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I'm just curious, did you end up replacing the motor? In the video, it didn't seem like the clicking was in sync with the motor speed, but I'm going to trust the people who could actually put their hands on it. If you did remove the old motor, did you open it up?

I had the dealer put the bike together because I didn’t want to pay $2500 for a new motor.  The dealer said zero doesn’t open the motor they just replace it and it was his opinion that it sounded like a bad bearing. With that info, I looked into replacing the motor bearings. someone reached out and told me about a specialist that had replaced their motor bearings on their old Zero and was happy with the work. Since the guy quoted me about 30% of the price of a new motor, it made sense to me to ship my motor to him for bearing replacement. He is actually working on it now. He told me he can confirm one bearing was bad and he replaced both of them since he had it open. I’m hoping to get the motor shipped back soon so I can put my bike back together and get riding again.

Hello! I am removing the motor from my 2015 SR for motor bearings replacement. I have someone lined up to do the bearings and I just need to get the motor out and ship it to him. I am following the Unofficial Zero Service Manual/wiki and have a couple questions.

For Step 3, "Unplug the sensor connector near the front of the controller on the riders right side of the bike."
I'm assuming I need to get under the seat and find this connector. From what I've gathered, I will have to navigate the nest of wires, cut zip ties, and make room by removing the Y bar under the seat and possibly the storage tank for extra room. Does this sound about right?

For Step 4, "Un-bolt the 3 phase leads to the motor controller."  I wish there were pictures for this step, too  I'm assuming once I get in and unplug the sensor connector from step 3, the 3-phase leads should be easy to spot, am I correct?

Thanks in advance for any help/advice you can provide. I am still learning about DIY work on my Zero and excited I got this far  The wiki and Zero community have been super helpful!

Reference to the Motor Removal Page:
https://zeromanual.com/wiki/Motor_Removal

I will keep you guys posted. My local dealer has had my bike since last week, trying to figure out the clicking sound. Since they are new to Zero Motorcycles, they send videos of what's going on directly to Zero and then Zero tells them what to try next. It seems that they don't communicate every day so the process is taking longer than I expected.

Just took a delivery of a 21 SR/F.    Flying down the freeway, bending around high speed turns.    Felt a bit odd.   Checked the tire pressure.    12 lbs front, 14 back.   I sent them a blistering email.       I guess I'm old school where Mr. Honda required a 7 point inspection before allowing a bike to be sold.

Ugh, frustrating. You'd think they would be on top of simple things like that. I'm pretty paranoid with my dealer already.

My 2018 SR has the OEM rear rack on it but the seat bolts are actually T-45 Torx, not allen head.   Not sure if Zero changed that between 2015 and 2018 or if it is because of the rack.   You're sure they are allen head?

This page said that early versions of the seat bolts were 5mm allen key. My 2015 SR seems to fit that.

https://www.af1racing.com/OEM-Zero-Seat-Bolt-M8X55-ZM90-08005

Let me just start by saying that everyone at my local dealer is SUPER NICE and good people. And I feel lucky to have a dealer that's about 30 min from where I live. However, after just acquiring a used 2015 Zero SR, I've had some unfortunate strokes of bad luck there.

I took my SR in for state inspection and new tires (in order for it to pass) and while it was in the shop, the bike somehow fell off the lift. They said they were able to catch it in time before anything else happened to it, but the front fender took the brunt of the fall and cracked off. They are replacing it free of charge and will color match it since my red is now a faded looking orange. I've had this bike for about 3 weeks now so I am a bit sad it's already been damaged (and I didn't even cause said damage ).

A week before that, I had them perform a firmware upgrade which required taking the seat off (I'm pretty sure you have to do that). I noticed a couple days later at my house that the seat bolts looked super stripped. I got a 5mm allen/hex wrench and found that it was slipping right through it. I can't say 100% sure that they stripped it while putting the seat bolts back in but all I know is that from the time they did the firmware upgrade and 48 hours later when I was looking over the bike at my house.. I'm not sure where else it could have happened. I did bring the bike back and they were able to successfully take the stripped screws out (It did take some time).

Now fast-forward to my next encounter, I have been talking to Zero Support about a 'resetting issue' while riding. I sent them my logs and they were not able to pinpoint the issue and said it should get a motor commissioning at the dealer. The service guy at the dealer I talk to everytime does not work on the Zero bikes himself but he did not know what a motor commision is or how much it would cost. I told him a little bit about it and also gave him the case number the Zero engineer gave me. I'm waiting to hear back from the dealer after they do a bit of research about it.

I guess I just need to vent some concerns I have. I know this is a fairly new zero dealer and they have been very transparent with me and I respect that. However, there's just a feeling I have where I wonder if my Zero is in good hands, will they know the right thing to do, is something else going to go wrong there? I'm not sure how I should feel.

@KillerTofu - I did “forget this device” via Bluetooth and reinstall the app and now it says firmware up to date. huzzah!

@JaimeC - I am in the states and while the firmware update was free, the dealers time/labor was not ;-) their rate is $110/hr and they charged me for 30 minutes.