I don't agree with your assertion that a service manual must describe from the bottom up on the flow of electrons. If this were so, internal combustion itself (not to mention highly complex carburetor operation) would need to be described in ICE service manuals, and this is simply not so.
Actually, yes it is so. Look at the "Honda Common Service Manual" part #61CM001
This is a manual that details what a shop tech needs to know before he picks up the model-specific manual for his bike. It details such things as:
* what different types of ball/needle bearings are, and how to take care of them
* what the strength markings on bolts means, what torque value means, how to torque down a bolt, and why there are special bolts in special situations, ways to keep your fasteners from loosening, and 20 types of fasteners other than nuts & bolts.
* how the throttle, choke, fuel pump and crankcase breather work, and the oil pump on a 2-stroke.
* what valve clearance means and how to use feeler gauges, including ancient torsion-bar style valve springs
* what chain sliders, chain guides, guide sliders and rollers are, on a swingarm
* how to change brake & clutch fluids
* the difference between chain, belt, v-matic, and shaft drives
* how transmissions and manual and automatic clutches work
* how to do compression and leak-down testing
* how carburetors, fuel injection, and emissions controls work, including PAIR valves and accelerator pumps, and the theory of the idle, main, and high speed jets and needles, as well as the difference between constant-velocity and flat-slide carburetors.
* how to change a tire on a rim
* how front suspension works, including scooter Earl forks and various types of "forkless" front ends
* several different frame types, including stamped metal, welded tube, and aluminum delta box
* how rear suspension works, including single-sided swingarms, and dirtbike progressive linkages
* electrical fundamentals, including
** how to not crush wires
** what DC is
** what AC is
** what current/resistance/amperage is, and Ohm's Law
** how a rectifier works, and spark plug coils
** how a alternator, generator, or magneto works (and shows several designs of each)
** how a breaker point system works
** how transistors & diodes work, and how the CDI & transistorized ignition systems work
** how switches and safety cutouts work
** basic diagnostics such as what a DMM is, and voltage drop testing
There's a ton more, but I got tired of typing. It's well-written and easily $120 worth of entertainment, which is what mine cost me, I think.
I don't know if other manufacturer's have such basic "starter" manuals, but everyone said "you gotta buy that Honda one, it's a treasure"
You didn't think service techs magically knew all this shit, I hope? Of course by the time they go "I wanna be a bike tech" they SHOULD, but then I know a ton of "software engineers" that have no clue what a linked list is.
My earlier point is that there's currently no such manual for EVs because each EV (including Tesla, Brammo, Zero, Mission, etc) is unique in its computer systems and controller design. To work on them, you have to start with a ton of electrical and computer knowledge, then get access to the manufacturer's "super secret sauce"
This sauce is so secret because (like software source code) it represents all the hard work and all the expensive design, testing, failure, redesign, retest, etc that went into things.
At the end of the day, a Zero is a battery pack, motor, frame, some computers, and firmware. The firmware probably is 75% of the work of designing a Zero, other than sourcing and manufacturing the battery pack.
This means the ICE tech at the local bike dealer probably takes a basic course from Zero, and then the troubleshooting procedure is mainly "1-800-CALL-ZERO" and this sucks. I don't think it'll improve until Zero can spend money on a REAL tech repair course.
Part of the problem is also no one knows the failure modes. What are the symptoms of a bad BMS versus the bad wiring harness that my bike had? How was Zero able to tell the difference over the phone? How do you tell if the Sevcon is bad, or maybe it's just a bad CANBUS connector?
However, the bikes themselves are evidence to buyers as to the care of the designers. There were some really amateur mistakes in the early models that give me pause. For example, I mentioned that operating the eco/sport switch on a 2011 causes the bike to come to a halt. Apparently, they fixed this in the 2012. However, what sort of self-respecting engineer programs firmware into an ECU module without any upgrade mechanism and then pours quarts of epoxy over the PCB?
Yup. I can easily see that as a software design mistake. I see crap like that all the time, like a customer service website that based everything on their registration number, but never gave them a place to enter it, or update it for new purchases.
Also, any industrial electronics are going to be potted in epoxy. This is for vibration and moisture resistance. Look at any motorcycle regulator/rectifier, ECU, or dashboard controller. Hell, I remember blowing a huge crater in a reg/rec once when my stator windings shorted, and it was over an inch deep in the epoxy.
I've seen Intel industrial evaluation boards back in the '80s that were program-once and toss the entire board.
However, I've seen the BMS board for my 2015 and it's not potted, which was a huge surprise to me.
Anyway, when these bikes were designed EVERYONE WAS AN AMATEUR. There were (and still are) very few electric bikes out there, and so they had to stumble across "oops don't do THAT" since they were the first ones to do whatever.
It's just like rockets in the '50s, when people realized "oops, don't let your turbine blades rub on the casing!", "don't put room temp fuel lines next to cryogenic oxidizer lines so they don't freeze" and "make sure your fuel lines don't vibrate until they snap!" - that's "common sense" only in hindsight.
Hell, the Russians, who are old hands at rockets, recently committed the "don't put room temp fuel lines next to cryogenic oxidizer lines so they don't freeze" mistake with the new Fregat upper stage design, and they sure as hell should have known better.
I have heard the military contract was a godsend, since the military beat the shit out of the bikes in ways a customer who had to pay for his bike never would, then gave them feedback on how it broke. It was a huge torture testing program for free.
Personally most of this is why I wasn't real interested in electric bikes until I saw Zero had ABS and real suspension. It meant they were perhaps not "grown up" but certainly past the "teenager" stage of being temperamental and throwing fits.
My Zero is fundamentally different from any bike I've ever owned. I don't consider it a motorcycle, but more as a battery powered computer network on wheels.
I consider it to be in the same era as ICE bikes in the 1920s. Read "Early Motorcycles, Construction and Repair" by Victor W. Page for an eyeopening look at the shit people had to put up with...
For example, one early "carburetor" was a set of cotton wicks in the fuel tank leading to the intake!
They didn't have clutches, so they had bicycle pedals to restart at every stop, or operated a sprocket to slip the leather belt.
They didn't have oil pumps, it was up to the rider to pump in oil every so often by hand.
Engines didn't have intake valve mechanisms, other than having suction open them.
An early ignition system was opening a small window showing the fuel vapors a flame.
I'm hoping we're kind of past that technical level of EV development. That's the lead-acid battery, 15 mile range level of EV.