ElectricMotorcycleForum.com
Makes And Models => Zero Motorcycles Forum | 2013+ => Topic started by: enriqueeeee on February 23, 2025, 06:46:37 PM
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Hi,
I was wondering if there is anyone that opened a pack to replace the flatband.
I have one with a damaged flatband and would like to replace it.
Before opening it and finding the partnumber so I can order one, Im looking on some pointers how to open it.
I've removed the battery from the bike, and removed the sideplates and the BMS, I wanted to remove the top plate, but before braking anything.
I'm not 100% certain how to open this part.
The battery in question is a Black Farasis PCM102064-D01, 14.4 Kwh from a DSR bike.
Thanks.
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Thanks, i have found his video also, I will show later what I have done, I have still some issues with getting it to work.
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What i have used so far info wise:
Removal of the Charger:
https://www.youtube.com/watch?v=DFHQgTOMxO8
Removal of the battery (its Really heavy... ) I used a Motor cycle motor Jack and lowered the Battery. Then pulled up the Front of the motor cycle on the front wheel to have the clearance to remove the battery. rear being on a stand.
Video of someone else removing the battery:
https://www.youtube.com/watch?v=XGm_BM4CPsM
The video mentioned earlier of Dr bass about the batteries and their differences and such:
https://www.youtube.com/watch?v=ZhPpuUaxeWM
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Maybe what you are calling "flatband" are the cells in pouch format?.. if so, that is a nearly impossible job. At least I know nobody that ever replaced a dead cell inside these fully potted battery. It would be VERy difficult to remove the dead cell without damaging the other cells. That potting is like a harder balistic gell that is both plastic/elastic and gummy and ultra difficult to work with. The closest job I have ever done was to solit one of the zero brick in two half back in 2014.
In my opinion it will be easier for you to simply disconnect that bad cell and connect an external cell to replace it but that external cell will need to be atthe same temperature to the battery so it will require to be stick close to it and well protected. here is a video I made where I converted a ZERo brick of 102V to a 51V https://www.youtube.com/watch?v=7stnShzd_08 (https://www.youtube.com/watch?v=7stnShzd_08)
Doc