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Messages - SteveA

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1
Been out to the garage to have another look at this. As I suspected, the switch is separate to the key, so the spray I put in won't have done anything for the electrical contacts. The switch itself is secured to the underside of the key barrel by two normal screws.




After some choice words I had the switch out




I made a half hearted attempt at taking the switch apart before discovering that putting a screwdriver into the switch enabled me to turn it through 360 degrees and in doing so (I suspect) cleaning the contacts much better that the usual 90 degrees when fitted.
I'll leave it alone for now as I need to continue using it for the commute, but at least replacement doesn't require removal of any security screws.

2
It's been okay for a few days, but this afternoon it took six or seven tries. I've discovered that by turning the key back slightly, contact is made and I can use the bike, so that really points to dirty and/or failing contacts in the key switch.

Given I've had the bike for about five years and on average use it five days per week, the swich has only had around 2,600 contacts made, so pretty low for a switch. I've squirted some WD-40 type oil into the switch and exercised the switch back a few times, but with no apparent improvement. The trouble is that I don't know how the keyswitch is assembled, so squirting something down the key slot may never reach the contacts if it's sealed off.

I might have to prepare myself to replace the key switch assembly with removal as suggested by Aaron

3
If it is just a matter of poor electical contact at the switch it could either be within the switch body or from the wires connecting to it. Hotwiring would get around the internal swich contact issue, if that's where the problem lies.
Either way, it looks like I may need to pull off some trim to check for any obvious damage/deterioration to the switch body and wires connected to it.

4
I've noticed a few times this week when getting on my bike that it appears to be unresponsive to turning the key to the on position. Turning it off and back on again gets it going, but I don't want to live with it like that and the fear it'll get worse. Any suggestions of what to check/service?
The bike is used five days a week, so the fault is unlikely to be down to lack of use.

5
Zero Motorcycles Forum | 2013+ / Re: Living with error codes, 2021 S
« on: March 03, 2024, 02:20:15 AM »
....I finally traced it down to the enabling circuit (ignition equivalent in ICE vehicles) getting wet & allowing a path to ground. ...

Sounds interesting and something I'd like to try too. Where can I find the enabling circuit? Is it part of the key circuit under the dash?

6
Zero Motorcycles Forum | 2013+ / Living with error codes, 2021 S
« on: February 24, 2024, 05:28:42 PM »
About 13 months ago my 2021 Zero S started showing error codes https://www.electricmotorcycleforum.com/boards/index.php?topic=12348.msg116608#msg116608, so it went back to the dealer for a new DC-DC converter, MBB and motor controller. This solved it for a few months before it went back again for a new loom, fortunately still under warranty.
More recently I have seen the same fault codes come back (0020 & 0028) after riding in heavier rain, but they seem to go away after a time, presumably after drying out. Has anyone else ended up just deciding to live with intermittent fault codes?

What I find odd is that I can have a 0020 error code on the dash, but no flashing red triangle until it is joined by the 0028 code, perhaps a software change by zero so as not to alarm the rider?

7
To (hopefully) bring this to a conclusion, I picked up my bike yesterday and rode it the 60+ miles home through patchy rain without issue.
The final diagnosis was that the DC-DC converter (Sevcon unit) was failing and had sent a voltage spike to both the MBB and motor controller, so all three have been replaced, fortunately under warranty.

8
A quick update on this. My bike is still at the dealer and the fault has not been determined yet.
A couple of new motor controllers have been tried, along with a new MBB, but the fault still exists. Fortunately it's under warranty, but I'm still paying a lot more for my commute, in addition to the cost of getting the bike back to the dealer.

Perhaps they'll diagnose the same fault as mdjak1 and try the BMS next?  :-\

9
The fault codes first started coming up on my first ride for about a week following my Christmas break, during which time the bike was in my dry garage. On the day there were only a very few drops of rain, nothing compared to what I have riden through on my daily commute over the past 18 months as a ride in all weathers apart from significant snow.

10
I got the bike back to the dealer 16th Jan, who diagnosed it as being a motor controller fault, which seems strange as all the faults refered to the BMS. They have replaced the motor controller and the same fault codes are present, though if they disconnect the motor controller they go away again. Thought possibly to be a faulty on arrival motor controller, but the dealer is now raising it further up the support chain.
Seems like I'm not the only one having this type of issue.

11
Thanks for that, my dash looks much the same as in your video. Just in case, I reset the BMS using the buttons on the front, which brough up a few new error codes including 0051 - BMS self-test warning.
At least my bike is only about 18 old, so there shouldn't be any problems about sorting it under warranty.

12
While out on my bike yesterday I saw lights flashing on my dash, but it appeared to ride much the same. I had a look at the fault codes on the dash and they are;
0020 - BMS Low Isolation
0028 - BMS Isolation fault
0044 - Kill switch disable
0045 - Kickstand switch disable

I put the bike on charge this morning and it appears to be taking charge, e.g. relay/contacter clicking, power draw in houshold supply and %age charge increasing.

It may be wishful thinking but, is there an easy fix/reset for this or do I need to get the bike back to the dealer?

13
Does anyone have a wiring diagram for the SAE J1772 Charging Adapter, Zero part No. 10-03267? I'd like to make my own version of this, but longer and with a plug on the end so I don't have to carry both the adaptor and plug to plug cable.
I'm guessing that there are additional components or links in the Zero adaptor to convince the charging station to give charge.

14
Zero Motorcycles Forum | 2013+ / Howdy, new Zero S bought
« on: June 12, 2021, 11:53:26 PM »
I've been reading this forum for the past few weeks since I put a deposit down on a new 'S', so I thought I'd reigster and show a couple of pictures.

I've been commuting about 30 miles per day with a Kawasaki Versys 300, but fancied a change to a full electric bike, though I've kept my Honda Deauville for longer journeys.

I'm waiting for the top box rack to come from Zero to fit my Givi box, but meanwhile I'm looking into heater grips and handguards, these ones at present https://smile.amazon.co.uk/Acerbis-0013046-030-Dual-Handguards-Black/dp/B001KODHFU/ref=sr_1_1?_encoding=UTF8&dchild=1&keywords=Acerbis+Handguards&qid=1623517891&sr=8-1

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