:13:32   Riding                     PackTemp: h 26C, l 24C, PackSOC: 73%, Vpack:103.773V, MotAmps:  89, BattAmps:  67, Mods: 10, MotTemp:  59C, CtrlTemp:  25C, AmbTemp:   0C, MotRPM:3704, Odo:    0km
 00263     09/30/2018 23:13:32   Batt Dischg Cur Limited    615 A (89%), MinCell: 3680mV, MaxPackTemp: 26C
 00264     09/30/2018 23:13:33   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 99, Unknown
 00265     09/30/2018 23:13:33   SEVCON CAN EMCY Frame      Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 01 00, Unknown
 00266     09/30/2018 23:13:43   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 4E, Unknown
 00267     09/30/2018 23:14:32   Riding                     PackTemp: h 27C, l 24C, PackSOC: 72%, Vpack:104.760V, MotAmps:  35, BattAmps:  31, Mods: 10, MotTemp:  60C, CtrlTemp:  24C, AmbTemp:   0C, MotRPM:3657, Odo:    0km
 00268     09/30/2018 23:14:32   Batt Dischg Cur Limited    662 A (95%), MinCell: 3704mV, MaxPackTemp: 27C
 00269     09/30/2018 23:15:32   Riding                     PackTemp: h 27C, l 25C, PackSOC: 72%, Vpack:105.464V, MotAmps:  88, BattAmps:  39, Mods: 10, MotTemp:  55C, CtrlTemp:  20C, AmbTemp:   0C, MotRPM:1762, Odo:    0km
 00270     09/30/2018 23:16:32   Riding                     PackTemp: h 27C, l 25C, PackSOC: 72%, Vpack:106.819V, MotAmps: -40, BattAmps:  -8, Mods: 10, MotTemp:  54C, CtrlTemp:  20C, AmbTemp:   0C, MotRPM:1215, Odo:    0km
 00271     09/30/2018 23:17:32   Riding                     PackTemp: h 27C, l 25C, PackSOC: 72%, Vpack:106.878V, MotAmps:   0, BattAmps:   2, Mods: 10, MotTemp:  51C, CtrlTemp:  18C, AmbTemp:   0C, MotRPM:   0, Odo:    0km
 00272     09/30/2018 23:18:32   Riding                     PackTemp: h 27C, l 25C, PackSOC: 72%, Vpack:107.004V, MotAmps:   0, BattAmps:   2, Mods: 10, MotTemp:  47C, CtrlTemp:  17C, AmbTemp:   0C, MotRPM: 217, Odo:    0km

[MicheldeL]

Small update:

Still waiting for the replacement motor. After 5 weeks and continuous calling on status-updates from my end they told me that the 'old' MY13 electro-motor wasn't available anymore and they would replace it with a MY18 electro motor. Only one issue with this: The software changes to allow the MY13 Controller to talk to the MY18 electro-motor wasn't finished yet. They are trying to finish this as we speak.

Positive note: After they told me they would have to replace with a MY18 engine, the European distributor has offered to 'loan' (free of charge) a MY18 DSR for my daily commute in the interim. This is a very nice gesture of them, seeing as my bike is 5 years old by now and I have no warranty rights what-so-ever anymore.

Will update when the electro-motor has been installed and driving my own bike again!

[Richard230]

Small update:

Still waiting for the replacement motor. After 5 weeks and continuous calling on status-updates from my end they told me that the 'old' MY13 electro-motor wasn't available anymore and they would replace it with a MY18 electro motor. Only one issue with this: The software changes to allow the MY13 Controller to talk to the MY18 electro-motor wasn't finished yet. They are trying to finish this as we speak.

Positive note: After they told me they would have to replace with a MY18 engine, the European distributor has offered to 'loan' (free of charge) a MY18 DSR for my daily commute in the interim. This is a very nice gesture of them, seeing as my bike is 5 years old by now and I have no warranty rights what-so-ever anymore.

Will update when the electro-motor has been installed and driving my own bike again!

It is about time we heard some good news regarding Zero's after-sales customer service.  That is great to hear that you are having a positive experience with your Zero ownership, which is probably facilitated by your country's importer.  Now if Zero could only keep treating their customers like that in the future.

[dennis-NL]

Good news!
Almost wish my 2013DS also quit... 
Getting a 2018 motor! Hope they make no mistakes with programming and you can enjoy again your own bike.
 

[Moravia]

Zero is shit. I bought my Zero DS 11.4 of MY2014 (first on road 2016, so warranty start 2016) in November 2018 with 29,000 km on it.
First issue at first ride, I could not make 40km on full charge. Went to dealer in Amsterdam and they came with this controller is broken, and the cost is 2000 euro. I am like, I just bought it from a dealer, so their responsibility to fix. Dealer fixed it for free.
Then I did not even make 2000, the whole thing started again.

They say 0 emission, 0 maintenance and that the cost of the motorcycle pays itself back. Bullshit, if something break, it will cost you 2000 euro. It is a costly bike. I rather have 100 small maintenance cost than this big cost that happens too often.
This sort of indestructible motorcycle must make 200,000km, cant even make 35,000km.

Zero is shit, stay clear from their bikes.

[DonTom]

stay clear from their bikes.

Sounds like you had some bad luck. I have more than 16 KM (10K miles ) on each of my Zeros and I am quite happy with them.

I cannot say totally problem free, but  reasonable. I had a front ABS sensor crap out in my SR (I replaced that myself  at my cost, even though the bike was still in warranty). And I had the battery replaced in my DS, which means now my 6.5 KWH is now a 7.4 KWH at no cost to me, as I let the dealer do that one, of course.  I consider that battery failure after three years to be good luck!

YMMV.


I belong to many motorcycle forums. All brands have their share of lemons.


-Don-  Auburn, CA

[Richard230]

Zero is shit. I bought my Zero DS 11.4 of MY2014 (first on road 2016, so warranty start 2016) in November 2018 with 29,000 km on it.
First issue at first ride, I could not make 40km on full charge. Went to dealer in Amsterdam and they came with this controller is broken, and the cost is 2000 euro. I am like, I just bought it from a dealer, so their responsibility to fix. Dealer fixed it for free.
Then I did not even make 2000, the whole thing started again.

They say 0 emission, 0 maintenance and that the cost of the motorcycle pays itself back. Bullshit, if something break, it will cost you 2000 euro. It is a costly bike. I rather have 100 small maintenance cost than this big cost that happens too often.
This sort of indestructible motorcycle must make 200,000km, cant even make 35,000km.

Zero is shit, stay clear from their bikes.

Perhaps your 2014 model sat around for two years before you bought it without being properly stored and charged by the dealer in accordance with the Zero-recommended procedure and you are suffering from a degraded battery pack.   

[Crissa]

Mine sat around getting 600 miles over its five-year life and I've put another 3000 miles on it in all weather and the worst thing that's happened is the turn relay died,

-Crissa