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[Brammofan]

Something with the government now that it made the NHTSA's most-wanted list?

From the little I know of the process, I'm pretty sure that it's not anything having to do with NHTSA's intent.  The decisions are made based upon either consumer-reported or self-reported (by the manufacturer) issues, and once the number rises above a certain threshold (x% out of units sold), then it's almost an automatic process that a recall notice is issued.

[Richard230]

My impression is that most motorcycle recalls are the result of the manufacturer going to the NHTSA with a problem that could result in a traffic accident. I think they do this to limit their liability exposure should they not take action to recall their bikes.

[CliC]

Right, but what I was getting at was whether the NHTSA notification changed whether Zero could send replacement parts directly to owners to let them fix the bikes themselves. It seemed that before the recall came out Zero would send you a new BMS board if you had the shorting issue, but someone earlier in this thread mentioned that they weren't sending the repair kits for the recalls to end users directly at present.

[Brammofan]

I see what you're getting at.  I'm not sure if a recall would affect Zero's decision on whether or not to send replacement parts directly to consumers. It's a valid question.

[protomech]

someone earlier in this thread mentioned that they weren't sending the repair kits for the recalls to end users directly.

Zero has a dealer service kit they send out. Kit has a net book with support software loaded and a number of custom interface cables.

When my board faulted they gave me the option of either bringing the bike to a Honda or Yamaha dealer (and they would send the support kit there, and I would be bikeless for probably a week) or to me directly, and I could swap the board.

If I had a nearby Zero dealer, the latter probably would not have been an option. My nearest dealer is in Atlanta (~180 miles away), getting the bike there would have involved significant expense.

[Electric Terry]

 

[Electric Terry]

This is what the new BMS's will look like that dealers should be getting next week to perform the recalls.  The whole board has better sealant and there is caulking at the 2 external ports.  Just got it this morning and it's in and the bike is powered up and working great!

[CliC]

Zero has a dealer service kit they send out. Kit has a net book with support software loaded and a number of custom interface cables.

When my board faulted they gave me the option of either bringing the bike to a Honda or Yamaha dealer (and they would send the support kit there, and I would be bikeless for probably a week) or to me directly, and I could swap the board.

If I had a nearby Zero dealer, the latter probably would not have been an option. My nearest dealer is in Atlanta (~180 miles away), getting the bike there would have involved significant expense.

Hmm. I assume you contacted Zero directly?

My dealer is also about 200 miles away, in Austin. I've hauled the bike there once already for a fork seal issue. I do have a pickup to transport the bike, but I have to arrange with the dealer to get it turned around in a day (which they graciously offered to do last time), take a day off work, and get it up there early (or go the night before and spend the night). Or I can bring it on a Saturday, leave it, and return again to pick it up, which is what I did last time. Either way it's not trivial, and is about $100-$200 in gas plus everything else (I have a free place to stay there, fortunately).

I'll probably take it up there again this time, since I've already been in contact with the dealer, but I'm thinking that in the future I might go the DIY route. Did you get to keep the netbook?

[protomech]

I wish : p

[Electric Terry]

I never used the diagnostic kit.  They offered to send it twice when it shut down on me on road trips, but I already knew it was the BMS getting wet so the computer was not necessary in my opinion because i knew each time I rode through heavy rain.  I just took it out and dried it at a mcdonalds hand drier.  I would say the BMS replacement is a home repair that could easily be done with a good set of instructions and 1 allen wrench and 1 phillips head screwdriver if you didn't want to drive 200 miles.  I guess it all depends how  comfortable you are using tools and repairing things. Did you do your own work on your previous gas motorcycles?  If so this should be a breeze.

[CliC]

I just took it out and dried it at a mcdonalds hand drier.

Dude, you're my hero

Yeah, I did do some work on my ICE bikes. I have enough tools, but my problem right now is no garage/shop. This, however, I could do in my living room. The fork seals, probably not, due to possible oil spillage.

Austin's fun to visit, so I don't really mind going all that much. I had an ulterior motive in that if I got to keep (or even use) the netbook/software/interfaces, I might be able to reprogram the bike to give me full torque/power in both sport and eco modes, with only the amount of regen changing between them. It would save me a little hacking, when I got around to doing it (though the hacking is arguably more fun). I'll probably talk to the guy at the dealer's about doing this. Maybe I can pique his interest

[CliC]

Some related, but not identical, behavior I saw today. I pulled the bike from of a 72-degree house out into 80-degree, 95%-humidity outdoors. Mirrors immediately fogged up, and of course my next thought was, S&*t, BMS board" I pulled out onto the street, no problems, but at the first stop I noticed the regen braking to be choppy and weak in eco mode. This continued for the next several stops, but the bike never lost power. Finally, about a minute after the mirrors had defogged, I got smooth, normal regen at a stop. I suppose the condensation had evaporated from the electronics by then.

[Harlan]

Some related, but not identical, behavior I saw today. I pulled the bike from of a 72-degree house out into 80-degree, 95%-humidity outdoors. Mirrors immediately fogged up, and of course my next thought was, S&*t, BMS board" I pulled out onto the street, no problems, but at the first stop I noticed the regen braking to be choppy and weak in eco mode. This continued for the next several stops, but the bike never lost power. Finally, about a minute after the mirrors had defogged, I got smooth, normal regen at a stop. I suppose the condensation had evaporated from the electronics by then.

I think the choppy regen you were experiencing was probably due to the battery being fully charged, a protective measure indicating that the BMS is working, not failing.  Regen can overcharge a battery without proper precautions.

[craigq]

The choppy regen on a full battery happens with the XU too, every morning for the first couple of stop signs on my commute.

[Electric Terry]

Harlan is exactly right.  Happens each and every time off a full charge for the few mile or so on the 2012 ZF9 also.  Remember recouperating the momentum of the motorcycle is a crap load of amps all at once, and a 95% full battery starts to keep voltage constant but taper off amps until finally it's nothing. 

Imagine filling a gallon jug with a garden hose at full blast.  It works till it is almost full, but to top it off as full as possible you have to set the hose lower and lower till finally you'e collecting just a drop at a time.  On a full charge you have to go down a few percent before the batteries even have a place to store the energy, especially that fast.