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Makes And Models => Zero Motorcycles Forum | 2013+ => Topic started by: DonTom on June 03, 2026, 12:38:44 AM

Title: 2023 Zero DSR/X not charging
Post by: DonTom on June 03, 2026, 12:38:44 AM
Are there other fuses hidden somewhere in my 2023 Zero DSR/X?   If so, I cannot locate them. I did find the two HV fuses on the left side of the battery pack which test okay.


I need a starting point to troubleshoot, I just now discovered my bike will not charge up after it has been sitting for a few months.


It is well charged at 67% SOC. SOC limit set to off (100%). It starts the "charge" at 0.0 KW and after a couple of minutes of that, the bike just turns totally off.


The same charging setup works perfectly on my Energicas and other EVs, so it has to be the the bike, not my EVSE.


-Don-  Reno, NV
Title: Re: Zero DSR/X fuses?
Post by: princec on June 03, 2026, 03:31:36 AM
Sounds more like software to me. Storage mode snafu?

Cas :)
Title: 2023 Zero DSR/X not charging
Post by: DonTom on June 03, 2026, 04:45:43 AM
Quote from: princec on June 03, 2026, 03:31:36 AM
Sounds more like software to me. Storage mode snafu?

Cas :)
I think you're correct. Is there a way for me to deal with it?


See my screen below, before and when it gives up.


BTW, the kill switch is NOT on when it shows on when it gives up with the charge.


-Don-  Reno, NV
Title: Re: 2023 Zero DSR/X not charging
Post by: DonTom on June 03, 2026, 06:51:26 AM
I have to see what "automatic updates" does which was on.


I just discovered my bike is several updates behind on the MBB as well as for BMS stuff. So it has not been "automatic" at all.


Hopefully one of the updates will fix the charge problem.


I am doing the updates now, with the app, as I type this.


When it is done, I will post the results here, of course.


-Don-  Reno, NV

Title: Re: Zero DSR/X fuses?
Post by: DonTom on June 03, 2026, 09:22:20 AM
Quote from: princec on June 03, 2026, 03:31:36 AM
Sounds more like software to me. Storage mode snafu?

Cas :)
SW update are now done. Here is what I now have:


MBB=44
BMS:20
FW=8V33


It still will not charge, but now it shows an error that can perhaps be helpful. It showed no errors before the updates, Now it show:


Error Code=31    It still will not charge, but it says wait two minutes and try again. I will wait a few minutes before I post this just to be sure.




Okay, the three minutes are up:


No difference.


But I have not yet checked the low voltage fuses. The owner's manual says I must remove the 12V battery to get to the fuses, so I will check those next.


At least I learn a little about the bike this way. I would rather have all this happen here at home than on the road!


-Don-  Reno, NV







Title: Re: 2023 Zero DSR/X not charging
Post by: DonTom on June 03, 2026, 02:27:27 PM
I could not find anything interesting today, the low voltage fuses are difficult to get to, but they all check okay. There are four different fuse current ratings, but only a spot for three spares, The 10 amp spare fuse was in the fuse holder not connected to anything, not in a slot, just loose, and it can move around in there but is unlikely to cause a problem. But I decided to leave it out and put it with my other junk that is always with the bike.


See the photo for the location of the low voltage fuses. The "tank" cover in that area must be unscrewed and lifted up to get to any of the low voltage fuses and is a hassle for just getting to fuses.  The two HV fuses on the left side of the battery are the opposite, very easy to get to.



Next, I will check the BMU (Battery Management Unit) area. But that will be tomorrow or some other day.


I expect the problem is in that area, if not the BMU itself. Perhaps it crapped out when I tried to charge the bike the first time after the bike has been sitting for a couple of month. Or perhaps a flakey connection--or something got wet. I will soon find out. I hope to find something I can fix, of course.


I do not think it is a SW issue now that the bike has been updated to the latest versions and made no difference.


-Don-  Reno, NV
Title: Re: 2023 Zero DSR/X not charging
Post by: princec on June 03, 2026, 03:15:30 PM
Did you hear the contactor click?

Cas :)
Title: Re: 2023 Zero DSR/X not charging
Post by: DonTom on June 04, 2026, 12:17:10 AM
Quote from: princec on June 03, 2026, 03:15:30 PM
Did you hear the contactor click?

Cas :)
Yes, the contactor clicks even when I try my unsuccessful charge. And clicks again when it gives up. So that is NOT the issue.


-Don-  Reno, NV
Title: Re: 2023 Zero DSR/X not charging
Post by: DonTom on June 04, 2026, 03:22:26 AM
I just now removed the BMU. It shows a flashing red light, even with the HV and 13V battery disconnected.


I tried to charge again after reseating all the connectors and putting the bike back to normal. No obvious problems seen inside.


Still will NOT charge.


I have no idea what the flashing red light means. A flash red flash.


See photos.


-Don-  Reno, NV
Title: Re: 2023 Zero DSR/X not charging
Post by: Richard230 on June 04, 2026, 03:28:44 AM
Why not contact Zero's customer service and ask them about the problem?
Title: Re: 2023 Zero DSR/X not charging
Post by: Curt on June 04, 2026, 04:16:54 AM
Could it be the 10A charging fuse holder in the wiring harness? A similar thing happened on my bike and several others as described in this thread:

https://www.electricmotorcycleforum.com/boards/index.php?topic=11400.msg117610#msg117610

You can first clean the fuse holder contacts and see if that fixes it. If it does, then replace the whole fuse holder, as it's not the fuse but the fuse holder itself, and the problem will otherwise return. If it does not, then this is probably not the problem.
Title: Re: 2023 Zero DSR/X not charging
Post by: DonTom on June 04, 2026, 04:29:04 AM
Quote from: Richard230 on June 04, 2026, 03:28:44 AM
Why not contact Zero's customer service and ask them about the problem?
That is not my style until I give up and get desperate.


I am not quite that far YET, but perhaps soon will be.


I just like to figure out such things for myself, when possible.


At least by the time I give up, I will know what I am talking about if there are any questions as well as understand what I need to do.


-Don-  Reno, NV
Title: Re: 2023 Zero DSR/X not charging
Post by: DonTom on June 04, 2026, 04:31:59 AM
Quote from: Curt on June 04, 2026, 04:16:54 AM
Could it be the 10A charging fuse holder in the wiring harness? A similar thing happened on my bike and several others as described in this thread:

https://www.electricmotorcycleforum.com/boards/index.php?topic=11400.msg117610#msg117610 (https://www.electricmotorcycleforum.com/boards/index.php?topic=11400.msg117610#msg117610)

You can first clean the fuse holder contacts and see if that fixes it. If it does, then replace the whole fuse holder, as it's not the fuse but the fuse holder itself, and the problem will otherwise return. If it does not, then this is probably not the problem.
Are you referring to a 2023 Zero DSR/X ?  Is there a fuse in a harness somewhere that I have not yet found?  A photo of the area of the bike would be helpful.


-Don-  Reno, NV
Title: Re: 2023 Zero DSR/X not charging
Post by: DonTom on June 04, 2026, 04:45:58 AM
I discovered the BMU LED is green until AFTER the rejected charge is completed and it stops trying to charge at the 0 watts. The Zero APP also shows "normal" until after the charge fails and then I get the BMU error 31.


While I expect the problem is either in the BMU or from the things it senses. I know a large cell imbalance can cause problem to the BMU, but I am not getting any such errors. Unlike earleir Zero models, the Cell balance true MV numbers are not shown with the DSR/X, only an error message if cells are too far out of balance and I am not getting any errors other than the Code 31 which ONLY shows after a failed charge.


Until the code 31, all seems normal except it "charges" at 0 watts. After the failure in 30 seconds or so, I get a fast red blinking light at the BMU as well as the screen showing my kill switch is activated when it is not.


-Don-  Reno, NV
Title: Re: 2023 Zero DSR/X not charging
Post by: DonTom on June 04, 2026, 05:57:51 AM
I decided to count the red light blinks on the BMU before it returns to green after the charging failure. So I put the electrical stuff back to normal for to see a failed charge again.


I wanted to count the red blinks, but . . .  .





I never got that far, because the bike started to charge. But seemed a bit abnormal as it only charged at 3.3 KW for two minutes or so and then it started to look perfectly normal at 6.6 KW after those two minutes.  This make me wonder if the 6.6KW comes from two 3.3 KW chargers in there. I will check the service manual  for that later.  For now I am letting it charge. I am trying to decide if I want to let it charge to 100% SOC or if I should stop it before then.




I do NOT think of this as good news, because I found no problem. That means I cannot trust it to always charge.


Or perhaps this problem is only after the bike sits long enough to go into storage mode. I really do not know what to think.


My gut feeling is after it charges up to full, it will continue to be okay until it sits for more than a month again. Which means there is still something wrong, but if that is the case, it will make the bike rideable again but I will not ride it far enough to need a charge for quote a while because I cannot trust anything with just guesswork, not knowing what happened.


-Don-  Reno, NV
Title: Re: 2023 Zero DSR/X not charging
Post by: DonTom on June 04, 2026, 06:32:46 AM
I went to stop the charge so I can see if it will start the charge gain normally. But I was too late, it charged up to 100% SOC.


I will start putting the bike back together and ride enough to discharge it and then try to charge again.  I see no reason to take it apart again, I got all the info. I wanted already.


I will post here the results after some riding and then try to charge again.


-Don-  Reno, NV
Title: Re: 2023 Zero DSR/X not charging
Post by: DonTom on June 04, 2026, 10:52:32 AM
I put the bike back together and tried to charge using the "extended range charging". Same old problem.


The one time it charged was just a fluke. But I now have the bike at 100% SOC so I will ride it around a little tomorrow and try to charge it up again after a few miles.


My guess is there is something flakey in the BMU, but I cannot prove it.


-Don-  Reno, NV



Title: Re: 2023 Zero DSR/X not charging
Post by: princec on June 04, 2026, 03:21:24 PM
Unlikely the BMU itself has managed to fail all on its own. Much more likely to be a little bit of corrosion and / or moisture on a critical connector, which happens when things get left alone for months. Make sure your 12V battery is fully charged too, which apparently can also cause init problems.

Cas :)
Title: Re: 2023 Zero DSR/X not charging
Post by: DonTom on June 05, 2026, 12:33:32 AM
Quote from: princec on June 04, 2026, 03:21:24 PM
Unlikely the BMU itself has managed to fail all on its own. Much more likely to be a little bit of corrosion and / or moisture on a critical connector, which happens when things get left alone for months. Make sure your 12V battery is fully charged too, which apparently can also cause init problems.

Cas :)
My 12V battery is at 13.0VDC after the bike not being on for a day. It is at 13.22 VDC when the DC2DCC is active (when bike is keyed on, 13.30  when trying to charge).


I already did remove every connector I could get to and looked inside for issues and then reseated them.


The BMU always has voltage on it, even when the DC2DCC fuse is removed and the 12v battery disconnected. The LED on it can blink even when the contactor is open. I assume that is normal, getting it's voltage from the HV battery somehow, but at a very low voltage.  The LED on it can light up full even when the contactor has been open for hours. So just sitting, it is somewhat active. And a capacitor can dry out internally or whatever to give problems. While I expect a bad BMU, I have no known way to prove it. I could buy one and see what happens and then simply have a spare BMU if I still have the same problem. I assume such a module has no programming info inside to match my bike and I can simply replace it.


I never counted the blinks for the error that it gives after a failed charge. It does NOT repeat, so I need to count the blinks the first time or try to charge and wait again for the failure.


I will do that later today and see if I can get more info.


I was was ready to do that yesterday--but that was the time the bike charged up.


-Don-  Reno, NV



Title: Re: 2023 Zero DSR/X not charging
Post by: TheRan on June 05, 2026, 01:48:28 AM
Error 31 means battery module ineligible, whatever that means, but I would take that to mean the fault lies within the battery and not the charging. I would also assume this wouldn't allow the bike to ride, did you try this?
Title: Re: 2023 Zero DSR/X not charging
Post by: DonTom on June 05, 2026, 02:02:32 AM
Quote from: TheRan on June 05, 2026, 01:48:28 AM
Error 31 means battery module ineligible, whatever that means, but I would take that to mean the fault lies within the battery and not the charging. I would also assume this wouldn't allow the bike to ride, did you try this?
The bike rides fine, but so far, I only rode it a very short distance, from my driveway back into the garage just to test that it runs.


The battery seems to be fine (both of them). I did mange to charge it to 100% soc one time yesterday. But it started out a little flakey at 3.3 KW until a couple of minutes and then went to the full 6.6 KW. Why it charged one time after this problem is a mystery. But still didn't seem to charge correctly for the first couple of minutes.


I will start doing a little more testing in a few minutes. And then go for a ride of several miles and then try to charge again. Perhaps I will ride it to Reno's Zero dealer to see what the price is of a new BMU.




I will not ride far enough to need a charge before coming back home.


-Don-  Reno, NV
Title: Re: 2023 Zero DSR/X not charging
Post by: DonTom on June 05, 2026, 04:03:44 AM
I normal the bike up to count the red blinks from the MCU. 22 reds, but I could have miscounted, so I do it again, changing nothing at all. One difference, I also got an error 27 besides the error 31. But just one time. 27=12V Low Voltage Fault. It measures as 13.5 VDC across the 12V battery just seconds after this fault. Makes no sense to me.


Second try to count the blinks . . . I cannot do it, as then it starts charging (I am at 101% SOC, so this is the extended range charging).


I stop the charge and try again. It starts charging again. And again, and again and again.


I can no longer get the bike to fail to charge after many tries to try to make it fail.


It is only charging at 2KW, but I think that is normal for when above 100% SOC, isn't it?


I read somewhere that the BMU prevents charging to very unbalanced cells to help protect the battery.


I have been wondering if my battery cells got way out of balance from sitting, but not more than enough to show the imbalance error  code, but enough imbalance for the BMU to stop the charge.


Unfortunately, only the Zero dealers can check the balance MV numbers on the DSR/x, unlike gen two bikes where the owners can check it. The Zero DSR/X models only give an error code, so I cannot tell if I am on the edge of an acceptable balance or not.


My understand is near the top of the charge is the best cell balancing and best is the lowest useable charge current so it takes longer to give more time to balance better. Balancing takes time near the end.


So I unplugged my 240 VAC and plugged in a 120 VAC 1.2 KW unit.  The bike charges up again just fine, but now at 1.2 KW.


I still am not sure about anything, so I do NOT trust the bike to charge. I will not take it far enough to charge for quite a while. And for the time being, I will only home charge with 120 VAC to give it more time to balance the HV battery cells.


-Don-  Reno, NV
Title: Re: 2023 Zero DSR/X not charging
Post by: DonTom on June 05, 2026, 06:31:20 AM
I now have my bike charged up to 110% SOC. So all I can do from here is put it back together to ride it.

BTW, the green LED on the Zero DSR/X  BMU never stops flashing. Bike is off, 12V battery disconnected. DC2DCC fuse removed, MMB fuse removed, and the LED flashes bright green about one time per second, non-stop.  There has to be voltage for the key to close the contactor and perhaps that is where it gets its voltage. Even when the bike is sitting for months, that green LED I assume must be flashing one time per second.

Not a real issue when from an 17 KWH battery, just interesting that it never shuts off.

The BMU is easy to get to. Just remove both fuses in the HV battery, disconnect the 12V negative to the 12 volt battery and remove the small top front battery cover. Two screws. The BMU is seen on the very top, but still below the orange connector going to the charger that you will NOT see unless looking up inside above the BMU.

Be sure to remove both connectors when reinstalling or else it can get stuck in there and take a while to get back out. You can guess how I know. Be sure it is fitted into the two grommets.

There is a reset button on the BMU. in case you get red lights flashing when playing around checking other things or just after putting things back to normal.

This is the first time I dug into my Zero DSR/X. I now have a rough idea where everything is at and how to get to it. I took more of the bike apart than was necessary just to find things and check connecters, etc.

See below for when  was working on the bike and when back to normal with the green light on.  I timed the camera just right each time to show it with the key out. And then green after the reset.

-Don-  Reno, NV

Title: Re: 2023 Zero DSR/X not charging
Post by: DonTom on June 05, 2026, 09:01:08 AM
I am now  in Verdi, 15 miles west of Reno on the CA boarder where they have free to use Tesla Destinaion Charge  Stations.


I selected extended range charging again, and now at 101% SOC it charges at 5.5 KW with a Tesla tap.


My gut feeling is the BMU did like the cell blanace and there was really nothing else wrong,  Nothing I can prove, but it sure looks like it is all back to normal for no reason other than a good long 120 VAC (1.2 KW DC) charge to the very top 110% to give it extra time to balance the cells after the long sit.


Perhaps my BMU is just being  too sensitive to cell balance and turns off before I can get the cell unbalance message, It's a bummer that only the Zero dealers can looking at the cell balance in the DSR/X.


I decided I will ride this bike to my Auburn house in the morning. 99.0 miles. I have several places on the way where I can recharge. Just in case, I will make sure I can make it all the way there--or back to Reno in case of any charging problems.


BTW, one thing I forgot to check. I think the app shows log files. I never looked at that.  Perhaps that should have been the first thing to do.


-Don-  Verdi, NV
Title: Re: 2023 Zero DSR/X not charging
Post by: eglatzer on June 05, 2026, 12:32:01 PM
You can download the log fiels with the app.
They are binary and you can analyze them with https://ernstgl.github.io/ZeroGen3LogParser
You can see the voltages of highest and lowest cells.
Title: Re: 2023 Zero DSR/X not charging
Post by: DonTom on June 05, 2026, 01:36:47 PM
Quote from: eglatzer on June 05, 2026, 12:32:01 PM
You can download the log fiels with the app.
They are binary and you can analyze them with https://ernstgl.github.io/ZeroGen3LogParser (https://ernstgl.github.io/ZeroGen3LogParser)
You can see the voltages of highest and lowest cells.
Thanks, I will look into it. I have never used the parser before. I knew it existed, but this is the first time I really want to know what was going on by looking at log files. Perhaps that is the first thing I should have done. But now I am glad I worked on the bike so I know how to get to things. The 12 volt fuses are in a real stupid location in the DSR/X.


Anyway, even though I did nothing to break the bike, I also did nothing when it decided to fix itself. It now charges fine every time I try it.


But I cannot say I trust it 100% yet, I will be careful how far I go on a charge for a while to make sure I can get to one of my houses. Going between here in Reno and Auburn is a perfect test as there are many places to charge up on the way. I will keep it charged up to make sure I can make it all the way there or back, in case of another charge issue. I could make the trip in a single home charge otherwise.


-Don-  Reno, NV

Title: Re: 2023 Zero DSR/X not charging
Post by: DonTom on June 06, 2026, 09:22:29 PM
I have now charged the bike several times without the slightest issue.


Here is an interesting area of the log files. I have to main questions about below:
l
1. What does "no cell type" mean?
2. And how can the date before these errors be in year 1970?


70761/2/1970 7:32:04 AM558000478483500003652365236554313825510255100710230301825264713831620143811030
532531/2/1970 7:32:04 AM3270002486197Saving stats, hibernating for 86400 sec
312539/29/2025 6:10:12 AM180000086228Exiting Hibernate
832539/29/2025 6:10:12 AM180000186311Board was reset. Source: Hib Wak n, Power-On, Supply WD, Power Val
422539/29/2025 6:10:12 AM181000286353Entering ZERO_BMS_STATE_IDLE
312539/29/2025 6:10:12 AM181000386384Discharge enabled
632539/29/2025 6:10:12 AM182000486447ERRO eroBmsManagePackIo returned ZERO_RET_FAIL
452539/29/2025 6:10:12 AM341000586492Entering ZERO_BMS_STATE_STANDBY
52759/29/2025 6:10:13 AM210006865440003237850379300215101200003106104132
642539/29/2025 6:10:13 AM640007866081000000 baud: Could not read eeprom from cellbox 0
642539/29/2025 6:10:13 AM790008866721000000 baud: Could not read eeprom cellbox 1
962539/29/2025 6:10:13 AM102000986768400000 baud: cellbox_id 0 CRC invalid. value: 0x02, crc_read: 0x20, crc_calc: 0x0E
962539/29/2025 6:10:13 AM12200010868644000 aud: cellbox_id 1 CRC invalid. value: 0x02, crc_read: 0x20, crc_calc: 0x0E
392539/29/2025 6:10:13 AM1520001186903cellbox_id 0: 0x16 (22MY)
392539/29/2025 6:10:13 AM2220001286942ellbox_id 1: 0x16 (22MY)
382539/29/2025 6:10:13 AM2220001386980Cell type detected: 22MY
562539/29/2025 6:10:13 AM2220001487036Latching 12V Output ON, lowest cell:3785mv
452539/29/2025 6:10:13 AM2220001587081Fault set: INVALID/NO CELL TYPE
492539/29/2025 6:10:13 AM2250001687130Fault cleared: INVALID/NO CELL TYPE
[/t]
Title: Re: 2023 Zero DSR/X not charging
Post by: DonTom on June 06, 2026, 09:32:07 PM
I do not know why the date shows as 1970, but I think this is really when the problem first started to show up with no charging:




632531/2/1970 2:43:40 AM192000475929ERROR: ZeroBmsManagePackIo urned ZERO_RET_FAIL
452531/2/1970 2:43:40 AM332000575974Entering ZERO_BMS_STATE_STANDBY
52751/2/1970 2:43:40 AM7330006760260003236540365700285101200003102366614
652531/2/1970 2:43:40 AM7330000760911000000 baud: Could not read eeprom from cellbox 0
642531/2/1970 2:43:40 AM8020008761551000000 baud: Could not read eeprom from cellbox 1
962531/2/1970 2:43:40 AM802000976251400000 baud: cellbox_id 0 CRC invalid. value: 0x02, crc_read: 0x20, crc_calc: 0x0E
962531/2/1970 2:43:41 AM390001076347400000 baud: cellbox_id 1 invalid. value: 0x02, crc_read: 0x20, crc_calc: 0x0E
392531/2/1970 2:43:41 AM1080001176386cellbox_id 0: 0x16 (22MY)
392531/2/1970 2:43:41 AM1480001276425cellbox_id 1: 0x16 MY)
382531/2/1970 2:43:41 AM1480001376463Cell type detected: 22MY
562531/2/1970 2:43:41 AM1480001476519Latching 12V Output ON, lowest cell:3654mv
452531/2/1970 2:43:41 AM1500001576564Fault set: IN D/NO CELL TYPE
[/t]
Title: Re: 2023 Zero DSR/X not charging
Post by: TheRan on June 06, 2026, 11:38:12 PM
January 1st 1970 is when Unix time started, which is basically the zero point from where all computers count from to know what the time is. It's why in many calendar apps you can't scroll back before then, because to the computer that time doesn't exist. Being the first entry in the logs it can be assumed it writes that before it does the count to figure out the actual date and time.
Title: Re: 2023 Zero DSR/X not charging
Post by: DonTom on June 07, 2026, 12:06:13 AM
Quote from: TheRan on June 06, 2026, 11:38:12 PM
January 1st 1970 is when Unix time started, which is basically the zero point from where all computers count from to know what the time is. It's why in many calendar apps you can't scroll back before then, because to the computer that time doesn't exist. Being the first entry in the logs it can be assumed it writes that before it does the count to figure out the actual date and time.
Thanks for the info. I assume that means it is expected and normal to start with a date of 1970.  So then for me to see the real date, I need to look at the date where it first changes.


Does anybody here see an issue in those logs why my bike would not charge the other day? All seems to be well now, charges every time.


I even had the opportunity to recharge it 67% SOC and all was fine yesterday. It was at 67% when I first had the issue the day before.


-Don-  Auburn, CA
Title: Re: 2023 Zero DSR/X not charging
Post by: princec on June 07, 2026, 12:31:11 AM
The EEPROM read fails are probably an issue.

Cas :)
Title: Re: 2023 Zero DSR/X not charging
Post by: DonTom on June 07, 2026, 12:51:29 AM
Quote from: princec on June 07, 2026, 12:31:11 AM
The EEPROM read fails are probably an issue.

Cas :)
Perhaps because of the "BMU ineligible" error.  But neither error  tells me why it happened.


But . . . I just now noticed it has dates for 2025.  I will now recheck the entire log looking more careful at the dates. 


-Don- Auburn, CA
Title: Re: 2023 Zero DSR/X not charging
Post by: DonTom on June 07, 2026, 03:53:54 AM
I took a better look at the dates and time:


32536/4/2026 9:31:10 PM764000481114Fault set: CONTROLLER_WARNING
352536/4/2026 9:31:10 PM766000491149controller warning 50
272536/4/2026 9:31:11 PM314000501176MBB RTC Valid
382536/4/2026 9:31:11 PM316000511214Fault cleared: DC_DC_LOW
472536/4/2026 9:31:13 PM736000521261Fault cleared: CONTROLLER_WARNING
692536/4/2026 9:31:22 PM982000531330CHARGER LSS: Freeing CHARGER node id 0x10 for charger 0
262536/4/2026 9:32:22 PM610000541356Key Sw = OFF
642536/4/2026 9:32:22 PM704000551420Control flags changed. Old: 0x204076 New: 0x204078
432536/4/2026 9:32:22 PM705000561463State change from STOP to HIB
502536/4/2026 9:32:22 PM725000571513MTC pending change by 3 from 0 to 0
75816/4/2026 9:32:22 PM726000581588000961143000010000HIB48296037340013296640
702536/4/2026 9:32:22 PM727000591658Disch limits: curr 897 cap 897 act 2147483647 pow 102527
632536/4/2026 9:32:22 PM728000601721Ch limits: curr 83 cap 83 act 2147483647 pow 9486
29846/4/2026 9:32:22 PM7280006117510-650280-1
642536/4/2026 9:32:22 PM731000621815Control flags changed. Old: 0x204078 New: 0x200070
602536/4/2026 9:32:22 PM733000631875Disable flags changed. Old: 0x0000 New: 0x0004
1062536/4/2026 9:32:22 PM739000641981Stopping 12v charge. DC-DC 13378688uV, Battery 13296640uV, Combined 13135518uV, Ambient 30C
[/t]
Title: Re: 2023 Zero DSR/X not charging
Post by: electrictwowheeler on June 09, 2026, 11:15:13 AM
Maybe it's a little too late but here is a trouble shooting suggestion. The unofficial Zero manual has a description for building an adapter to read information through the OBD port. It's for Gen 2 bikes but works on Gen 3 also. I think I had to switch the TX and RX wires and use a different Baud rate but after some messing around I got it to work on a laptop. When you key on the bike you can see all the start commands as it is happening. You can see all the commands just like you see in the logs, the same when you plug into charge. Pretty useful for trouble shooting. If you type in "help", you bring up a menu of all the info you can get. It's fun even if you don't need it. There are posts about it from a long time ago. Here is an example. This is "BMS interface" screen. You can see things like charge targets, lowest cell voltage, how many amps the headlights are drawing, pack capacity.
Title: Re: 2023 Zero DSR/X not charging
Post by: DonTom on June 09, 2026, 12:31:56 PM
Quote from: electrictwowheeler on June 09, 2026, 11:15:13 AM
Maybe it's a little too late but here is a trouble shooting suggestion. The unofficial Zero manual has a description for building an adapter to read information through the OBD port. It's for Gen 2 bikes but works on Gen 3 also. I think I had to switch the TX and RX wires and use a different Baud rate but after some messing around I got it to work on a laptop. When you key on the bike you can see all the start commands as it is happening. You can see all the commands just like you see in the logs, the same when you plug into charge. Pretty useful for trouble shooting. If you type in "help", you bring up a menu of all the info you can get. It's fun even if you don't need it. There are posts about it from a long time ago. Here is an example. This is "BMS interface" screen. You can see things like charge targets, lowest cell voltage, how many amps the headlights are drawing, pack capacity.
Thanks, that could be handy.


But so far, I have not had a trace of the no charge problem since the time I charged it up to 110% SOC and then rode it. I put on around 200 miles on it since then and charged it up a few times. But I am curious what caused it and if it will happen again. Perhaps I should have your suggestion handy just in case it does happen again.


-Don-  Auburn, CA
Title: Re: 2023 Zero DSR/X not charging
Post by: electrictwowheeler on June 09, 2026, 11:07:08 PM
Good to hear it's working. Intermittent problems are the worst! Make sure your towing insurance is paid up, ha ha!
Title: Re: 2023 Zero DSR/X not charging
Post by: DonTom on June 10, 2026, 05:47:42 AM
Quote from: electrictwowheeler on June 09, 2026, 11:07:08 PM
Good to hear it's working. Intermittent problems are the worst! Make sure your towing insurance is paid up, ha ha!
I think it all had to do something with the bike sitting a bit too long, such as the battery getting out of balance causing the BMU to stop the charge. Perhaps right on the edge. After around 20 charge attempts, it started to charge fine. IOW, I don't think the fix was anything else that I did.


But yes, I do have a couple of ways to call for a tow truck, AAA Premier (member since 1992) and the Spot Messenger towing service (SOV).


However, I somehow do not expect to see this problem again, but if I do, I will just keep on trying to charge unit it works--and then I will look into replacing the BMU.


-Don-   Auburn, CA