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Makes And Models => Zero Motorcycles Forum | 2013+ => Topic started by: xerxesz on December 08, 2020, 01:48:31 PM

Title: Zero S 2013 Not starting
Post by: xerxesz on December 08, 2020, 01:48:31 PM

I have posted this on the Facebook as well, but I am hoping, that others are reading it here :)

My Zero is not going anywhere. The relay switches periodically on and off. I read the Sevcon, and it says:

Code: [Select]

DEBUG:         54761  ..\src\Application\zero_mbb_module.c            : line  1906 - Restarting Sevcon to clear cutout Fault               
DEBUG:         54777  ..\src\Application\zero_mbb_module.c            : line  1108 - Disconnecting Module 00                               
DEBUG:         54796  ..\src\Application\zero_mbb_module.c            : line  1108 - Disconnecting Module 01                               
DEBUG:         55210  ..\src\Application\zero_mbb_sevcon_interface.c  : line   264 - Turning Off Sevcon                                   
DEBUG:         55382  ..\src\Application\zero_mbb_can.c               : line   779 - CAN1 ACK error                                       
DEBUG:         57232  ..\src\Application\zero_mbb_sevcon_interface.c  : line   251 - Turning On Sevcon                                     
DEBUG:         57265  ..\src\Application\zero_mbb_sevcon_interface.c  : line  2694 - Sevcon CAN Disconnected                               
DEBUG:         58239  ..\src\Application\zero_mbb_can.c               : line   704 - Initializing Sevcon CAN                               
DEBUG:         58257  ..\src\Application\zero_mbb_can.c               : line   831 - CAN1 BIT0 error                                       
DEBUG:         58270  ..\src\Application\zero_mbb_sevcon_interface.c  : line  2676 - Sevcon CAN Connected                                 
DEBUG:         58380  ..\src\Application\zero_mbb_sevcon_interface.c  : line  2928 - Precharge Complete (111 V / 113 V)                   
DEBUG:         58381  ..\src\Application\zero_mbb_sevcon_interface.c  : line   872 - Sevcon Contactor Drive OFF                           
DEBUG:         58432  ..\src\Application\zero_mbb_can.c               : line   980 - Sevcon CAN EMCY Frame, Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 01 00, Unknown
DEBUG:         58472  ..\src\Application\zero_mbb_can.c               : line   980 - Sevcon CAN EMCY Frame, Error Code: 0x0000, Error Reg: 0x00, Sevcon Error Code: 0x46C3, Data: 00 00 3E, Unknown
DEBUG:         58660  ..\src\Application\zero_mbb_sevcon_interface.c  : line   862 - Sevcon Contactor Drive ON                             
DEBUG:         58676  ..\src\Application\zero_mbb_module.c            : line  1578 - Connecting Eligible Modules                           
DEBUG:         58677  ..\src\Application\zero_mbb_module.c            : line  1171 - Connecting Module 00                                 
DEBUG:         58776  ..\src\Application\zero_mbb_can.c               : line   980 - Sevcon CAN EMCY Frame, Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x52C1, Data: 00 02 00, Encoder fault
DEBUG:         58813  ..\src\Application\zero_mbb_can.c               : line   980 - Sevcon CAN EMCY Frame, Error Code: 0x5000, Error Reg: 0x40, Sevcon Error Code: 0x46C3, Data: 1F 10 00, Unknown
DEBUG:         59177  ..\src\Application\zero_mbb_sevcon_interface.c  : line   825 - Contactor took 487 ms to close               
Reading this, I tend to believe, that there is no connection to the motor. Logical would be the connector between the Sevcon and the motor, but there is no visible issue. I tried to move it, clean it, but no success. I also measured the 5 wires, which are going to the Sevcon (between the 2 connectors) and they are OK. The 6th is going on, so I could not check that. I am not sure, how I could check it on the motor side.
Any help/idea is highly appreciated.

br,

aron

Title: Re: Zero S 2013 Not starting
Post by: xerxesz on December 08, 2020, 02:04:41 PM

Well:

https://photos.app.goo.gl/8TKFCAWEym2QGeyy5 (https://photos.app.goo.gl/8TKFCAWEym2QGeyy5)

I think I found it....

Title: Re: Zero S 2013 Not starting
Post by: Curt on December 08, 2020, 02:12:52 PM

Good detective work. Will you be able to repair it without replacing a wiring harness?

Title: Re: Zero S 2013 Not starting
Post by: xerxesz on December 08, 2020, 02:46:58 PM

Well, I have chosen a not so elegant but quick repair. I added one more connector (a single wire one) for the faulty cable. It seems to work (the bike switched on and moved fw 1m :) ). Replacing the whole connector would be pretty painful, most likely I should replace most of the cables since (as I can see now) the cabling is pretty much a chaos.