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Zero Motorcycles Forum | 2012 and older / Re: $30 sensor or £2000 for a new motor... choices, choices.
« on: November 25, 2017, 01:54:59 PM »
I have a 2012 Zero S that was suffering from the occasional stuttering and rough-running motor. It gradually got more frequent and had reached a point where I could pretty reliably get it to happen when opening the throttle wide and drawing a lot of power.
I bought a new sensor from Motenergy and followed David_Walsh's instructions for how to pull the motor out and access the sensor's cable.
After putting it all back together I went for a 25 mile ride and tried to make the bike glitch but did not experience any problems.
It appears to have fixed the problem.
Some advice I would offer for anyone who wants to try it themselves:
(1) Supposedly if you provide your full name and shipping address by email Motenergy can make a paypal invoice that you can buy online to get the part shipped out to you. I tried this option but John Fiorenza didn't follow through on providing the invoice so eventually I had to actually call and provide CC info over the phone to obtain the part. Leaving two messages did not get me any responses: I had to reach John Fiorenza when he was at the phone.
(2) The potting material on my board was black. It was pretty tough so scratching it off required patience. I used a dremel tool to clean the potting out of the four mounting screws, and then was able to start popping brittle chunks off of the board itself. The old board did not survive extraction intact: I broke several surface mount elements off the top surface trying to get the board out.
(3) The new sensor board needed some spacers to keep the bottom side electronics from touching the motor itself. I used a dremel tool to cut the circle of electronics out of the old board and used the remaining outer edge as a spacer.
I bought a new sensor from Motenergy and followed David_Walsh's instructions for how to pull the motor out and access the sensor's cable.
After putting it all back together I went for a 25 mile ride and tried to make the bike glitch but did not experience any problems.
It appears to have fixed the problem.
Some advice I would offer for anyone who wants to try it themselves:
(1) Supposedly if you provide your full name and shipping address by email Motenergy can make a paypal invoice that you can buy online to get the part shipped out to you. I tried this option but John Fiorenza didn't follow through on providing the invoice so eventually I had to actually call and provide CC info over the phone to obtain the part. Leaving two messages did not get me any responses: I had to reach John Fiorenza when he was at the phone.
(2) The potting material on my board was black. It was pretty tough so scratching it off required patience. I used a dremel tool to clean the potting out of the four mounting screws, and then was able to start popping brittle chunks off of the board itself. The old board did not survive extraction intact: I broke several surface mount elements off the top surface trying to get the board out.
(3) The new sensor board needed some spacers to keep the bottom side electronics from touching the motor itself. I used a dremel tool to cut the circle of electronics out of the old board and used the remaining outer edge as a spacer.