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[kasmtk]

Hi,
my2016DSR no longer powers up the MBB fuse blew (4A abc) diving no power anywhere on the 12v side ( that i know how to test) checking other fuses this was the only one blown. upon replacement of the fuse there was still no power and rechecking the fuse had blown again, I rechecked other fuses and the Low power module (under seat on left) was also blown.
I need some help diagnosing my next move.. MBB failure? Replacement possible without going to a main dealer?
I live in southern Portugal my nearest dealer seems to be Spain


some history -
 had intermittent power faults - lights often not coming on etc. power to motor and dash OK. checked on here for solutions, referencing ground wire or Connection problem. I checked a few suggestions initially suspecting the ignition switch, sometimes the power came on after ignition had been on for a few minutes.

The bike always was ridable (even without lights) until now..

[Auriga]

This looks like a painful failure. I've worked on a number of these where a DCDC failure has damaged both the MBB and BMS, blows the lower b+ fuse, and requires replacement of the MBB, BMS, and DCDC. There's no way to know if that's true without replacing parts iteratively.

First I'd disconnect the DCDC and then replace the low power b+ and mbb fuse. If the bike turns on and runs normally(without lights), great. If not, I'd suspect the BMS. You could try replacing that, and then checking again. If the bike still doesn't respond, I'd replace the MBB.

As you can imagine, those are three expensive parts on the bike, costing hundreds of dollars each. Zero in the US has sometimes helped out of warranty people bear the cost. No idea about Europe. Technically all the parts can be ordered from a dealer in the US, assuming the original dealer provides your VIN to Zero to program them. No idea about Europe.

It is a pretty hefty amount of work to replace a DCDC, BMS, and MBB, so it'd probably cost quite a bit at the dealer in labor, or quite a bit of time for you to figure out(if you're handy).

[kasmtk]

Thanks for the reply Auriga
Is there any way to test if each module functions before replacing each? I can carry out the work myself except the programming of modules where necessary, however living in Portugal there aren’t any experienced dealers here and getting parts will be a very slow process, otherwise ordering every module to test sequentially would be costly.
I can only perform continuity checks and basic multi-meter testing but have the time to strip and replace.
 I hope someone on this forum has access to wiring layouts or perhaps a workshop in Europe to assist or even repair my bike.

[Auriga]

Not really, an mbb has a serial output over the obd port you can access. If the board gets power and is good, the bike will work, and the serial will work. Not much else there.

BMSes do as well, but in most of these I've done  the bms serial can work but still need to be replaced. I think its the 12V signal that goes to the keyswitch that usually dies, so you could measure that.

[kasmtk]

Thanks Auriga,
Silly question from me, locating sim spare fuses to test as suggested.

[kasmtk]

Update , disconnected control cable to dc-dc, Replaced fuses in Mbb and low volt unit, the low volt fuse blew immediately, without keying on!
Seems serious, expensive. From your diag flow chart can I assume the BMS is faulty or has potentially caused the Mbb to fail too .

[Auriga]

That's interesting, usually the fuses survive after disconnecting the DCDC. You could try disconnecting the MBB and probing the voltage pins on those connectors to see if the BMS is outputting the correct voltage with the key on. I probably wouldn't plug the MBB in to a new BMS in case the MBB is shorting. If the BMS output seems fine, I'd replace the MBB first. Otherwise probably both.

[kasmtk]

I disconnected al modules with good fuses, then reconnected each checking fuses as I continued, key on then off each time . All okay except the one MBB plug which blew the low + fuse . I cannot find a pin out of the voltages I can expect from the plug detached (as photo)