ElectricMotorcycleForum.com
Makes And Models => Zero Motorcycles Forum | 2013+ => Topic started by: ethanh8791 on July 02, 2015, 06:16:32 AM
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So I drove about 40 miles to work the other day. Charged at work and noticed it only registered 97% charge despite being at above 60% & charging for 5 hr. +. Admittedly I was using an extension cord longer than 25 ft. Didn't think anything of it, drove home fine. I had it sitting uncharged for 3/4 of a day, drove with no problems and then went to charge and it did not recognize being plugged in. This is straight to an outlet with the provided cord. No error lights on the dash initially other than related to motor kill and kickstand down. Scrolled through the display this evening and noticed error 48 & 49. I read about some reset button underneath the seat. I noticed the star bolts are marked as far as positioning - is this going to affect warranty if I start troubleshooting this myself? >:(
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From the owner manual:
48 SEVCON Startup Disable
49 Contactor Open Disable
Sounds like an error Zero will diagnose. If you connect a phone to the bike with bluetooth (iOS / Android), you should be able to pull the logs off and email them to Zero.
http://www.zeromotorcycles.com/app/help/ios/connectivity.php (http://www.zeromotorcycles.com/app/help/ios/connectivity.php)
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Yah thanks - I sent the log. I saw what the error codes mean but manual doesn't offer any solution for those codes.
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You can try the BMS reset without taking anything apart.
On the front of the battery pack there are two round rubber seals, beneath one is the LED display, the other - two small buttons. Press the two buttons simultaneously for a couple of seconds, wait for another 10 seconds or so (you should hear a click and notice the dash display reset), then try plugging in again.
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Thanks for the tip - MAYBE I missed it but I swear the two button BMS reset procedure is not referenced in the manual. It's hard to tell whether they are depressed or not...obviously the audible clicks are a good indicator and it's very similar to some computer system "reset" type buttons if you are a hardware techy type - I would think Zero would point out the procedure and clearly in the manual but then maybe they don't want the avg consumer tinkering too much considering liability and what not. Drawn out post to say: it didn't work. Such a bummer - in to the shop it goes. I will be checking fuses this weekend before I make that drive with the last remaining %'s of charge remaining. :(
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I am having similar problems with my '15 SR. You should ask the dealer for a loaner bike. I got their demo Zero S. It's alot easier dealing with problems when you've got something to ride.
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Sorry to hear about the troubles. My two Zeros have died fully with no error messages because the screen was dead too.
I'd check the bms indicator as mentioned above, check the fuses, high voltage ones, etc, and call Zero if none of that works.
Zero hasn't minded me working a little on my bikes to troubleshoot them. So you should be fine. Don't break anything but you can check the simple stuff.
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I think there are several of us with similar problems. Do you have the PowerTank on your bike?
Mine is at the factory right now. I got a call on Friday from Zero - the problem appeared to be either the BMS communication between the two battery packs, or a problem with the PowerTank itself. They are checking both possiblities and I should hear back from them soon.
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I'm w/o a power tank....taking it back to the dealer as soon as I can - unfortunately I have not had the time to get it there.
error codes 48 & 49
bms button reset procedure done
error codes on 4 LEDs by BMS button are not anything representative of what is described in the manual
all fuses in the compartment under the seat checked and are OK
I've got 11% charge to make it 11.3 miles to the dealer :)
Oh and I WILL follow-up here once I find out what the issue is for the benefit of others.
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I have an update on my 2015 SR (with PowerTank).
Replacing the BMS boards did not fix the problem. Replacing the PowerTank appears to have helped, but while test-riding and recharging they found a problem with the onboard charger. So they replaced that today. I should know tomorrow if all is well.
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Seems to be many chargers fails, maybe they also damage other boards?
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Seems to be many chargers fails, maybe they also damage other boards?
I got my bike back today and I asked that question specifically. The answer was - it does not seem to be related.
I was told that the problem on my bike was resolved by replacing the PowerTank battery. Apparently there was a problem with the PowerTank that came with the bike - specifically the cell balancing between the two packs was off - when the difference in voltage was detected the bike quit charging/running.
They replaced my charger because it seemed a bit warm while charging at the factory. The heat did not exceed any safety limits, but they decided to replace it as a precaution.
Meanwhile - there are still a couple of error codes on the display... thus the new thread I just started.
( http://electricmotorcycleforum.com/boards/index.php?topic=4849.0 (http://electricmotorcycleforum.com/boards/index.php?topic=4849.0) )
I was told that these codes should "go away on their own" after a few charge/discharge cycles - hopefully that will be the case - I should know soon.
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They replaced my charger because it seemed a bit warm while charging at the factory.
I had a charger fail several months back, and the dealer said that Zero wanted to "wait until the new batch came in" before shipping me a warranty replacement. I have to think there was a redesign due to poor charger performance in field, and it wouldn't surprise me that they're swapping out units as they have the opportunity, especially if they're "running a little hot".
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"Knock on wood" but so far the on-board charger on my 2014 S is working perfectly. Kind of makes you wonder if the charger supplier changed manufacturers or made some other "improvement" that has resulted is reliability issues. ???
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I was told that I now have a "C" version of the charger, which replaced the "B" version.
Beyond that I don't know what the difference is.
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My dash is now also displaying error code 48 (SEVCON Startup Disable) intermittently.
I must admit I'm surprised that Zero returned the bike to me today with these error codes still flashing on the dash.
I'm an eternal optimist though - I will take them at their word and ride it for awhile to see if the error codes eventually disappear "on their own".
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I'll join in! I emailed support earlier today. I guess I'll be visiting the dealer soon. My 2015 SR does not start charging when I plug it in. I definitely have power and have even tried another cable and outlet. It behaves as if I haven’t plugged it in. There is no error code displayed on the dash and the BMS status LEDs indicate healthy
I have not tried the reset switch (it still has the protective gel over it.
Cheers!
Jay
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If the problem is the same as mine it may start charging after an hour or two.
To fix my bike Zero replaced a BMS board (but that didn't fix it), so they replaced the entire PowerTank, which did seem to fix it.
I've already put about 200 miles on the bike since getting it back last week and it seems to be running fine. The error codes on the dash that were worrying me (after I got the bike back) turned out to be just a normal part of the boot-up of the system.
I must say, despite the problems I've had with my SR, that Zero has really worked hard to get my bike running perfectly. It's obvious that they want happy satisfied customers - I'm sure they will do whatever it takes to get your bike fixed and back on the road.
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Oh and I WILL follow-up here once I find out what the issue is for the benefit of others.
Any updates Ethan?
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I'll join in! I emailed support earlier today. I guess I'll be visiting the dealer soon. My 2015 SR does not start charging when I plug it in. I definitely have power and have even tried another cable and outlet. It behaves as if I haven’t plugged it in. There is no error code displayed on the dash and the BMS status LEDs indicate healthy
I have not tried the reset switch (it still has the protective gel over it.
Cheers!
Jay
This is the same problem I had. The new charger is working fine now.
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I dropped it off last Saturday and they said it would likely be at least a week before a technician would begin looking at it.
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Crap, I have this problem now. My SR was assembled in April, delivered to my dealer in June.
It has been my experience that Zero is very good about addressing issues and it sounds like a new charger is the cure. That shouldn't be too hard to fix.
I hope to report back soon with the resolution.
I really love the bike...it make me smile and I feel happiness all over.
Update: Called Zero on Tuesday at 0900 and spoke to Manny. Great guy and I really felt like he cared about my problem. My dealer drove 77 miles (one way) to arrive at my house at 1300, same day, to pick up the bike to take it back to the dealership for service. I get chills thinking about how impressed I am with both Zero and Cycle Parts in Eugene, OR. Thanks guys!
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I got my bike back a couple of weeks ago - haven't had any problems since I got it back. I've been charging with 120V at night, and I tried the off-board charging last weekend (posted on Facebook (https://www.facebook.com/groups/zmcowners/)). I think Zero has succeeded in working out all the bugs - and I agree with oregonrider89 - the service was excellent - they came to my work, picked the bike up, and brought it back to my work when they were done.
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I'm glad to hear everyone is having great experiences with their dealerships. It looks like my new charger is working fine so far. Too bad we've been having crappy weather.
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Literally the moment I brought my bike in to address this issue the weather turned nice (hot as fballs but not much rain). >:(
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Just to close the loop on this:
My dealer replaced the charger and all is well again!
Doh! New charger failed just over a week later!!!!
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Called dealer today because I had not heard anything (dropped off July 18th). Promised a callback by EOD today (didn't happen) and only info they provided was that they had submitted diagnostic information to ZERO which is something I had done prior to dropping off the bike and also something a technician can do in < 30 minutes if you include all other troubleshooting steps (assuming they're talking about submitting the bike logs). :-\
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Seems to be a common theme. Before I sent mine in for repair I'd already set up a case with Zero and provided logs and video of the issue. They were super helpful and responsive. After 5 weeks of following up with the local dealer (ended up in daily phone calls) they managed to finally connect with a Zero tech who remoted in and diagnosed straight away. The bad news was it needed a new MBB (still waiting for this - arrived Friday and hoping for some good news later today). There's other similar reports over the forums.
Currently into month 3 of no bike. Parts, I have no problem waiting for but they need to work with their dealer network to boost their service game. Don't get me wrong, the local guys are nice, there just seems to be severe communication issues between Zero and their dealers or vice versa. Needless to say I'll be getting myself a reaper dongle and renewing membership to the Kustom Kommune (http://kustomkommune.com.au/).
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So even giving the dealer 1 week they quoted me before my bike would even be looked at it has been 31 BUSINESS days with essentially no news. I have had to call the dealer to get information.....never any updates..."hey this is where we are at with your bike" type of shit. I called them 9 days ago and dealer stated they were updating the ECU & a Zero tech was looking at the bike remotely. I'm getting in touch with Zero now because I have lost my patience.
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Mine (2015 SR w/ Power Tank) has had some squirrely intermittent issues with things like 'Monolith not connected', 'Battery Management System (BMS) Internal Disable', 'Contactor Error', along with some incidents where it didn't charge, or didn't charge fully. It has left me stranded a few times, and failed to function when at home a few times (i.e., "there, but for the grace of God..." ...Stranded.) I finally got fed up and traded it in on a Suzuki SV650.
Wait, no, that's not right. I didn't trade it in. Sorry, I just made that part up.
I took it back to AF1 Racing Saturday almost two weeks ago - Brent and ... John? got on the phone with Zero, gave them a bit of an earful, it sounds like, and got some troubleshooting engagement from them.
I got word about Thursday (week ago) that my bike (a 2015) had a 2014 Power Tank installed*, and Zero's just coming to the conclusion that the combination isn't a good one. Needs to be a 2015 PT on a 2015 model.
* There was a mix up when AF1 ordered the bike - it was supposed to come from factory with a PT already installed, but it didn't. AF1 called Zero, and Zero rushed one out to dealer - guess they sent the wrong model. Or maybe they didn't think it mattered back then.
Personally, I think it sounds a bit sketchy, but a new (2015 PT) one is on order, should arrive any day now. I guess next weekend (maaaybe this weekend, but I'm not holding my breath) I'll be heading back to Austin to pick it back up. Hopefully it fixes it. As for the 2014/2015 incompatibility, all I can think of is that the game they played** of upgrading the specs on the battery is biting them in the vittles.
** Of course, I don't know that they just slapped a new sticker on the old battery and adjusted a setting in the BMS, but that's the feeling I'm getting. And if they didn't just slap a new sticker on the same old power tank, they were (intentionally or not) ripping me off by giving me a 2014 PT when I ordered and paid for a 2015 PT.
Anyway, I give my vote of confidence to the AF1 Racing guys - I like them, and feel like they run a good shop. I just wish they were a little closer. (Ok, a lot closer.)