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[MikeL]

Hey all, I got home from work today and plugged in my bike and walked away assuming it would charge. I went to unplug it later as I assumed it would be fully charged and I noticed that the state of charge hadn't changed (89%) and the green charge light was off. I assumed maybe I didn't plug it in all the way or somehow tripped a breaker in my electrical box but I had power and nothing tripped.

What happens when I plug it in:

• Bike comes on in charge mode
• Charge light flashes green
• Audible click (of contact connectors I'm assuming?)
• No change in time to charge, stays at 0:00
• Green flashing charge light turns off completely after a few more seconds

I pulled error codes and only got the following: 44, 45, and 47. 47 is the only one that stands out to me as it's MBB but I honestly have no idea.

I pulled motorcycle and battery logs but don't know how to read .bin files.

Any thoughts or help would be greatly appreciated.

[TheRan]

You'll need to upload the logs to the log parser, I think you can also upload the .bin files here for others to upload and look at for you.

https://zero-motorcycle-community.github.io/browser-parse/zero-log-parser.html

44 and 45 relate to the kick stand switch and kill switch if I remember correctly, not that there's a problem with them but just telling you that they're on so nothing to worry about there.

[MikeL]

You'll need to upload the logs to the log parser, I think you can also upload the .bin files here for others to upload and look at for you.

https://zero-motorcycle-community.github.io/browser-parse/zero-log-parser.html

44 and 45 relate to the kick stand switch and kill switch if I remember correctly, not that there's a problem with them but just telling you that they're on so nothing to worry about there.

Oh that's awesome! We used a similar thing for drone logs after crashes at my last job. I was actually thinking "I wish we had an upload tool like I had before." Glad this exists.

I had to cut down a lot of the data to just the last few days to meet the upload limits - hopefully the logs will be helpful in figuring things out. I've attached them if anyone wants to take a look.

[princec]

Seems the CANBUS can't talk to the BMS:

Code: [Select]

07236     06/04/2020 18:17:23   ERROR: 1/1500   PL536 Read Attempts Failed. Breakdown: conv- 2, (crc,timeout)- 1=(0,0) 2=(0,0) 3=(0,0) 4=(0,0) 5=(0,0)
The PL536 I believe is this part: https://www.ti.com/product/BQ76PL536
 
Cas

[MikeL]

Seems the CANBUS can't talk to the BMS:

Code: [Select]

07236     06/04/2020 18:17:23   ERROR: 1/1500   PL536 Read Attempts Failed. Breakdown: conv- 2, (crc,timeout)- 1=(0,0) 2=(0,0) 3=(0,0) 4=(0,0) 5=(0,0)
The PL536 I believe is this part: https://www.ti.com/product/BQ76PL536
 
Cas

Appreciate the help! This may be a job for my dealership more then me if that's the case. This looks like an actual on-board chip which I don't want to mess with. I'm assuming my dealership would just want to replace the whole part it's attached to. Hopefully it's not too expensive.

[BrianTRice@gmail.com]

The PL536 chips are on the BMS board inside the battery case and will probably be covered under the battery warranty: https://zeromanual.com/wiki/BMS/Architecture

Replacing them would require some significant/professional skill and you'd have to de-pot and re-pot the board, so it's not worthwhile until the battery warranty expires.

[princec]

Might not be the chips; could be any part of the connection up to the chips (ie. the CANBUS). Could just be a loose wire or connector or a dry joint.

Cas

[BrianTRice@gmail.com]

Re-seating the BMS might fix it, but is a high voltage access job that should be done by the dealer if your battery is within warranty or if you're not experienced professionally and don't want to deal with the risk.

[MikeL]

Hopefully its just a connection issue that can be fixed easily at the dealer. Contacted them today and they said to drop it off tomorrow.

Thanks for the help all - I'll report back once it's fixed.

[MikeL]

Quick update from my dealer is that they were able to get it to charge - by just plugging it in. Which is a bit frustrating but glad to hear it's working. It's throwing a "check engine" light though and they are waiting to hear back from Zero on that. Hopefully will have more updates tomorrow when they open up.

[KrazyEd]

Isn't that always the case. You try something a dozen times with no success. Load it up, take it to the dealer and it works perfectly ( other than the light )
At least with the light, they can't just shake their head at you.

[MikeL]

Well, I forgot to update this post with the final conclusion. The conclusion was.. well... nothing haha. The dealership sent the logs to Zero and worked with them to see if they could find any issues. They said they didn't see anything in the logs that was of concern. They said it was probably a one-time fault that triggered it all or something along those lines. The dealership cleared the check engine light and documented everything for me.

They said it MIGHT be the charger, but unless it happens a again they can't be certain. I'm just hoping it was something minor and I won't see it again.

Isn't that always the case. You try something a dozen times with no success. Load it up, take it to the dealer and it works perfectly ( other than the light )
At least with the light, they can't just shake their head at you.

Seriously, when they called and said it's charging fine I was thinking just that lol. I'm just glad it wasn't anything in the end.

[buchandiver]

Hi MikeL

Has this prob re-occurred or have you any inkling what caused it?

I just had exact same on my 2019 FX - downloaded logs & they look much the same as yours - however my problem is that nearest dealer is +150 miles away in Edinburgh?

[Electric_Adventures]

I’m having this exact same problem right now, I have already posted my logs in the general chat under “bms issues”. I haven’t seen any improvement but I will be attempting to charge the bike tomorrow when I get the chance.  My nearest dealer is 180 miles away so I get it, but I’m just going to have to suck it up and get it there.

[Moto7575]

I have the same probleme with a 2017 FXS - the charging stops at 87%, and the range is indeed reduced by 13%..
Seems like a generic problem. Anybody from Zero having an idea about what can be done with this ?