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[Auriga]

My best guess from what you have is that the contactor is partially welded. With the bike turned off, can you use a multimeter to measure DC voltage on the two large pins on the anderson connector? If you get anything other than 0(with the bike keyed off and after maybe 20min or so since last key on), then your contactor is defective and needs to be replaced.

If you had the proper connector, you could connect to the BMS  and get the eventlog from that. That usually should tell you why the BMS is setting BMS 0 Internal Disable, but based on the other things I'm guessing it's the Contactor Welded message.

[HVMoto]

My best guess from what you have is that the contactor is partially welded. With the bike turned off, can you use a multimeter to measure DC voltage on the two large pins on the anderson connector? If you get anything other than 0(with the bike keyed off and after maybe 20min or so since last key on), then your contactor is defective and needs to be replaced.

Voltage at the Anderson connector (and the controller) measures 0 when the bike is off.

If you had the proper connector, you could connect to the BMS  and get the eventlog from that. That usually should tell you why the BMS is setting BMS 0 Internal Disable, but based on the other things I'm guessing it's the Contactor Welded message.

I'll make a cable for the BMS, but I may make it to the dealer before then.

One thing that stands out to my non-professional eyes is the variable output of the battery voltage.

106.295V from `show bms`
107.515V from start up
And all of these at the `Unexpected contactor close.` messages:
45875 mV
82812 mV
81375 mV
80000 mV
83875 mV

Yes, thanks for the input, not certain what that's all about.

Today I decided to disconnect the entire harness and removed the pack from the bike (it requires some serious cleaning - dirt, grease, coffee, donuts, etc.) Thankful I have an electric hoist, it made dropping the battery (see photo) a fairly easy task. I did another visual inspection on the BMS and also inside the doghouse (see photo). There's a Gigavac contactor and a 300amp DC fuse. I didn't poke around much but did attempt to measure voltage on what I thought was the contactor voltage out side, with no success. I sealed everything back up, cleaned the battery casing and was going to call it a day, when I tried one more thing.

Wondering how someone would charge a pack off the bike I rolled the battery close and reattached the harness to everything but the motor controller (all exposed ends taped off) and plugged it in via the killawatt meter. Could have sworn I heard the contactor close and wattage was measuring higher than before (35, 45, 54, 42 watts). Voltage measured at the Anderson and controller B+ B- cables were 107.6 to 107.7.

I began smelling something and quickly pulled the plug (with no controller connected voltage dropped immediately). Turns out my neighbor was cooking (more like burning) dinner. Freaked me out!

Plugged it back in but this time the contactor didn't click, so I called it a day.

[HVMoto]

Got to do a thorough cleaning this weekend while the battery was off, not the easiest task getting it back in place. In just checking to see that I did everything correctly I keyed the bike on and no error codes, ready light was green. Unfortunately, when I turned the throttle there was no response and the contactor error resumed. Isolation fault appears to be gone (for now).

I can see where having passwords for the MBB via terminal could be helpful. I looked around but haven't found anything that gets me beyond level 1. I'm not even sure what level login is required for temporarily setting the override charger disable or to ignore isolation error.

I'll get to the dealer this week and will know soon enough.

[HVMoto]

Woohoo! I have a running bike.

Got the bike out to Hollywood Electrics today and they took great care of me. Turns out the BMS was not programmed to the upgraded battery so dealer visit was necessary. I heard the contactor close as the firmware was being updated. Bike powered up (65% SOC) and throttle engaged. I took it for a short first ride when I got home.

I have a few repairs to go but happy so far. Thankful for all the information I have found here and in the unofficial manual.

[staples]

Glad you and Hollywood got it running. Have fun!