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[Robrecht]

Hi all,

This morning i wanted to ride my 2015 SR after a week standing still.

I noticed when powering on the bike, that the dash showed 5% charge (i charged it 2 weeks ago and did not drive it that much), when i open the Bluetooth app, the app says that the charge state is 5% but battery voltage is 112v

When i lift the sidestand, the green ready-to-drive LED starts flashing, together with the red warning LED. After less then one minute, the dash starts flashing and Bluetooth connection is lost.

For the past 3 years i charged my bike with an external TCC charger, bridging pins on the onboard charger plug to enable charging. The reason i did this is because my internal charger died 2 times and the second time they did not want to replace it under warranty. A 3.3kW TCC charger was a cheaper option. I tried charging today,  but this also doesn't work. The charge led lights up on the dash, but the charger can't connect to the battery.

When i checked the BMS leds, under the plug, the only led that lights up is led 4, and this one is flashing.

If i measure voltage on B- & B+ on the motor controller, i measure 59volts, when the bike is powered on. When the key is removed from the ignition this is almost 0.

Is my battery dead ? Is the contactor dead ? Can i measure the battery voltage somewhere else ?

Thanks (me panicking)

Update : I measured the battery voltage at the DC-DC converter, the multimeter verifies the 112.6V, so i don't think my battery is dead.
Can i somewhere bridge some pins to enable the battery contactor, to check if this still works ?

[NEW2elec]

Try to see if you get any error codes.

https://zeromanual.com/wiki/SDS_Platform/Unofficial_Service_Manual#System_Warning_Sequences

[Robrecht]

After switching on i have the following error codes.

25   Contactor Open Warning
27   Precharge Error (only shows up 1-2 times)
31   SEVCON CAN Error
45   Kickstand Switch Disable
48   SEVCON Startup Disable (only shows up 1-2 times)
49   Contactor Open Disable

Owboy

[NEW2elec]

Perhaps some guys who have had this issue will chime in but not a lot of activity on Sundays.

My guess is same as yours either a bad contactor or MBB or controller isn't giving it the power needed to close it for some reason.

I guess you could try a BMS reset as described on the unofficial manual.  Sorry I can't be more help.  This may need a dealer.

[Shadow]

There should be an audible click of the contactor if it is closing/opening. Does this bike have only a ZF monolith battery and not also a power tank?

When you are in the charging mode, it is the same (electrically where the contactor and motor controller terminals are concerned) as run mode. Only the app may tell a different voltage from the MBB data aggregation depending on if the bike is keyed on in run mode and safety interlocks are active or not (kickstand, killswitch). On a bike I rode where the power tank and monolith battery modules' pack voltages drifted too far out of sync, the voltage displayed on the Zero android app was not always consistent with what is measured at the AUX charging port (i.e. motor controller terminals with only some wire and a fuse in that wire harness between). Those voltage measurements should be the same unless something is wrong, so I never got to figure out that as a diagnostic aid; Although unfortunate your bike isn't working quite right I'm reading similarities to that situation, at least for diagnostic steps.

Zero keeps proprietary all the tools and parts needed to service this kind of thing, so even though it's not complicated there's not much more to recommend except going to a Zero-certified shop.

[Robrecht]

I am at it again this weekend.

Dumped the battery BMS via the BMS diagnostics port, with a DIY cable, no real usefull errors and SOC @90%, i'm now waiting on the parts to make an OBD cable, to look at the other logs.

Can somebody provide me with the 'passwords' via PM ? Thanks.

Has anyboady already opened the contactor area ?

[Auriga]

It's far more likely the mbb or bms is throwing a fault and preventing the contactor from closing then the contactor or batery being damaged. Pulling MBB and BMS logs with the app or cables should give you some insight here. Feel free to post them if you'd like a second opinion.

Or your dealer can do it.

[gt13013]

Your problem looks similar to the problem I got 2 months ago. See here:
https://www.electricmotorcycleforum.com/boards/index.php?topic=11244.0