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[Two2010Ss]

Seems likely to be brushes, motor made a noise, smelled burning and lost all ability to move the bike. I've hooked the motor to my bench supply and get nothing. I have spare motor I can drop in so I won't be down long. Little disappointed since the odometer was only at 2200km. Guess it's a good excuse to try the @Camresearch mod (http://electricmotorcycleforum.com/boards/index.php?topic=5126) to use the non-stock brushes. I'll write it up and post here if I get that going this summer.

[BrianTRice@gmail.com]

Good luck! I guess having a spare in this case is sensible.

[Two2010Ss]

So yeah, pretty burnt up Removed brush holder . The alignment marks weren't even on the same side Marking 1 , Marking 2, so that might explain the short life? Temperature sensor is a bit melted too looks like 

[Two2010Ss]

I've confirmed my motor seems to be alright still. 3d printed a brush holder so I can clean the commutator and test out the new brushes. Video of it spinning: https://drive.google.com/file/d/1edoEXf9K6vGkcd6muz1omokENVlm6pKh/view?usp=sharing

[Two2010Ss]

Quick update, got my first printed aluminum brush holder in this week. https://drive.google.com/file/d/1kdFROK_-b0KuBI4Tlv-XkxZltFLIw4bp/view?usp=sharing Had to do a lot of filing to get the brush to fit, going to modify my model and get another one printed. Looks great though!

[Two2010Ss]

So this is me just yelling at the sky, but I have to say the original Agni brushes are terrible. So far my two sets burnt out at ~2200km and ~2700km. I went to swap in my third motor and checked the brushes, basically crumbled dust at ~900km. Going to have to wait for my Shapeways order and get these new brushes going ASAP before I can ride again.

[Two2010Ss]

Wrote up my project. Thanks again @Camresearch for the inspiration and the valuable info. I've only done two short trips, but seems to be working. https://medium.com/@ryan.mcneely_93025/modding-an-agni-95r-motor-brush-holder-for-a-2010-zero-motorcycle-de7de812c6e2

[Two2010Ss]

Ugh, yeah. So that didn't last very long. One of the brush holder columns must of came loose and fried everything... Back to the drawing board. https://miro.medium.com/max/700/1*T5nguZle_JE0OOuZD6go5w.jpeg

[igorbaldo]

Thanks for the valuable information! I hope I don't need to follow your steps!   

[Two2010Ss]

I hope I don't need to follow your steps!

Yeah, don't recommend that route. Right now I'm trying with the original holder just drilled out a bit so that the new brushes fit into it (like @Camresearch did in his first posts). Seems to be working and gets my bike going again very cheaply. Don't have a great picture https://drive.google.com/file/d/1rHj8QTPdJMdsG26X4UWwJjPDDdWZLIpw/view?usp=sharing

[Two2010Ss]

Just a quick update. The drilled out brush holder is working well it seems, lasting longer than my aluminum one anyways Working on a completely 3D printed brush holder (https://drive.google.com/file/d/18Ri8ywRA7s058x7mnOilnxVLxTK3tAan/view?usp=sharing) to give more long term options. Need to research the best plastic to print in for when I go to actually use it.

[rollandelliott]

thanks for posting this. Once I get my dead battery fixed Murphy's law states I will soon have to replace the motor. 2200km is 1370 miles. Zero Must be laughing all the way to the bank if they expect us to pay $500 every 1370 miles for a new brush holder. I bet I have less than 300 miles on my bike. it was a really bad investment.

[Two2010Ss]

No problem. I haven't quite finished the 3d printed brush holder yet, but a link to the latest write up is https://medium.com/@ryan.mcneely_93025/modding-an-agni-95r-motor-brush-holder-part-2-2eda52cfe2ac The drilled out holder is working so well that I haven't been pressured into finishing the project.

thanks for posting this. Once I get my dead battery fixed Murphy's law states I will soon have to replace the motor. 2200km is 1370 miles. Zero Must be laughing all the way to the bank if they expect us to pay $500 every 1370 miles for a new brush holder. I bet I have less than 300 miles on my bike. it was a really bad investment.

[BrianTRice@gmail.com]

I don't think Zero means or ever meant to make money from customers because of brush holder failures. They clearly jumped over to brushless PMDC as soon as they could invest in it.

Best of luck, and I'll try to index efforts (like the 3d-printing files) to keep these motors running.