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[GoneToPlaid]

We're on our way now, and the ride report is up:

https://advrider.com/f/threads/two-bikes-one-jug-2eride-the-2021-tat-with-the-electric-zero-dsr-coast-to-coast.1514716/

[MVetter]

Really like the charging luggage! One minor thing I did on our units was to mill a small channel for that 12v fan cable so the entire face could be flush with whatever it was mounted to. Gotta be careful not to nick it, because that wire will nuke the whole charger if it shorts. If you ever decide you want liquid cooling, those lines can be repurposed to run a water pump. Have fun!

[NoMoreIdeas]

Thats so awesome, I've been waiting for one of these to pop up on ADV rider. Can't wait for more updates!

[mdjak1]

From the ADV thread:
2) Riding forest roads without engine noise is like magic. So many people lament the lack of audio cues and engine noise that’s missing from electric vehicles, but the trade-off is sometimes entirely worth it. You can hear the birds signing while riding. You can hear the tires squirming for traction, even when riding normally. It’s immersive, somehow both exhilarating and peaceful, and completely addicting. It’s like combining all the best parts of mountain bike riding and motorcycling, without any of the down sides. On the faster paved roads it matters less, wind noise at highway speed makes the difference less noticeable, but on a forest road, I am envious that Kevin is on an electric bike, I want one.

To be able to go out and cruise through nature without making a ton of noise would be great.  I await the day when all motorcycles, especially offroad motorcycles are electric and have lots of range and easy, fast charging.   

As for the power tank issue, it wasn't mentioned what the problem ended up being that I could see.    What was the issue?  Failed BMS? 

[Shadow]

... Gotta be careful not to nick it, because that wire will nuke the whole charger if it shorts..

Yeah, seen that 12Vdc output start a fire in the connected fan on the bike I had, also just randomly short out because a loose fan siezed up and was a dead short, and adding a fuse doesn't redress the problem of shorting on the enclosure due to unbroken (sharp freshly machined) edges in a vibration-rich environment wearing against the wires insulation. Being careful to guard the insulated wires you could break the sharp edge on that milled hole and then whack some silastic and/or heatshrink tubing surrounding the wires and down into the hole.

Maybe it will be fine...

[princec]

Just wanted to say that's a great write-up and I've really enjoyed reading it!

Cas

[MVetter]

Yeah, seen that 12Vdc output start a fire in the connected fan on the bike I had

You did somehow manage to inject mud deep into those connectors. Not like, "rode in a muddy area" but actively dredged the open connectors through mud.

[Shadow]

Yeah, seen that 12Vdc output start a fire in the connected fan on the bike I had

You did somehow manage to inject mud deep into those connectors. Not like, "rode in a muddy area" but actively dredged the open connectors through mud.

   Come visit sometime! We'll rent heavy equip and build ramps! Or just ride slowly on the local road, it's kind of the same effect either way.

"When it rains, the mud just distributes evenly"

[GoneToPlaid]

Morgan, I thought of milling a channel like you say, but I don't have a mill and didn't trust a machine shop to get it right.  So I had some spacers laser cut to make room for the fan wires.  The wires are insulated with heat shrink, then gobs of RTV silicone keep them from moving/ vibrating.  3000 miles so far, including a lot of rough road, and it's good so far.

mdjak1, the BMS failed in the power tank, and was replaced under warranty by the Raleigh Zero dealer.  I used the blanking plug to keep the bike on the road, and have it in the toolkit now just in case. 

There will be another update on advrider tonight.

[MVetter]

You're probably fine. I'm totally rooting for you and your trip.

[mdjak1]

mdjak1, the BMS failed in the power tank, and was replaced under warranty by the Raleigh Zero dealer.  I used the blanking plug to keep the bike on the road, and have it in the toolkit now just in case. 

There will be another update on advrider tonight.

I wonder what Zero's failure rate is on the BMS boards on the power tank/modular batteries?    I had one replaced on my modular FXS.   

[GoneToPlaid]

We're in OK now, and it's going pretty well.  Charger controller is working great.  See the advrider for full report.  I need some help on two issues:

1. The steering head nut loosened up today.  I felt a clunk in the front end and found the nut finger tight.  Anyone know what size nut and the torque spec? Suggestions on what do to beyond retorqueing?

2. I converted to chain drive 4500mi ago, and the rear sprocket is quite visibly worn. It's aluminum, 65 teeth, from the Zero chain conversion kit.  I very much doubt it will last to Oregon. Does anyone know where to buy a matching steel sprocket? Or, failing that, just another rear aluminum one?  I don't need the full kit; the chain and front sprocket are fine.

[GoneToPlaid]

Updates:

1.  Fixed at a diesel truck repair shop. Soaked in red loctite.

2.  Stll need a sprocket.  AF1 and other zero shops are closed today, so I'll try tomorrow.

[nnelson65]

KTM 85 SX... it's supposed to have the same bolt pattern (but I have not tried myself) https://electricmotorcycleforum.com/boards/index.php?topic=4559.0

Updates:

1.  Fixed at a diesel truck repair shop. Soaked in red loctite.

2.  Stll need a sprocket.  AF1 and other zero shops are closed today, so I'll try tomorrow.

[GoneToPlaid]

Thanks!  I looked at 85SX sprockets, but they are all for 428 chain.  Maybe the Zero chain kit used to be 428, but it's 520 now.

My Zero dealer (Team Powersports in Raleigh) was able to sort this out today. There is no Zero part number for just the rear sprocket, but they still can ship me one.  It should arrive in CO by Friday, as will we.