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[ethanh8791]

So I drove about 40 miles to work the other day. Charged at work and noticed it only registered 97% charge despite being at above 60% & charging for 5 hr. +. Admittedly I was using an extension cord longer than 25 ft. Didn't think anything of it, drove home fine. I had it sitting uncharged for 3/4 of a day, drove with no problems and then went to charge and it did not recognize being plugged in. This is straight to an outlet with the provided cord. No error lights on the dash initially other than related to motor kill and kickstand down. Scrolled through the display this evening and noticed error 48 & 49. I read about some reset button underneath the seat. I noticed the star bolts are marked  as far as positioning - is this going to affect warranty if I start troubleshooting this myself? 

[protomech]

From the owner manual:

48 SEVCON Startup Disable
49 Contactor Open Disable

Sounds like an error Zero will diagnose. If you connect a phone to the bike with bluetooth (iOS / Android), you should be able to pull the logs off and email them to Zero.

http://www.zeromotorcycles.com/app/help/ios/connectivity.php

[ethanh8791]

Yah thanks - I sent the log. I saw what the error codes mean but manual doesn't offer any solution for those codes.

[oobflyer]

You can try the BMS reset without taking anything apart.

On the front of the battery pack there are two round rubber seals, beneath one is the LED display, the other - two small buttons. Press the two buttons simultaneously for a couple of seconds, wait for another 10 seconds or so (you should hear a click and notice the dash display reset), then try plugging in again.

[ethanh8791]

Thanks for the tip - MAYBE I missed it but I swear the two button BMS reset procedure is not referenced in the manual. It's hard to tell whether they are depressed or not...obviously the audible clicks are a good indicator and it's very similar to some computer system "reset" type buttons if you are a hardware techy type - I would think Zero would point out the procedure and clearly in the manual but then maybe they don't want the avg consumer tinkering too much considering liability and what not. Drawn out post to say: it didn't work. Such a bummer - in to the shop it goes. I will be checking fuses this weekend before I make that drive with the last remaining %'s of charge remaining. 

[Fivespeed302]

I am having similar problems with my '15 SR.  You should ask the dealer for a loaner bike.  I got their demo Zero S.  It's alot easier dealing with problems when you've got something to ride.

[walla2]

Sorry to hear about the troubles.  My two Zeros have died fully with no error messages because the screen was dead too. 

 I'd check the bms indicator as mentioned above, check the fuses, high voltage ones, etc, and call Zero if none of that works.

Zero hasn't minded me working a little on my bikes to troubleshoot them.  So you should be fine.  Don't break anything but you can check the simple stuff.

[oobflyer]

I think there are several of us with similar problems. Do you have the PowerTank on your bike?
Mine is at the factory right now. I got a call on Friday from Zero - the problem appeared to be either the BMS communication between the two battery packs, or a problem with the PowerTank itself. They are checking both possiblities and I should hear back from them soon.

[ethanh8791]

I'm w/o a power tank....taking it back to the dealer as soon as I can - unfortunately I have not had the time to get it there.

error codes 48 & 49
bms button reset procedure done
error codes on 4 LEDs by BMS button are not anything representative of what is described in the manual
all fuses in the compartment under the seat checked and are OK


I've got 11% charge to make it 11.3 miles to the dealer 


Oh and I WILL follow-up here once I find out what the issue is for the benefit of others.

[oobflyer]

I have an update on my 2015 SR (with PowerTank).

Replacing the BMS boards did not fix the problem.  Replacing the PowerTank appears to have helped, but while test-riding and recharging they found a problem with the onboard charger. So they replaced that today. I should know tomorrow if all is well.

[firepower]

Seems to be many chargers fails, maybe they also damage other boards?

[oobflyer]

Seems to be many chargers fails, maybe they also damage other boards?

I got my bike back today and I asked that question specifically. The answer was - it does not seem to be related.

I was told that the problem on my bike was resolved by replacing the PowerTank battery. Apparently there was a problem with the PowerTank that came with the bike - specifically the cell balancing between the two packs was off - when the difference in voltage was detected the bike quit charging/running.

They replaced my charger because it seemed a bit warm while charging at the factory. The heat did not exceed any safety limits, but they decided to replace it as a precaution.

Meanwhile - there are still a couple of error codes on the display... thus the new thread I just started.
( http://electricmotorcycleforum.com/boards/index.php?topic=4849.0 )

I was told that these codes should "go away on their own" after a few charge/discharge cycles - hopefully that will be the case - I should know soon.

[Doug S]

They replaced my charger because it seemed a bit warm while charging at the factory.

I had a charger fail several months back, and the dealer said that Zero wanted to "wait until the new batch came in" before shipping me a warranty replacement. I have to think there was a redesign due to poor charger performance in field, and it wouldn't surprise me that they're swapping out units as they have the opportunity, especially if they're "running a little hot".

[Richard230]

"Knock on wood" but so far the on-board charger on my 2014 S is working perfectly.  Kind of makes you wonder if the charger supplier changed manufacturers or made some other "improvement" that has resulted is reliability issues.   

[oobflyer]

I was told that I now have a "C" version of the charger, which replaced the "B" version.
Beyond that I don't know what the difference is.