Print

Please login or register.
1 Hour 1 Day 1 Week 1 Month Forever
Login with username, password and session length

[fredx]

Hey all,

I've got a 2020 SR/F that won't charge.  It has always worked great, until now.  I hadn't ridden the bike in a few weeks (left it at about 80% charge), and then rode it this week, and tried charging it today.  The contactor clicks, the cooling fan fires up, and no charging happens, the cooling fan winds down, and eventually the red battery indicator light illuminates.  I've tried two separate EVSEs.

Looking through the menus, I get error codes 26, 28, 31, 33, and 37 showing up.



Up until now, I could consistently get 5.7kW or more charging.  Today, zero.

I love this bike.  Until today!

Thanks,

 - Fred

[lunarx]

I'd start by checking your 12V Battery, per Code 28.

It's under the Seat, behind a plastic cover.
You will see the +/- Terminals and a Strap that holds it in.
It might need to be charged (but only with a special charger for Lithium Power-Sports [low AH] Batteries).
Also, only charge it, if it's fully disconnected from Bike & only by connecting direct to it's Battery Terminals.

If you take it out, I'm curious if it has any Group Size Designations allowing for a Universal Replacement.
Although probably best to buy a new one, from Zero, if it wont charge back to > 12V.

BTW - What FW are you on?
Just wondering if newer/older FW has more/less issues with 12V Static Drain.

[fredx]

Thanks, lunarx, that's very helpful.  I tried simply turning on the bike for awhile last night, in the hopes that it would charge the 12V battery on its own with more time turned on, but no luck.  And then I simply left the charger plugged into the bike when I went to bed, wondering if it might come to life at some point.

Bad idea!  When I woke up, the bike was completely dead.  I unplugged the charger and disassembled the plastics to get at the 12V battery.  It read 3.7V.  Ouch.  I connected it to a small 12V li-ion Battery Tender, and managed to get it charged up properly.  Now the battery reads around 13.5V.

Now the bike is back to life, but it still refuses to charge.  It's the same behavior; I plug in the charger, the bike wakes up, the contactor clicks, the cooling fan comes on, no charging happens, the cooling fan slows and stops, and eventually the red battery indicator comes on.  The error codes are 26, 31, 33, and 37.

One of those errors is a CANbus error, another says low DC-DC converter voltage, and the others just say to disconnect the bike, turn it off, wait 2 minutes, and try again.  Very helpful.

I even tried the https://zeromanual.com/wiki/MBB_Hardware_Reset procedure, with no luck.

The bike's firmware version is 6V26

I'd love to avoiding bringing this bike to a Zero dealer and having it out of commission for awhile, but alas, I'm getting discouraged!  Thanks for your help. 

[DonTom]

One of those errors is a CANbus error, another says low DC-DC converter voltage,

My guess is your DC2DC converter crapped out or has a flakey connection somewhere. The low voltage is probably giving you all the other errors.


-Don-  Reno, NV

[DonTom]

Hey all,

I've got a 2020 SR/F that won't charge.  It has always worked great, until now.  I hadn't ridden the bike in a few weeks (left it at about 80% charge), and then rode it this week, and tried charging it today.  The contactor clicks, the cooling fan fires up, and no charging happens, the cooling fan winds down, and eventually the red battery indicator light illuminates.  I've tried two separate EVSEs.

Looking through the menus, I get error codes 26, 28, 31, 33, and 37 showing up.



Up until now, I could consistently get 5.7kW or more charging.  Today, zero.

I love this bike.  Until today!

Thanks,

 - Fred

What percentage SOC are you now at? Get it down to 70% before you try to charge. I have noticed on my Zeros, they will not START a charge at 80% SOC correctly, but will be fine at 80% SOC as long as the charge is started below 70% SOC.


-Don-  Reno, NV

[lunarx]

Well at least Code 28 is gone (hopefully) 

Code 26 does support what DonTom is saying.
The DC-DC Converter looks easy to get to, if your "Tank" is off.

I'll share; that when I took possession of my 21 SR/S it also had Codes 31, 33, 37 stored.
However it charged fine and those codes haven't returned since Clearing them.

My FW was also reported as 6v26 (per Dash Menu).
Interestingly, it still displays 6v26, despite being updated from v18 to v19 (per Performance/Manage-FW in the App).

Maybe see, if you can Connect your App via BT and check what FW it reports.
It might be worth a try, to update, if it lets you (assuming your 12V is healthy enough now).

[Hans2183]

still looks so shiney underneath that tank cover 

But indeed the dash firmware version is not related to the bikes firmware versions. Those 18 and 19 versions are for the bike updated from the app or directly on the bike. For the Dash firmware a dealer would have to connect the dash itself to update that but I didn't see that done so far. So I would say that version is just what it got in the factory.

You have a premium so 2x 3kW right? You could try to charge it from an outlet so that only the first 3kW is used. Compared to using a charge station that will trigger both chargers. 

[fredx]

Just a quick update to say that I was unsuccessful diagnosing or remedying this problem.  The bike is at 63% SOC; I trailered it to the dealer this morning to avoid showing up there at 10% (my dealer's an hour away) and having the bike sit there for an extended period with the battery discharged.

I tried disconnecting the 12V battery, the DC-DC converter, and the MBB for a bit to reset everything, and it had no effect.  I neglected to check the firmware version...

My guess is a DC-DC converter failure.  I'll report back when the dealer service department diagnoses the problem.

At least the bike is under warranty, but this really sucks, with the weather getting beautiful here in Colorado!

Thanks for all the help, folks!

[lunarx]

Just a quick update to say that I was unsuccessful diagnosing or remedying this problem.  The bike is at 63% SOC; I trailered it to the dealer this morning to avoid showing up there at 10% (my dealer's an hour away) and having the bike sit there for an extended period with the battery discharged.

I tried disconnecting the 12V battery, the DC-DC converter, and the MBB for a bit to reset everything, and it had no effect.  I neglected to check the firmware version...

My guess is a DC-DC converter failure.  I'll report back when the dealer service department diagnoses the problem.

At least the bike is under warranty, but this really sucks, with the weather getting beautiful here in Colorado!

Thanks for all the help, folks!

Very interested to hear what it is.
If it's the DC-DC Converter, then I'm ordering a spare.
They aren't very expensive (which maybe is part of the problem 

[Zelidar]

At 22'000 km two days ago with 30% SOC, I had a very similar problem (only code 28 + code 31). Also both the yellow CEL and red battery lights were lit in the dashboard. That is the first major issue I am having with this bike.

First, just like you it would not charge, then it would not move, and finally, it could boot with the Zero logo, but then would go back to a black LCD in matter of seconds. Luckily this happened after I arrived home. By the way, in my case the 12 V battery measured 12.62 V.

I contacted the dealer who told me without hesitation that they needed seeing the bike, hooking it up on their diagnostic computer. Luckily again my insurance covered such a case so now my bike has already been picked up and will be next week at the dealer.

What bothers me a little, is that it just went to that same Zero dealer for a full service at 20'000 km.

[Crissa]

Electronic failures sometimes give little warning.  A connection was conducting, and then it melted/rusted/popped and then it doesn't work anymore.

-Crissa

[Zelidar]

Electronic failures sometimes give little warning.  A connection was conducting, and then it melted/rusted/popped and then it doesn't work anymore.

What bugs me is how powerless I felt, as you said, there were zero warning. Within minutes, the bike turned from fully functional to totally dead.

I have been driving ICE bikes most of my life and I always knew what was going on, often even what needed be done. EV on the other hand, with their onboard computers, connectivity and software, have gone out of reach for a majority among us here, but also dealers are facing very different issues than what they had with ICE motorcycles (or cars for that matter).

[Syawedis]

Sounds like a low isolation issue. Curious to know, do you ride in rainy weather?

[Crissa]

To me, the electronics are easier, but I did vocational electronics in high school, not autoshop

-Crissa

[fredx]

Hey all,

I just picked up the bike today, and it's working just dandy again.  It's so good be back on the electric tire roaster!   

The dealer notes say "DIAG NO CHARGE  Description: CUSTOMER STATES THAT THE UNIT WILL NOT CHARGE, THE FAN WILL TURN ON AND SLOWLY DIE THEN FOUR CODES COME ON
Resolution:- FIRMWARE UPDATED
CHECKED HIGH VOLTAGE FUSES (GOOD)
- SENT LOGS TO ZERO
- CHARGING NOW (THRESHOLD SET TO 80%)"



The current firmware is 19.  I now wish I'd checked the firmware version before I'd brought the bike in, but it apparently was something before 19.

I don't understand why it seemingly randomly decided to stop charging, but it's charging again fine now.  I rode it home, plugged it into a 6kW EVSE, and saw it charge at 5.7kW.

It was very strange to be without my fave ride for a week.  I got back on the SR/F, and kept reaching for the clutch lever.   

Thanks for all the pointers and suggestions, folks!

 - Fred