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[gt13013]

Hello,

My 2016 FXS was running fine until these days. Some days ago I have charged the bike during night using the standard cord and a manual timer. The bike charged from 58% to 73% in 1h 30min. Until there all seemed OK.

But when I tried to use the bike the day after, the bike did not start.
1) When keying on the bike: no "click". After 1min 30s the headlight turns off and the screen starts flashing.
2) When I plug in the charging cord: no "click". After 1min 30s the screen starts flashing.

I have written a page with much more details (MBB log, errors on dash, videos showing the dash and the BMS LEDs in both above cases): https://bit.ly/FXSbreakdown

I am looking for a way to diagnose the problem, and, if possible, to solve it myself in order to save time (I am afraid that if I take the bike to the dealership, there will be weeks of downtime...)

Thank you in advance for your expert advice!

[Say10 15FX 16FXS]

I've had a similar experience on both of mine. Try cycling the key a few times. Mine came back after a few tries and I heard the contactors chooch. Was fine after that.

[gt13013]

I've had a similar experience on both of mine. Try cycling the key a few times. Mine came back after a few tries and I heard the contactors chooch. Was fine after that.

Thanks for the advice, but I have tried turning the key about 30 times and it did not solve the problem.


By the way, I noticed that in the logs, it appeared new lines that I have not seen before:
DEBUG: Reset: Software
BMS Reset     Software

So, I will look now deeper in the  BMS resetting possibilities...

[Richard230]

The only times I have seen a flashing dash is when I get a firmware update and once when my OBC was being tested by the BMS and it apparently determined that there was a malfunction. Turning the key on and off cleared that issue and it never returned - until the OBC finally failed. 

[gt13013]

Some updates (all the details are in the page https://bit.ly/FXSbreakdown that has been updated).

It does not seem to be a problem with the BMS and the battery

Abnormal behavior :
- bike does not start
- bike does not charge
- no click
- dash is flashing 1min 30s after keying or after attempting to charge
- the red triangular indicator on the dash does not behave the same way when side stand is up or down
- when side stand is up, the red triangular indicator says "Contactor error"
- the dash indicates errors :

        25  Contactor open warning
        27  Precharge error
        48  SEVCON startup disabe (only once, not cycling)
        49  Contactor open disable
        58  BMS sensor warning

- when trying to charge, the BMS LEDs indicate that the bike is balancing, instead of indicating the SOC

[Richard230]

That sounds like something that the factory would need to investigate. It sounds like a real mess to me. 

[DonTom]

If the contactor is open, nothing will work, but since you have all those errors, I wonder if something is preventing the contactor from closing.


Did you try a reset of the BMS?


-Don-  Cold Springs Valley, NV

[gt13013]

Did you try a reset of the BMS?

Yes, I tried the hardware and software reset on the BMS, with both batteries.
I also tried to run the bike with only one battery.
But that was not successful...

[NEW2elec]

Sounds like you may have a wielded contactor.

It wouldn't be the first one but not real common.

[DonTom]

Sounds like you may have a wielded contactor.

But can a contactor welded closed give the error of "25 Contactor open warning"?


-Don-  Reno, NV

[gt13013]

Do you know where is the contactor on a FXS ? And how does it look like ?

[DonTom]

Do you know where is the contactor on a FXS ? And how does it look like ?

See here.


-Don-  Reno, NV

[gt13013]

Thanks Don.
I opened the bike looking for a Gigavac GX11 contactor, but I was not able to find the contactor(s?) (since I have 2 removable batteries, is there one or two ?)

[DonTom]

Thanks Don.
I opened the bike looking for a Gigavac GX11 contactor, but I was not able to find the contactor(s?) (since I have 2 removable batteries, is there one or two ?)

There is contactor  in each battery case.  The contactor is  inside the battery case.


-Don-  Reno, NV

[gt13013]

OK. Thanks !
That is confirmed by the exploded view.

By the way, it means that the problem probably does not come from the contactors themselves (it is very unprobable that they both die at the same time!).
Consequently, the problem must be at a upper level...