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[Richard230]

I replaced my rear tire last Saturday. I thought I had the belt aligned properly, with a 1mm gap between the belt and the flange. But after riding the bike for 40 miles I was feeling a vibration through the handlebars that I hadn't felt previously. So I rechecked the belt position and discovered that it had moved over that 1mm and was now rubbing slightly against the flange. Time to make another adjustment again.  Let vibrations be your guide to belt condition and setup.   

[sharagan]

I was checking the belt tension every week with the gates cricket tool, I tried loosening and also tightening it, but the clicking sound was always present. I have never heard such a clicking sound from another Zero. The statement that it is completely normal is very strange to me, not to mention the cracks in the belt.

[Crissa]

The warranty applies to the date you reported the failure, not the date they discovered it.

-Crissa

[sharagan]

I meant that it will be declared normal as it still runs even though it makes strange noises because it is under warranty.

[Crissa]

Even if it fails after the warranty, you reported the damage before it expired.  The date you reported it to them counts, not the date it fails or diagnose it.

-Crissa

[sharagan]

Hi all,

the dealer is trying to convince me that the crackling sound is caused by the carbon fiber construction of the belt and completely normal (also the cracks). Bike is still at the dealer. Could maybe someone with an FXS record the sound of the motor pulley when rotating the wheel with the bike turned off, so that I can see if it is really normal or show them some proof, that it is not normal at all and have them investigate it properly.

Thanks in advance.

[Red Clay]

If your dealer says that the belt is causing the noise and is "normal", then they should put a new belt on to back that notion with evidence.

Here is my experience with bad motor bearing noises. A popping sound that matches the RPMs, this seems to be a single ball or spot within the bearing, indicates a defect from the bearing manufacturer. A grinding sound from dirt intrusion into the outer bearing (just behind the front sprocket).

https://www.electricmotorcycleforum.com/boards/index.php?topic=10880.0

Ride On, red clay

[droidish]

My 2017 SR has made a sound very similar to the OP’s since new.

[sharagan]

Hi everyone,

new belt was fitted in July, at first there was no crackling sound nore cracks in the outer layer, after 1500km same situation. Tension is at 25 to 30 kg on the krikit tool from the beginning. One dealer says it is normal, other dealer says that there is nothing they can do. Any ideas?

[Crissa]

That does seem weird.

-Crissa

[ZeroChrissy]

Have exactly the same on my SR2017.

Also, after changing to a new belt and pulley.
(Belt tension at lower limit.)

I can hear the cracks by moving,- pressing the old belt in my hands. It comes really out of the belt.
But, it semms the new belt has it, too !?
Something wrong with some belts!?!

I can hear the crackling specially during BRAKING and REGEN.
That's not nice and very annoying.

Zero promissed me a silent bike...

[sharagan]

The noise is annoying, but my main concern is that it is a symptom of a failing belt which might break any time.

How many miles did you make already since the crackling started?

What if it is caused by some kind of misalignment in the drive train and not by a faulty batch of belts?

My FXS is one year old and has 3000 km (1800 miles) and this is already the 2nd belt with the same crackling sound, which developed over time together with deep visible cracks on the outside.

Unfortunately, this is only one of more issues, none of which Zero wants to acknowledge....

[Curt]

new belt was fitted in July, at first there was no crackling sound nore cracks in the outer layer, after 1500km same situation. Tension is at 25 to 30 kg on the krikit tool from the beginning. One dealer says it is normal, other dealer says that there is nothing they can do. Any ideas?

In the very last few frames (0:33) of the video, it looks like the belt is cracked clear across, isn't it? That's absolutely not normal and no dealer can tell you it is. Do you often ride a section of gravel road?

Also, I would not be at all surprised if there was a batch of bad belts, similar to that batch of spoke-breaking front wheels on the 2016's.

[sharagan]

the motorcycle hasn't seen gravel and I haven't given it even full throttle for the last 1500km since I have the new belt as I wanted to be sure that it is not my fault. Yes, the belt has cracks across on multiple spots, which appeared already after the first 100km. The new belt is from a completely different dealer and fitted July this year. The old belt was from the factory and the bike is from early last year. I am also not willing to accept that this is normal.

[ESokoloff]

How tight is the belt?

Present belt tension is not what I was asking but rather the tension at the time of discovery.
Excessive belt tension can/will damage bearings.
Surface cracks on every one of my numerous belts (60+k miles) is an expectation as the outside has to expand going around the sheaves (pulleys).
The way I see it the outside “skin” merely protects the load bearing cords.

Make sure there is nothing stuck in the teeth of the sheaves (unlikely but has to be ruled out).