ElectricMotorcycleForum.com
Makes And Models => Zero Motorcycles Forum | 2013+ => Topic started by: PeterFSX on May 06, 2023, 05:16:20 PM
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Hi all,
My FXS 2019 with just 7000 km stopped charging. I use this bike for commute, even when it rains. A new onboard charger wasnt the solution, it still doesnt charge. I dont have any error codes on the display.
When I plug in the onboard charger, I hear that click, the green charge light keeps flashing and the charge time displays 0:00. After a while the green light turns off and nothing happens.
In the bin files I can only find this relating to charging errors: DEBUG: Charge Fault Occured. Sevcon trying to close contactor, but one was not closed quickly enough.
Does this mean replacing the SEVCON converter? Can someone look at the bin file to see if thats correct?
Are there other things to check first?
An other option could be this, since I only charge at home, I am leaning towards buying an offboard charger, could that be the solution even if the onboard charger doesnt work?
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"One was not closed quickly enough." Sounds like a problem with the contactor in one of your battery modules ... or the system that monitors it.
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Have you checked fuses? I had an intermittent charging issue with my 2017 FXS that eventually became a full time issue. I tracked it down to the 10 amp fuse that supplied power to the OBC. First I
cleaned the contacts of the fuse holder. Eventually I replaced and relocated the entire fuse holder to a better location.
https://www.electricmotorcycleforum.com/boards/index.php?topic=11400.msg107353#msg107353
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Thanks for the replies!
"One was not closed quickly enough." Sounds like a problem with the contactor in one of your battery modules ... or the system that monitors it.
It sounds like it is. Its hard to interpret these logs right without experience, this is my first electric motorcycle.
Have you checked fuses? I had an intermittent charging issue with my 2017 FXS that eventually became a full time issue. I tracked it down to the 10 amp fuse that supplied power to the OBC. First I
cleaned the contacts of the fuse holder. Eventually I replaced and relocated the entire fuse holder to a better location.
https://www.electricmotorcycleforum.com/boards/index.php?topic=11400.msg107353#msg107353
Thanks, didnt know about that, I will check the fuses tomorrow.
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Sounds exactly like my 2016 FX earlier this year. I also tried a new charger, to no avail. It was the 10A fuse holder hidden in the wiring harness on the right side. Like mdjak1, I fixed it by cleaning the contacts, using emory paper, bending the prong inward a little, and spraying some WD-40. I then ordered the new waterproof fuse holder, and plan to put it in upon the next recurrence.
https://www.newark.com/eaton-bussmann-series/bk-hfa-r/fuse-holder-in-line-waterproof/dp/65K4436
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Hello
I have the same problem on my 2016 FXS.
Since a few days, my bike does not charge fully with the onboard charger. It stopped sometimes at 78%, sometimes at 58%.
But I am able to finish the charge to 100% using my external charger.
The logs give the errors (see attached file)
ERROR: Internal Fault on BMS1
ERROR: Internal Fault on BMS0
DEBUG: Charge Fault Occured. Sevcon trying to close contactor, but one was not closed quickly enough
I will try cleaning the fuse holder, as Curt said.
Gerard
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Hello
I have the same problem on my 2016 FXS.
Since a few days, my bike does not charge fully with the onboard charger. It stopped sometimes at 78%, sometimes at 58%.
But I am able to finish the charge to 100% using my external charger.
The logs give the errors (see attached file)
ERROR: Internal Fault on BMS1
ERROR: Internal Fault on BMS0
DEBUG: Charge Fault Occured. Sevcon trying to close contactor, but one was not closed quickly enough
I will try cleaning the fuse holder, as Curt said.
Gerard
My daughter's 2014 S had the same problem which was cured by installing a new (and improved?) OBC.
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Thanks guys! The bike is charging now. It was indeed the onboard charge fuse.
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I have the same problem on my 2016 FXS.
Since a few days, my bike does not charge fully with the onboard charger. It stopped sometimes at 78%, sometimes at 58%.
But I am able to finish the charge to 100% using my external charger.
Crap, that sounds exactly like the classic Green Watt Power EVC-116-720 charger failure. I was able to find a replacement on eBay for $418 shipped, which it turned out I didn't need because it was the fuse holder. I keep it in case I get your same failure. I wonder if it is easy for you to get one in Europe.
There is another one here.
https://www.ebay.com/itm/266184083677?hash=item3df9cec8dd:g:qqgAAOSwxPFkGxmF&amdata=enc%3AAQAIAAAAwCEpVe1Urd66ge3bCUYH6GJjYmBQU86uMIXwS%2BzIF%2BG28gGg44EtbWinvkmiiGEUBs9QeazQ8FvbCIQYGw4joUMJa9Vm3gtwiX0P%2FGa1evaysKqUTWYOo%2Fr2ToIbGFHRU6B%2BiLFb28dwRf%2FCBGQPBjW6GINT3HI%2FHY8Rc1K3VjoUnDLpzS3yxWABlpIcxaissEBE%2BgsMIOd3Yw1O2vz0kJFMjlpc7p01WpmOFpfexUz2JjCC0Ly%2BW77QFWxxGFi%2FgQ%3D%3D%7Ctkp%3ABk9SR6L9z9D_YQ
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Thanks guys! The bike is charging now. It was indeed the onboard charge fuse.
Excellent news. Glad we were able to help with the issue.
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I have the same problem on my 2016 FXS.
Since a few days, my bike does not charge fully with the onboard charger. It stopped sometimes at 78%, sometimes at 58%.
But I am able to finish the charge to 100% using my external charger.
Crap, that sounds exactly like the classic Green Watt Power EVC-116-720 charger failure. I was able to find a replacement on eBay for $418 shipped, which it turned out I didn't need because it was the fuse holder. I keep it in case I get your same failure. I wonder if it is easy for you to get one in Europe.
There is another one here.
https://www.ebay.com/itm/266184083677?hash=item3df9cec8dd:g:qqgAAOSwxPFkGxmF&amdata=enc%3AAQAIAAAAwCEpVe1Urd66ge3bCUYH6GJjYmBQU86uMIXwS%2BzIF%2BG28gGg44EtbWinvkmiiGEUBs9QeazQ8FvbCIQYGw4joUMJa9Vm3gtwiX0P%2FGa1evaysKqUTWYOo%2Fr2ToIbGFHRU6B%2BiLFb28dwRf%2FCBGQPBjW6GINT3HI%2FHY8Rc1K3VjoUnDLpzS3yxWABlpIcxaissEBE%2BgsMIOd3Yw1O2vz0kJFMjlpc7p01WpmOFpfexUz2JjCC0Ly%2BW77QFWxxGFi%2FgQ%3D%3D%7Ctkp%3ABk9SR6L9z9D_YQ
Its very easy to get one, just expensive. Cost about 900 euros.
My motorcycle unfornately left me stranded today. I got a new issue. Which probably is not going to be so easy to fix. I drove to work and it decreased power untill it stopped. Went to the side of the road and now the motor goes backwards after turning it off and back on.
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Sounds like the motor timing is out of spec. The dealer should be able to "commission" it or whatever it's called. May fix it.
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Hello everybody
Thanks for your messages. Indeed, it seems that my problem comes from a defective onboard charger. But I will try to inspect the fuse first. Who knows... Yesterday the SOC was at 31% and the onboard charger did not start. The happy end would be a random bad electrical contact in the fuse ::)
I will let you informed.
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Bingo ! It was the fuse ! This crap was completely out of order. Unable to open the fuse container: everything was clogged. I cut the wires, soldered a new 10 amps fuse, and the bike charged immediately as usual. It is now at 100% and balancing :)
This means that when the charger fuse begins to malfunction, the symptoms are not only the inability to charge, but it can also lead to charges starting, and then stopping prematurely.
Thanks guys !
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The fuse holder is supposed to be waterproof or water resistant. But it really isn't long term. Also, the location is pretty low in the bike and if you ride in the rain or through a lot of water, or if you live near salt water, it is more likely to corrode and fail. That is why I relocated mine to a higher, and more accessible location on my FXS.
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Sounds like the motor timing is out of spec. The dealer should be able to "commission" it or whatever it's called. May fix it.
You were right the timing is out of spec. The dealer could fix it and it work for about 3 km. Than the same problem is comes back. Probably something wrong inside the motor....
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Or just the sensor is going bad, needs to be adjusted. It tells the motor, spin at 400 rpm and looks for the signal to tell it how fast it is spinning, if that signal is 'dirty' or breaking up, or not there, it faults. If it's a mag head, or a proximiter using RF, then even a piece of crap stuck on the sensing head can throw it off.
Aaron
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I see this is a topic that hasn't been posted in a while but I am having a similar problem with my 2017 FX and this came up when searching. I don't know where this fuse is and wondered if someone could tell me? Is it item number 28 in the parts catalog? Remove the seat and plastic around the battery to access? Thanks.
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https://zeromotorcycles.com/owner-resources
2017 FX
https://prismic-io.s3.amazonaws.com/zero-cms-disco/c55944fa-499e-48e2-83f0-c8dd36657607_OM-XMX-MY17.pdf
Page 6.34, fuse 4, ABC10A, Charge fuse (on-board)
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Got it - thank you very much.
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See also the link given by mdjak1, in the third post of the present topic
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Thanks very much for all the help and pointing out things I should have found on my own. I removed the side cover and the area around the wires and the fuse holder is clean and dry. I removed the fuse and did a continuity test and it checks out OK. The inside of the fuse holder looks fine - clean, no corrosion. Put the fuse back in and no change. I'm going find a replacement fuse and try that and then do some of the things mdjak1 did wrt cleaning it up. Maybe I just need a new OBC. I will update after trying a new fuse.
Again, thanks to all. This forum is great.
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A new fuse didn't make any difference.
The piece with the spring that holds the fuse looks like new and I used a light to look inside the fuse holder and don't see any corrosion or do-dah. I may get a new fuse holder but it looks like there would more dis-assembly in order to install it. I put the side cover back on for now and will see what happens for a while. From looking around the forum, it seems like a lot of OBCs fail. This bike started showing these symptoms right at the 5 year mark and I intially thought it was the battery going down hill but it seems like there is more experience suggesting it is the OBC or this fuse holder.
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I became convinced it was the fuse holder after messing with it temporarily fixed the problem. My fuse holder also looked fine, with no evidence of water getting in, and replacing the fuse did nothing. More likely, it has to do with fatigue of the spring or some other manufacturing defect in the fuse holder. Maybe you could try bypassing the fuse to diagnose it before buying a new OBC like I did.
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I agree with Curt. And if you want to take precautions, you can bypass the fuse with another 10A fuse.
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You can goto autozone or any parts store and get an external barrel type fuse holder with two wires hanging out for a few bucks. get two alligator clips on the wire ends and use this as your bypass. That way you are protected, and can jack right in without having to cut any wires or make any modifications to stuff, hopefully.
On those type of fuse holders, you *might* be able to push the wires from the outside of the fuse holder, to the inside of it, basically sliding the plastic container back, exposing the contacts (you may find the spring side, the spring is soldered to the wire or something like that) and then just hook your jumper to it like that, this will also allow you to examine the holder for any issues. Remember with low voltages, it does not take much crud at all, to wreck a connection. The slightest rust, green, blue, brown on the pad end and it won't work, or can over heat and melt.
Aaron