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[Dryer667]

2020 FXS 1300mi. Trouble free until last night. I went to leave my destination, turned on the bike and it read 0% charge and would not switch into drive mode. I flipped the key switch off and on and it started up correctly and read the expected charge (~68%) but had a check engine light on. I was able to ride home without incident.

I let it sit for 24 hours and when keyed on still has the check engine light and displays (25 - Contactor Open Warning, 44, 45, 48 - SEVCON Startup Disable, 49 - Contactor Open Disable) error codes on startup. All but 44 and 45 leave after a few seconds (check engine light still on).

The bike will ride normally and accept a charge when plugged in. When charging it has one additional error code (44, 45, 47 - MBB Charger Connected Disable). I am thinking my next step would be a BMS reset but wanted to reach out for consultation. I am also emailing my nearest dealer.

Can anyone confirm what side of the battery the BMS reset button(s) are for a FXS? Its cold as hell right now in WI and Id rather not fumble around looking if someone knows. I also took logs that I could send if someone is savvy.

I plan to update this post with any solutions to help future owners as well. Thanks!

[rgutt]

I don't have an FXS, but I just googled the manual which shows a graphic of the same inspection window as the other models. I suspect you could identify the location from the graphic.

You probably don't need it though. The check engine light is most likely leftover from when you keyed it on and saw 0% on the dash. If you had been able to pull codes then, or if you dump a log file from the MBB now, you'll probably see the check engine light was set due to a BMS CAN error. The check engine light might go out on its own. It does for a lot of errors. If you send the log file to Zero, they'll likely tell you to bring it to a dealer for diagnostics. That's what they told me when I had the same thing happen on my '21 SR. In my case, the dealer is over 200 miles away, so that ain't happening. And I don't know about your model, but on mine, the OBDII system responds to the standard OBDII commands. I can reset mine with a standard scan tool.

[Dryer667]

Thanks for the response, I appreciate the feedback. Zero reached out to me from my facebook post so I will see if they give me that recommendation.

[Dryer667]

You were quite correct rgutt! Zero got back to me yesterday with nearly that response verbatim. I have a OBDII reader I use connected to my phone; is your scan tool standalone or similar?

[rgutt]

I have an old ELM327-chip based USB module I bought back in either the late 90s or early 00s that came with software that has long since become no longer freeware. I actually have to plug mine into a computer it's so old.

[Dryer667]

Update: After 500 lovely miles over the last few weeks the same thing happened tonight (read 0% charge when it was 57% 15 min earlier) but this time the key off/on did not reset it. Had to push it 3mi home. Thankful I wasn't further away.

This time the errors are 6 - BMS Throttle Enable Wire Error, 25 - Contactor Open Warning, 30 - BMS CAN Error, 40 - BMS Throttle En Wire Disable, 48 - SEVCON Startup Disable, 49 - Contactor Open Disable, and the usual 44, 45.

When I got it home and plugged in the charger, it didn't accept the charge and flashed (XX-XXX) which is a CAN error.

Next steps are clearly contact Zero/dealer but any guesses on might be causing this?

[Dryer667]

Spent some time with the log parser. Looks like my FXS is moving into hibernate mode for some reason and that might be causing the problem. Looks like a few folks had this on the facebook forum.

 07274              0   DEBUG: Reset: Power-On
 07275              0   Power On                   Key Switch
 07276              0   Key On
 07277              0   DEBUG: Module scheme changed from None mode to Stopped mode
 07278              0   Module 00 Opening Contactor  vmod:   0.000V, batt curr:   0A
 07279              0   Module 01 Opening Contactor  vmod:   0.000V, batt curr:   0A
 07280              0   Turning ON DCDC
 07281              5   Entering Hibernate
 07282              10   Disarmed   PackTemp: h 156C, l 156C, PackSOC:  0%, Vpack:103.660V, MotAmps:   0, BattAmps:   0, Mods: 00, MotTemp:-100C, CtrlTemp:-100C, AmbTemp:  13C, MotRPM:   0, Odo: 2981km
 07283              22   Power Off                  Key Switch
 07284              22   Module 00 Opening Contactor  vmod:   0.000V, batt curr:   0A
 07285              22   Module 01 Opening Contactor  vmod:   0.000V, batt curr:   0A
 07286              23   Turning OFF DCDC. Flags: 0x00
 07287              23   Key Off

[gt13013]

I have a MY2016 FXS, and some "Entering Hibernate" in my logs. But the bike works.
Here is a link with
- screen copy of a search engine that shows the files in my computer and containing "Entering Hibernate"
- some examples
https://www.dropbox.com/sh/yt08k905wfev9lh/AABCG1Xcf-FbbleotbTt-2cta?dl=0

[Dryer667]

Thanks for the post gt13013. Have you ever turned on your FXS and had 00% charge displayed?

I recall this happening to me ~4times since I have owned the bike and that is how many times the word "Hibernate" pops up in my log (not including the 10 that occurred with me turning it on and off yesterday). All times but the instances yesterday, a key off/on reset it back to normal but yesterday I tried it 10 times without luck and instead got my exercise for the week.

Update: my bike turned on normally just a few moments ago. 

[gt13013]

Have you ever turned on your FXS and had 00% charge displayed?

No.

2 or 3 times, when I turned on the bike with the key, nothing happened. But by insisting a little the problem solved itself.

1 time the bike did not wake up at all. That time the controler died, and I had to have it replaced. 

[Skidz]

07282              10   Disarmed   PackTemp: h 156C, l 156C, PackSOC:  0%, Vpack:103.660V, MotAmps:   0, BattAmps:   0, Mods: 00, MotTemp:-100C, CtrlTemp:-100C, AmbTemp:  13C, MotRPM:   0, Odo: 2981km

This line suggests the BMS is unable to communicate with the MBB, because all values seem to be wrong except the temp and odo. I've had this after a LBS fumbled up a MBB upgrade but forgot to update the BMS causing these errors.

[Dryer667]

Thanks Skidz. It sounds like a BMS replacement was a fix for another person on the facebook forum. Ill be taking it in next week to hopefully get it fixed.

[Auriga]

Y'all are onto the right idea. The BMS and MBB are both supposed to enter hibernate to save power when keyed off. Zero has had a longstanding issue where the BMS doesn't want to come out of hibernate. Some people are able to fix it by pushing the reset buttons, some people by disconnecting and reconnecting all BMS cables. And some don't come out and need a BMS replacement.

We've been seeing these for years, I wonder why Zero hasn't fixed it yet.

[rgutt]

Y'all are onto the right idea. The BMS and MBB are both supposed to enter hibernate to save power when keyed off. Zero has had a longstanding issue where the BMS doesn't want to come out of hibernate. Some people are able to fix it by pushing the reset buttons, some people by disconnecting and reconnecting all BMS cables. And some don't come out and need a BMS replacement.

We've been seeing these for years, I wonder why Zero hasn't fixed it yet.

Yeah, I guess they took their programming cues from Microsoft.

[Dryer667]

Y'all are onto the right idea. The BMS and MBB are both supposed to enter hibernate to save power when keyed off. Zero has had a longstanding issue where the BMS doesn't want to come out of hibernate. Some people are able to fix it by pushing the reset buttons, some people by disconnecting and reconnecting all BMS cables. And some don't come out and need a BMS replacement.

We've been seeing these for years, I wonder why Zero hasn't fixed it yet.

Thanks for the confirmation. Ill pass this forward and eventually update with the outcome!