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Messages - tafka

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1
Zero Motorcycles Forum | 2013+ / ZERO DSR 2017 Fork alignment
« on: April 03, 2025, 09:55:11 PM »
Hi All,

I noticed the forks on my DSR look a bit skew.  I have fitted a new handle bar, so I know that is straight.  I can try to straighten them pretty easy BUT measuring the top of the triple clamp, the forks stick out from the top clamp a different amount on each side.  It is hard to get a measure exactly but I think I can even see it by eye, one of the forks is protruding by about 1mm more than the other.  Should I sort this out first before attempting the bouncy bouncy procedure for fork alignment?

If so, what is the correct amount to protrude? Of course it depends where you measure but mine seem to be about 8/9 mm going from the point where the handlebars start.  I.e, If I hold a micrometer against the back of the bars and use the end measure of the micrometer to measure the distance from the top (outer) of the fork to the clamp, the difference is about 1mm for the two sides (8ish on one side, 9ish on the other).

Incidentally, despite this, it looks like the wheel is out of vertical alignment in the opposite direction from the misalignment in the top of the forks (almost like someone has attempted to correct this by adjusting the top of the forks).  I'm hoping resetting the lower clamps/axle clamps will sort this.

Opinions?  Anyone know the exact measurements?

Anything else to watch out for with the fork alignment?

Thanks for any help.

regards,

Taf.


2
Zero Motorcycles Forum | 2013+ / Re: Critical Zero DSR Brake failure
« on: January 10, 2020, 07:16:19 PM »
Hi Again,

I just thought of one thing...

Would the dealer have to take the back wheel off to replace the charger?

That was the last thing replaced on the bike when it last went from ABS ok to ABS light on.  I was just wondering if they disturbed the sensor/cable?

regards,

Taf.

3
Zero Motorcycles Forum | 2013+ / Re: Critical Zero DSR Brake failure
« on: January 10, 2020, 03:57:16 PM »
Hi All,

Thanks for the replies. I appreciate that this brake lever thing is difficult to understand but I'll give it a try.

So, when I say locks up, I mean it really locks up.  It is absolutely solid, almost like there is a mechanical block as someone said.  However, this *always* seems to coincide with the ABS light going off.  No matter how much I pull on it it will not move.

BUT, that only lasts for a second or two, next time I pull it, it moves a little bit but it feels 'jerky'.  Not like brake pedal in a car when the ABS is triggering jerky, but almost like stuck caliper or releasing valve jerky.  Bit by bit, the brake lever moves in and eventually the front brake engages with more and more force.  After that, the brakes work fine again.  This has never happened again after the ABS light has gone off during a riding session.

So, just to clarify, the behaviour is this...

Riding with ABS light on (maybe for miles and miles) - brakes work fine
ABS light just switched off - front brake fails for a few seconds
Riding with ABS light off - brakes work fine

Also, note that the master cylinder has been replaced.  The disc is fine (not warped), the caliper seems to move freely.

As I said before, the biggest problem with this is that "Brakes not working" is not an acceptable failure case for an ABS system.

I'm going to (at least visually) inspect the wire to the sensors at the weekend to see if I can see anything obvious but otherwise I am at a loss.  I will try removing the fuse and hopefully that will at least stop me from soiling my underwear occasionally.

:-)

Taf.


4
Zero Motorcycles Forum | 2013+ / Critical Zero DSR Brake failure
« on: January 08, 2020, 04:52:43 PM »
Hi All,

I thought I would share the story of my experience with my 2017 Zero DSR with you just in case anyone has seen similar problems to me.

I live in the UK and I got the bike in March 2017.  I used it almost continuously (mostly commuting 50 miles a day) for a year with no issues, took it in for servicing when it needed it etc.  After about a year, the original tyres were looking a bit worn so I ended up changing them to road tyres.  I spoke to my dealer and they recommended a brand for me.  Incidentally, I think this added about 10% to the range and made for a much smoother ride. (130/80V17 AVON ROADRIDER, 100/90V19 AVON ROADRIDER)

I rode it for another year with no problems then just after the warranty ran out (isn't it always the way), I started having issues (maybe april(ish) 2019).

First the belt snapped (after only about 14k miles), which was not too much of a problem, I replaced it and carried on.  A few days later, I noticed (just once) that the front brake didn't work.  I tried to pull the lever and it was locked solid (the lever that is).  After a few more yards the brake released (with a sort of shuddering feel to the lever) and then everything was fine again.  I thought the front calipers might have been sticking, so I took then apart, checked them, put new pads in etc.  All seemed fine.  Then a few days later it happened again.

At this point, I contacted the dealer and explained what happened.  They arranged to take the bike in (they are some distance from me) and did some investigation.  Of course, they couldn't reproduce the problem and as a precaution (under advice from Zero) they replaced the master cylinder which I paid for.  I got the bike back and all seemed fine for a while until it happened again on the way to work.  Then when riding the bike back from work, I noticed that the ABS light was on.  I just happened to be looking at it when I used the front brake and the lever locking happened again.  This time I noticed that as that problem happened, the ABS warning light went out.

Of course, I passed this information onto the dealer and they took the bike back in.  Under Zero's advice they replaced the ABS pump.  This time, Zero did pay for it because they had given the advice to replace the master cylinder.  I got the bike back and all seemed fine for a month of riding.  Then one day, the bike stopped charging.  So off it went back to the dealer again to get the charger replaced.  In fairness to Zero, they covered the cost of the parts because of the other issues I had had with the bike.

I got the bike back and this time didn't even manage to ride it because the ABS warning light was on again.  So, back it went.  By now (I've missed out a lot of to-ing and fro-ing for brevity), it was getting to Winter.  Eventually, Zero said it must be because I have non-standard tyres on there.  I explained that (on and off) I had ridden the bike for 18 months or so with those tyres, a year of which I had no issues - note that the dealer doesn't understand this explanation either.  I sent the logs from the bike (which apparently just say "ABS SILA reporting an error") and Zero just insisted it is because of the tyres.  I asked the dealer if there would be any other issues, other than the ABS being disabled (remember the ABS system had been replaced at this point and since then the front brake locking hadn't happened).  They said, no it should be fine.  So I accepted their explanation that the tyres were the issue and thought I would ride with them until they needed changing and then put the 'official' tyres back to see if it solved the problem.

I was reasonably happy with that situation until (last night) going home, just riding the bike up onto my driveway (obviously there is a bit of a bump), the ABS light went off and the front brake lever locked up again.  I test rode it after that and the ABS light is staying on (as it has been since I got it back from the dealer the last time).  So, now I have a bike where (randomly) the front brake may or may not work one time when I pull the lever.

It certainly makes for an interesting Russian roulette experience when riding.

So, today, I am waiting again for a reply from Zero in order to work out what to do next.

I have to be honest, it has completely destroyed my confidence in Zero that they actually know how their own bikes work as I have never really had a satisfactory explanation as to what mechanism could cause this behaviour (Again, I have missed out a number of conversations in this explanation). Even if it is the tyres (which I don't believe), causing a critical failure in the front brake doesn't seem like the fail safe option.  Okay, disable the ABS but not the entire front brake.

I have sent emails to Zero directly but they just forward onto the dealer.

Does anyone on this forum have any ideas?

thanks,

Taf

5
Zero Motorcycles Forum | 2013+ / Re: Insurance Costs?
« on: March 16, 2017, 07:27:53 PM »
Hi All,

I added a tracker to my 2017 DSR and it brought the cost down dramatically. (1700 pounds! to about 400)

Other things that made a big difference are accessories (luggage, screen, heated grips etc) and amount of annual mileage.

Hope this helps.




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