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[Charlyseabass]

Hi there does anyone had this sound inside the motor of a zero fx???
The bike is 2015 and 10000km, bought second hand,pulley and sprocket changed and well tight....
I’m afraid that a bearing inside suffered previous chain kit instalation with a chock air
tool..,.please check those vids thanx....





Bike is out of warranty and i guess that here in france dealers will ask me to pay for a whole new zf engine....

[Moto7575]

1) Might be the engine bearings. Try to run the bike while on a stand, and check where the noise comes from. Changing the wheel bearing will cost you 100$ parts + work. I would suppose it is the same for the engine.
2) Before this you might want to ask you dealer for a solution. Probable cost: 3000 euros parts + works.
3) Engines can be opened, even if Zero does not recommend it. If you do so, take pictures & share with the community !
4) You can order a new engine via AF1racing - if the shipping is too expensive, ask a US friend to bring it back to you : https://www.af1racing.com/store/Scripts/prodView.asp?idproduct=89773&sku=ZM12-08041&description=ZF75-5+IPM+25T+MOTOR+KIT+-+ZM12-08041

[BrianTRice@gmail.com]

That would be a pre-IPM motor. The bearing hypothesis is the best to check right now, but I have a suspicion that there's a loose magnet in there. In either case, definitely don't ride the bike hard until it's sorted.

[Charlyseabass]

Thanx for your reply moto7575
Bought the bike 7000€ last year, dealer said after 1 month i send those vids it was probably coming from a loose sprocket....and fairly paid for the new parts....

I don’t feel like opening the motor myself as my mechanic knowledge is basic....and a powerfull hydraulic press is probably needed to extract the bearing....
I have not seen any topics about motor opening on the forum...
3000€ after one year😭😭😭😭
1) ask a dealer
2)I have to find someone to open it and find the right bearing
3)you come on holidays to my island with a motor in your luguage...!!!
4)i keep on going for this summer and see.....

[Charlyseabass]

Hi briantrace

Do you know if there is a zero recall campaign about that issue on pre ipm-motors??
Or anyone having the loose magnet pb and sorted it??
Thank you

[Moto7575]

There is indeed a known loose sprocket defect. It is very cheap to solve - see the "click sound" section in the zero unofficial manual (google for it).

[Charlyseabass]

It’s all done...( thanx to that topic) i changed pulley and sprocket already...the videos are made just after the change ,everything tightened properly..... but seems to be worth...magnet or bearing as master briantrace said.....
I will check the forum for motor remove....and/or bearing access...

[Charlyseabass]

http://electricmotorcycleforum.com/boards/index.php?topic=8512.msg72116#msg72116

Hey moto7575
It seems that you had issues too... something flying inside the motor.....
Pre ipm motors could get hot enough to melt epoxy fixing magnets....

Did you change your motor??

[Moto7575]

The dealer did a misdiagnostic and while Zero refused to move i was left for weeks before I went to the shop and did the diagnostic myself. It was the wheel bearing, which is easy to fix. What i heared is that engines can be opened and fixed - Zero opposes this but if they dont help you I dont think you owe them anything.

This is a good case of how Zero customer service goes (very) bad : dealers how little knowledge on the bikes, and Zero says basically "f**k off" after the warranty period instead of finding fair solutions. The customer end up being locked in this mess even for very small issues.

[BrianTRice@gmail.com]

Yeah, when Zero decides it can’t deal with risk, it shuts down all lines of communication, at least from the customer perspective.

This is why the unofficial manual exists. I’ll try to catalog these diagnoses but any detailed reasoning you can provide will help.

[Moto7575]

Yes. How to kill customer experience (and long term shareholder value) 101. Sad.

[flattetyre]

Yeah that stinks. Zero lied to my dealer while repairing my bike, but at least they eventually got it fixed (after over a month in the dealer).

Don't understand why so many of us are brand fanboys. The bikes the company makes are what we love. There's not very much to love about the company itself.

[Moto7575]

I think there are a couple of company employees here. But most real customer would agree with you ;-)

[Charlyseabass]

Thanx to everyone for your support
 I brought the bike to a dealer 200km from home(closest dealer for me)
They said that some zero staff was coming two days later for technical training.....
And they also have a show event of the new ds-r next week with some more zero dealers.....

Now the only thing i can do is waiting to know.....
I will keep this post updated, for everyone to know how is after warranty service for people like me owning older bikes....( zero fx 5.7KW 2015 10000km in france)

[Moto7575]

Finger crossed. Keep us posted !