ElectricMotorcycleForum.com
Makes And Models => Zero Motorcycles Forum | 2013+ => Topic started by: johnz on September 16, 2021, 09:39:09 AM
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I went to charge the FXE, when I turned the ignition to see how much battery percentage showed, it showed 0 but I know it was around 50% when I parked it 20 minutes ago. The error codes were 25, 30, 06, 40, 44, 45, 48, 49 and the engine light stays on.
Anyone have any idea what it could be? I only used zero quickcharger that I bought with it. Did I get a lemon?
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Have you tried using just the onboard charger?
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Check engine light turns on when I plug it in to on board charger.
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https://zeromanual.com/wiki/Gen2/Error_Codes
It's using Gen2 codes, I believe.
25 Contactor open (hence no battery level)
30 BMS CAN error (the mainboard can't talk to the battery manager)
06 BMS throttle enable error (since no voltage is coming from the contactor, the throttle is disabled by the battery)
40 BMS throttle enable active (same)
44 Kill switch enabled (you have the kill switch flipped off, as you should)
45 Kickstand kill enabled (the kickstand is down)
48 SEVCON startup failed (without the contactor closed, the motor controller won't work)
49 Contactor open disable (same as 25 but for a bad reason)
Sounds like the BMS is throwing a safety issue. It could be the battery, or just the manager, these are separate components a Zero Dealer can replace. There's lots of unlikely ways these can get damaged or be misassembled.
Time for warranty!
-Crissa
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It does look like, after just 500 miles, a critical connector has rattled loose somewhere in the CANBUS.
Cas :)
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Wow, thank you all for your help, I'll be calling the dealer today. Hopefully it wont take long to fix.
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Yeah, probably something came apart that shouldn't have. Hopefully it's as simple as a mis-applied zip tie. You're still in the burn-in shake-down honeymoon, and why there's dealers and warranties!
Good luck!
-Crissa
PS - this forum, that unofficial manual, is why I was okay with a Zero ^-^
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Anyone want to buy a used FXE with about 500 miles?
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I'll give you £5k for it :D
Cas :)
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Anyone want to buy a used FXE with about 500 miles?
Give your dealer a chance to fix it.
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Any update from dealer on this issue?
I have a 2021 DSR, delivered in May. Similar problem for me first occurred in June. Exactly the same error codes. Bike would not start. But 24 hrs later error reset and bike was ridable. Reported to Zero with logs, rode 150km to dealer, dealer replaced BMS board and firmware update. All good for another 3 months. Same thing again. Stranded and unable to drive but reset after 24 hours. Rode for a couple of weeks. Same thing. Back to dealer; they updated firmware, said it was fixed. And errors occurred again a couple of days later. The bike rides great when it runs, but getting stranded by this error is frustrating. Lost confidence that Zero can figure out what's causing it. Yes, repairs are covered under warranty but getting the bike 150km to the dealer is not. Not to mention finding ways to get home when stranded. If they fixed yours, maybe there's hope.
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Any update on this issue? My new 2022 FX with just under 500 miles has the same exact problem. Stuck at work right now and it won't start.
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Any update on this issue? My new 2022 FX with just under 500 miles has the same exact problem. Stuck at work right now and it won't start.
If you have access to tools to get to the BMS reset switches located on the battery and covered by a round plug/cover, you can try to do a BMS reset, some time that's all that is needed.
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Check the logs to see if hibernation mode is causing the problem. That was my problem which appears to have been fixed by a BMS replacement (knocks on wood).
https://www.electricmotorcycleforum.com/boards/index.php?topic=11675.0
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Thanks for the fast reply. I tried resetting the BMS by holding down the buttons under the seat and it was a no go. Luckily the dealer is just down the street from my work and they diagnosed it today as a bad BMS board. It reset itself this morning as others said it might and he confirmed with Zero the board was bad. Replacement is being ordered. Appreciate all the help here. Hopefully it'll be up an running again soon.
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2022 DS same issue here!!!! 600 miles total and I am regretting the purchase … maybe too soon to buy in fully on this generation of E Bikes.
I had to walk 4 miles home last night after getting the same error codes as you … used my last bit of phone battery trying to find a solution. Fun!!
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I've had 3 instances where my FXE would not start. Many codes showing. All three times it started fine the next day but still showed the engine fault that went away after 30-40 miles. Bike has 2600 miles now and the 3rd fault was just last week. I can elaborate when I get back home Monday from a trip. I just saw this thread today. BTW. I managed to squeak 85 miles out of it on a charge Labor day. The highest yet.
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While it wont speed up the fix, make sure to use the log parser to troubleshoot what might be going wrong. Gave me some piece of mind to figure out what was happening even though I had to wait for a BMS for the fix.
https://home.hasslers.net/zerologparser/log_parser.php
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There's your problem. You're looking at the check engine light, and it doesn't have an engine.
I've spent so much money repairing my '18 S, I'm hoping and praying every day that it just keeps going. Electric cars yes absolutely, never had a major problem with any of them. Electric "motor" cycles, I'm not sold yet, and that's from my experience (with this company).
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I've had 3 instances where my FXE would not start. Many codes showing. All three times it started fine the next day but still showed the engine fault that went away after 30-40 miles. Bike has 2600 miles now and the 3rd fault was just last week. I can elaborate when I get back home Monday from a trip. I just saw this thread today. BTW. I managed to squeak 85 miles out of it on a charge Labor day. The highest yet.
Hey! Please send us a private message so that we can look into this for you.
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Just experienced the same thing for the 4th time, Today !
All 4 times there was NO incident. Parked the bike for a short time after starting with a full battery and riding 30-40 miles, then when I went to go, It was another no-go! I had about 30 miles of battery left It does respond to plugging into onboard by changing from battery level 0 to 00:00 charge time. Same bunch of codes..
Solid green charging light, engine light on and the usual blinking red red light. I"m leaving it plugged in all night even tho it's not charging. I'll see what happens tomorrow.
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So this morning I unplugged to the on board charger and turned on the key. It showed the same battery and miles to go like when I powered it down yesterday before the issue of not wanting to initialize later. I believe that the 45 code was the only one still showing and the engine light was lit. I plugged it in again and it started to charge. It showed full charge about 4 hrs later so I unplugged it, turned on the key and it became ready to ride again! I let it sit and rode the XMax mostly because it was a chilly cloudy day with drizzle and it has good weather protection.
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Joining the FXE problem club.
Purchased new FXE in Dec 2021. Now have about 400miles on it. Parked it last Friday with ~90% battery. Turned on saturday am, 0% charge and that same set of error codes quoted above. Looks like some component is going bad frequently on these.
Called dealer (~60miles away), guess I will have to take it in to them.
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After reading this thread again, I went to garage to try zero FXE again. Powered up, showed error code 45 for a second, cleared then turned on. So looks like same behavior as SHAG (and some others) above.
Great, 60 miles from dealer and an *intermittent* problem. I can see taking it to them, and it works fine there.
Grrrr.
Would be nice to know if Zero has found a bad board and it could just be replaced. Maybe not that simple.
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Sorry to hear that you seem to be having the same problem. At least you can ride yours to the dealer if you go 40 mph and regen when you can!
I've been riding mine almost daily and will not turn the key off unless I'm home. I leave it on if I stop somewhere for a few minutes or visit a friend. 20-30 minutes max.
I don't have a way to get it to the dealer and the intermittent thing will probly not allow them to diagnose the issue right now.
Please take yours in and I'll wait for the recall.......... TIA ! SHAG
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Thanks for reply.
btw error code 45 is kickstand disable, so not really an error.
Rode around the neighborhood this evening and all ok. Might try to commute as usual tomorrow (not a long commute, so not a huge risk).
I see below that Zero asked you to contact them, did you?
I downloaded the error log so can provide that if they can diagnose. Maybe just a firmware error and that can help?
Will let you know.
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I was really considering one of these. Have they sorted out the issues and no return of the problems?
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I've got 350 miles on my '22 FX. I'm hoping Zero just got a bad batch of BMS modules and only some of the models are affected. But I'm still keeping a close eye on this thread.
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I was really considering one of these. Have they sorted out the issues and no return of the problems?
It's a great bike! I bought it to do daily loops of 40-80 miles around the Allegany National Forest on mostly dirt roads. I wouldve bought the FX but didn't want the higher seat or inner tubes. I have a better set of tires to put on it soon before I hurt myself.
If my dealer was within riding distance or I had a way to get it there without sitting on the seat, I would be happier.
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Update on my Zero FXE problems: None since the no-go issue ~1 week ago... and I have turned on-off ~10 times since then, charged twice.
I agree with SHAG that it is a great bike (other than recent no-start issue). I had a 250 Yamaha WRX (supermoto type) and and don't miss it with this bike. Low speed torque is amazing and 0-60 is comparable to my 1199 Panigale. I just ride it around town for commuting and it is perfect for that. Range is ~50miles the way I ride it, but doesnt matter for 5-10 miles commute.
Would be good to hear if Zero has figured out it is a specific part causing the problems, such that if I take it in, they upgrade firmware, swap out a board or some such. I am worried I take it in and dealer says "we dont see anything wrong - bring it back when you have a problem again" (and repeat).
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One other thing that might matter for people thinking to purchase a Zero... or electric moto in general. I did get 10% rebate of purchase price on 2021 taxes. Guessing that will be same for 2022. (It would have been 30% if BBB act passed, is my understanding).
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I've had 2 more issues with the will not start problem. This is the 6th time at 4300 miles. The only thing different on the last one, Friday, was that after unplugging it in the morning, turning key on and writing the range down in my log book, it would not go a few hours later when I wanted to ride. The reason for keying it on every morning and writing the information down, is when I come home from work (I ride the XMax) and have lunch, I gear up and go. Been doing this since bike was new. Anyway, the bike would not power up again until the next day after sitting overnite.
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4300 miles! You ride quite a bit more than I. I continue to have no more problems since 1 problem ~1month ago. I just ride few miles around town though. Total miles ~500 as of now.
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Number 7 was Wednesday 7/20. After riding about 40 miles and returning home for dinner, the bike sat for about 2 hrs and would not go when I wanted to go back out riding again! I messed around again as usual, cycling the key switch and plugging and unplugging in the chargers several times with no change. Yelling at it and kicking didn't help again either. The next morning, it would not go, which surprised me because the other 6 times it powered up to ride after sitting overnite. I called the dealer and asked to have it picked up when the driver is coming close to me for someone else.
Well, that afternoon it became ready to ride again, so I put it on the slow charge to top it up for the next day. After it showed a full charge and I turned the key on, all was good! It was odd for it to show est miles 110 which the previous high was 72! Had other things to do yesterday afternoon and today, so I'll see what happens tomorrow afternoon when I can try to go for a ride.
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Zero sold a bunch of "authority" legacy models to various government agencies over the past 10 years, although I haven't heard anything about them selling the SR/F bikes to police departments. I wounder if government agencies are having similar issues with their SP/FXP/DSP/ model bikes? I would think that if they were, the word would get around pretty fast and that would quickly be the end of most Zero police-model sales. Cops won't put up with the kind of crap that you hear about on this forum.
Personally, I wouldn't be surprised if H-D develops a police version of the LiveWire eventually. There is big money in the cop motorcycle market, especially when used in cities and in public parks.
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This thread has been helpful as with only 170 miles on my '22 FX I came home to go for a ride after work and was frustrated by the same codes.. ugh. Tried the BMS reset and alike and still no love. Hoping tomorrow she will come alive again for me but I'm not sure if I'll trust this bike as long as this issue remains unresolved. Nothing like having a bike you can't fix yourself. As much as I love it, totally second guessing this purchase after this....
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I experienced #8 several days ago. Powered up in the morning after unplugging from onboard charger, recorded the battery, 100% and est miles 70 in my log book. After lunch, when I tried to go and thinking I would hit the 5k mile mark, It would not go. Worked fine the following day and the engine light stayed on for 2 days as usual.
I used the fast charger a few days ago after a 60-mile ride and all was good. I still do not turn the key off unless I'm in my driveway. Good rides yesterday and today.
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My possible related experience with my (new to me) 2020 FX 7.2 with single "long brick" battery
Purchased and trailered home on 2022-06-18
During Safety Inspection notice that brake lever brake light switch is faulty. Switch is always stuck at High Ohms. Can hear switch click. Zero emailed, on 2022-07-17 bike examined at dealer (and new firmware installed) and seems like Zero will fix switch as a courtesy. Good dealers experience at Mitchell's Cycles, but they ain't close. Waiting for part.
On 2022-08-18 for some time (0.5-2hrs?) FX would not go, or charge, engine light displayed.
I had never set my display to show errors so I have no idea if errors had been earlier quietly generated. I learned how to have display show errors.
During the 0.5-2hrs. "no go time" Errors 25,06,54,55,48 and 49 are displayed when power "Keyed on" with side stand up..
I email Zero the logs. They recommend I go to a dealer so they can further diagnose problem.
After awhile throttle works, Error displays 25, 48, 49, then 0 are displayed when power "Keyed on" with side stand up. Engine light disappears after a few km. of riding. Confirm chargers work with bike the next day.
2020-08-08 hrs. Motorcycle consistently displays 25, 48, 49 and then 0 on key on. Rides and charges with no apparent issue. Sent new logs to Zero. The agreed plan is that when I get my front lever brake light switch replaced at the dealer that my FX gets plugged in to the dealers computers to try to diagnose the problem.
Thankfully I have saved all my logs and have availed myself of home.hasslers.net to try to figure out what I can. There is a suggestion in my first MBB log file that the BMS,battery or BMS battery combination was swapped out sometime earlier this year. From the MBB log ...
02422 1 Module 00 Registered serial: 19lb2135, vmod: 95.545V
02423 12/05/2021 15:04:56 Sevcon Turned On
...
02479 1 Module 00 Registered serial: 19lb4278, vmod: 106.020V
02480 06/01/2022 09:00:02 Sevcon Turned On
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No-go #2 for me this am. Same error codes as before. Plugged in, and went to work. Tried this evening, no luck.
I am just waiting until riding weather stops, then will take to dealer. Hopefully they can fix the firmware and/or swap out the right parts.
Anyone hear any rumors about what this issue is?
Other than that (the no-go that is), great bike.
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.. and same behavior as before: 24 hrs later it turned on an ran fine.
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... and #3 occurrence for me this am. grrrr.
I am waiting for someone to say... I took it to dealer, they said" "yeah it some faulty firmware/part... swapped it out and you should be good to go"
Anyone... ?
I am ~1hr from dealer and putting off the hassle and, ideally, I hear the statement above and not... "been to dealer 5 times and still not fixed... "
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Sorry that you are having the same problem as I am, TRex. We are not alone. My guy says they're not sure what's wrong yet. It acts like a bad solenoid on an ICE bike.
Another guy said that it's a problem that won't go away on its own. I was at a place, and they had a new FXE in the back that was gutted, waiting on parts.
I just cracked 7k miles yesterday and have had 8 No-Goes! Since I started leaving the key on during rides, I haven't had a fault in a while. What I mean is that I can't ride it to work and expect it to run after sitting for 4 hrs. If I ride it till the battery is almost dead without turning the key off, all is good. It has never quit on me.
Hopefully a solution will be found soon.
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Thanks for the fast reply. I tried resetting the BMS by holding down the buttons under the seat and it was a no go. Luckily the dealer is just down the street from my work and they diagnosed it today as a bad BMS board. It reset itself this morning as others said it might and he confirmed with Zero the board was bad. Replacement is being ordered. Appreciate all the help here. Hopefully it'll be up an running again soon.
Update... Next day after no-start #3, all is fine. Rode today, no problems.
Thanks for info SHAG...
I did go back and look thru this thread and see this post from WeGo4x4 who had a bad BMS board and it was replaced. I dont see later post by him. Did it fix problem?
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Zero relased a firmware (MBB v35 and BMS v42) supposedly to solve the issue with BMS stuck in battery hibernation mode when powering on the bike, did you update to this latest firmware?
https://www.zeromotorcycles.com/firmware
The issue is that when BMS is in hibernation and don't wake up at key on, it does not communicate with MBB and you will get 0% battery on the dash due to no canbus communication.
Every day the bike do a BMS autoreset this is why the day after the issue disappear, if you want to do a manual reset of the BMS, you can remove for few seconds the B+ fuse from the left side of long brick battery (on FXS it's located under the rubber, a little lower than OBD connector).
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Thanks for that information, dalamario.
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Update on this from my end. Finally got the FXE into dealer (~beginning of Jan). Pulled bike off of trailer and it had the issue (battery at 0% and error codes as discussed above). Two weeks later I picked up... Mechanic didnt acknowledge specific problem (maybe it didnt happen for him), but he did upgrade firmware. I am hopeful that did it, as several has reported here. Only rode a couple of times since then, so not yet sure. I think I will have to figure out the firmware update myself and try to keep on top of that. Will see over next weeks if issue solved.
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This is very discouraging seeing a problem like this, that is still alive and well for this long and nothing 'official' has been said about it.
Not trying to play tit for tat but this makes the whole e bike industry look bad, and gives fuel to the nay sayers. Given how many people seem to have this issue I am very surprised there is not a recall on the thing already.
Aaron
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My bike was picked up by the dealer Thursday to have the issue addressed.
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Riding more frequently and no problems. So I think that firmware upgrade got it. (fingers crossed).
Probably need to figure out firmware update myself... as the dealer knew less about the issue than I did. Any hints on that? When I have looked on the app, the firmware upgrade feature didnt want to work. Will chase in the future.
I see SHAG hasnt posted about the issue in a while. Hopefully the firmware fix worked for him.
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Hey TRex ! Ya, I think my issue was also solved by the update. I was afraid to say anything. Didn't want to Jinx myself !
Have only put 600 miles on it since, and have shut the key off probably 6 times in the middle of rides so far. I also did a 2hr charge the other day with the onboard charger and the fast charger at the same time without an issue. I'll slowly break the habit of leaving the key on when I stop during a ride, except for out in the woods.
The bike is a blast to ride, and I'm now very happy with the purchase.
Best of luck to you and everyone else that bought one !!
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Greetings,
Just a quick update that I have had no problems with the FXE since that firmware update in Jan'23. Can report fixed!
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Just an update. My FXE was just short of 15k miles when I put it away for Winter! I've had NO problems with it since my last post.