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[E-Luke]

Hi all,

I'm experiencing a squeak/creak/clicking sound that is increasing in volume the more I ride. I took my DSR to Hollywood electrics (twice) and they said it was the new belt (3rd belt in 3000 miles mind you) on the bike. My gut said it was the motor or wheel bearings, because the sound would happen in time with the revolutions of my front sprocket... The mechanics inspected it and said the bearings were fine, and to ride it some more to see if it happens after a few more hundred miles.

So here I am now, and the sound is getting worse, I feel a shudder through the frame every now and then, and I feel (though this may be paranoia) that there is resistence when coasting - I have zero engine regen setting and maximum braking regen. The other weird thing is that the creak/squeak doesn't appear to be as loud, or apparent, when I'm accelerating, plus there's a new sound: when I touch the brake regen there's an initial slight clunk.

I'm not hugely across the electric motor dynamics, but is is possible there's something loose inside? Like a magnet has come loose?

I'm taking it back into Hollywood Electrics on Friday. They're awesome guys, and I have no doubt they'll find out whatever's happening (if something is) with a deeper inspection, but I wanted to check if this has happened to anybody else out there?!

Hope all are great!

[skoleskibe]

Definately not a loose magnet. ;-)
Check the rearsprocket for faults in its teeth, signs of uneven wear etc. Check that the sprocket is correctly tensioned.

Three belts in such few miles!! Either you must go A lot in the terrain or gravel roads, or something imust be wrong with allignment or tension.


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[ESokoloff]

Can you find a long downhill to coast down with the key off & then repeat with the key on for comparison?

[E-Luke]

Yeah the noise is there regardless of key on or off, rolling fwd or back... There's a strange vibration going through the frame at times too. Back sprocket doesn't look to have any damage, and the guys at Hollywood Electrics took the wheel off, made sure the tension was spot on, and the noise is only getting worse. They did say that belts can be noisy and it may need to wear in some more, but the noise is increasing in volume to where it's now audible at speed and over the helmet wind noise! Definitely a strange one. Thanks for the thoughts and feedback!
The belt snapping situation is highly fristrating - the first belt I can say was probably me, I was jumping gutters and heard a few crunches. It snapped at 1500 miles! Also ride very aggressively. But never on any gravel roads etc. The next belt snapped at 3000 miles, and I was cautious on it most of the way... It happened in traffic and was pretty scary with cars flying around and past me... now I'm at 4600 miles and this noise is happening - seems like a 1500 mile curse or something?! It's weird to not feel confident or comfortabke when accelerating. Not confidence inspiring...
Full disclaimer on the second belt: I did put a 25 tooth front sprocket on to get more torque... Harlan down at the shop explained the belt would be under more stress, so I accepted that. But did not go crazy riding it - I didn't want to get stuck. I guess there's a reason the 2017 DSR has a wider belt😳😳

[hubert]

there's a new sound: when I touch the brake regen there's an initial slight clunk.

This is when the torque is reversed. Definitely something loose in the motor. Or probably between motor shaft and sprocket (spline key?). Could maybe also cause some early belt wear due to vibration or misalignment.

[Fivespeed302]

Yeah the noise is there regardless of key on or off, rolling fwd or back...

My 2015 SR has started to make a similar sound, even when pushing it around turned off in the garage.  It reminds me of a rusty spring.  WTF?  It sounds terrible and is loud.

Sorry, I'm not try to hijack your thread, but my issue is so similar that I don't see a reason to start a new thread. 

Here's a short video with good sound to demonstrate my issue.

[odedmaz]

Try pulling down the belt with your fingers (like inspecting belt tension) and see if you hear any noise. Start there.

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[E-Luke]

That sounds almost exactly like my sound... It was a super similar sound, but mine was in tune with the revolution of hte front sprocket. Hollywood electrics ended up diagnosing it as a loose screw (I can't remember the actual name of it) on the front sprocket I believe.

They fixed it easily and that noise went away, but now I've got a crazy high squeal, which sounds like a bearing is shot, once I accelerate beyong two bars at any speed. I think I feel some resistance aswell.

I love my bike, but in 5000 miles I've snapped two belts, had this front sprocket problem, and now the high pitched acceleration squeal and fine vibration/resistence. I think the biggest problem they're going to have is find a robust drivetrain that maintains the simpleness they're going for. Whenever I pass a Harley or BMW etc, I always look at the thickness of their belts and shake my head - my bike has more torque and it's like a piece of spaghetti down there!!!!

[skoleskibe]

Yeah the noise is there regardless of key on or off, rolling fwd or back...

My 2015 SR has started to make a similar sound, even when pushing it around turned off in the garage.  It reminds me of a rusty spring.  WTF?  It sounds terrible and is loud.

Sorry, I'm not try to hijack your thread, but my issue is so similar that I don't see a reason to start a new thread. 

Here's a short video with good sound to demonstrate my issue.

Sounds like the belt rubbing on the shoulder of the pulley. Try lubricate the pulley with a thin whisp of silicone spray. That might help, or even better adjust the alignment to avoid belt rubbing.


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[Fivespeed302]

That sounds almost exactly like my sound... It was a super similar sound, but mine was in tune with the revolution of hte front sprocket. Hollywood electrics ended up diagnosing it as a loose screw (I can't remember the actual name of it) on the front sprocket I believe.

They fixed it easily and that noise went away, but now I've got a crazy high squeal, which sounds like a bearing is shot, once I accelerate beyong two bars at any speed. I think I feel some resistance aswell.

I love my bike, but in 5000 miles I've snapped two belts, had this front sprocket problem, and now the high pitched acceleration squeal and fine vibration/resistence. I think the biggest problem they're going to have is find a robust drivetrain that maintains the simpleness they're going for. Whenever I pass a Harley or BMW etc, I always look at the thickness of their belts and shake my head - my bike has more torque and it's like a piece of spaghetti down there!!!!

Those bikes need a thick belt to deal with the massive amounts of torque produced while shifting gears.  It sucks about your belt.  I am not nice to mine but it's the original one.

Yeah the noise is there regardless of key on or off, rolling fwd or back...

Sounds like the belt rubbing on the shoulder of the pulley. Try lubricate the pulley with a thin whisp of silicone spray. That might help, or even better adjust the alignment to avoid belt rubbing.

Thanks, I'll give it a try.  I'm pretty sure that I'll be taking the wheel off before it's over.  I might have time today, but I'm going on a ride with some friends on the R1 so it may be a few days before I get a chance.  I'll report back with my findings. 

[Electric Terry]

I love my bike, but in 5000 miles I've snapped two belts, had this front sprocket problem, and now the high pitched acceleration squeal and fine vibration/resistence. I think the biggest problem they're going to have is find a robust drivetrain that maintains the simpleness they're going for. Whenever I pass a Harley or BMW etc, I always look at the thickness of their belts and shake my head - my bike has more torque and it's like a piece of spaghetti down there!!!!

Yes I agree, Zero is a fairly new company and the 2017 bikes (which began design in 2014) got bigger stronger belts, but back in the day the smaller belts were fine for the power output.

Talk to Maria or Harlan at Hollywood Electrics.  It sounds like the way you ride you would benefit from the stronger belt on the 2017 model.  They should have some good end of year incentives right now and work with you on your trade in since you bought your first bike there and are experiencing issues.   Plus the 2017 has more power, so even without the belt issue, that would be a good enough excuse to upgrade right there!

[Fivespeed302]

I got bored waiting to hear from my riding buddy.  It's the belt.  I can feel it in the belt, plus it did it with no brake pads installed.  The sound completely stopped and the wheel rolled silently when all the tension was removed. There's no missing teeth on the belt or sprockets/pulley whatever, and the belt looks like it did the day I got it.  It has 15,300 miles exactly on it.  It probably needs to be replaced is my guess.   I don't have a tension gauge, but it feels pretty tight like ain't always has. 

[odedmaz]

Glad to hear that. Try using a low pressure water hose and get the belt and sprockets wet & clean. It will resolve the problem, even temporary.
You can also use a silicon spray but I would wait with it.

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[Fivespeed302]

YES!!! Washing it down with a hose made it silent.  What type of silicone spray should I get?

[JaimeC]

Be careful with using any kind of "permanent" spray-on protection for your belt.  Back when Harley Davidson switched from chain drive to belt drive (early 80s) they used to sell a "Belt Dressing" to preserve and protect the belt.

Turns out having a liquid dressing on a belt is not all that great an idea as any road grit thrown up by your tires will stick to it.  Some of that road grit is amazingly abrasive and it didn't take long for those "preserved" belts to fail prematurely.  You'll note that Harley no longer sells a "belt dressing."  Neither does any other manufacturer who sells belt-driven motorcycles.

Just keep the belt clean and wash the bike regularly.  It's better for the belt AND the bike.