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1
Zero Motorcycles Forum | 2012 and older / Re: BMS broke Who can Help
« on: September 16, 2019, 05:51:31 PM »
Alltrax controller is blue and white, Sevcon is black

I know how to bypass mbb on alltrax machine, not sevcon

2
Zero Motorcycles Forum | 2012 and older / Re: BMS broke Who can Help
« on: August 28, 2019, 05:45:27 PM »
What controller does your bike have?

3
Zero Motorcycles Forum | 2012 and older / Re: 2011 Zero S , will not charge
« on: August 21, 2019, 07:14:29 AM »
What is the pack voltage?

4
Zero Motorcycles Forum | 2012 and older / Re: BMS broke Who can Help
« on: August 21, 2019, 07:12:16 AM »
I thought the pouch cells came out in 2012...

What exactly is your BMS doing?  Is there pack voltage at the anderson connector coming out of the battery?

I have a 2011 running without the mbb so it might be possible to bypass the bms as well but I'm not sure of all the functions it performs etc

5
Zero Motorcycles Forum | 2012 and older / Re: Trouble shooting a 2011 xu
« on: February 27, 2019, 11:17:30 PM »
There is a led on the top of the controller that has its own codes.  The controller is the white and blue brick under the steering head area.  It is hard to see without removing the shrouds but it is possible to watch it as you turn the bike on

6
Zero Motorcycles Forum | 2012 and older / Re: Doesn't want to hit 35 MPH. What's wrong?
« on: February 15, 2019, 11:36:28 PM »
Buy this, install it and see if it makes a difference. 

https://www.ebay.com/itm/New-Magura-Twist-Grip-Throttle-0-5k-ohms/273407351484?hash=item3fa8591abc:g:3jkAAMXQ-KRRgOfF:rk:3:pf:0

while you wait for shipping etc, see if you can duplicate the issue with the bike on the stand by adding load to the motor with the rear brake.  You might have to disconnect (or jumper) the brake switch to fool the software

7
Zero Motorcycles Forum | 2012 and older / Re: Doesn't want to hit 35 MPH. What's wrong?
« on: January 29, 2019, 05:36:01 PM »
I'm guessing that your battery is worn out and the voltage sags as your speed increases.  One of the components then shuts down the system. 

You could test this theory by hooking up a voltage display to see what the battery is doing when you accelerate

8
Zero Motorcycles Forum | 2012 and older / Re: Trouble shooting a 2011 xu
« on: December 17, 2018, 07:28:56 AM »
You're probably going to find that your controller is failing at the throttle initializing sequence. 
what do the controller LEDs do during initialization?  You are supposed to see a single green blip followed by steady green LED.

You might get it to work intermittently if you unplug and replug various connectors (like the throttle) but if it is like mine, controller replacement is in your future.

Other gas bike dead CDI tricks like heat gun (xr650)  or brick compression (tw200)  are free and might be worth trying as you fiddle with it. 
The controller is a potted brick so internal component repair isn't easily attempted.

9
Zero Motorcycles Forum | 2012 and older / Re: 2011 XU Battery Retrofits
« on: December 17, 2018, 07:19:03 AM »
Can you say what was done to rebuild your battery?    How much hassle involved in shipping your 40 pound battery?  price range?

10
Zero Motorcycles Forum | 2012 and older / Re: 2011 Zero DS - Diagnosing throttle issues
« on: October 31, 2018, 08:47:40 PM »
Ahh ok great.  Is the OBD male terminal optional if I just plug the TTL cable ends  directly into the correct holes on the bikes female OBD port?

11
Zero Motorcycles Forum | 2012 and older / Re: 2011 Zero DS - Diagnosing throttle issues
« on: October 23, 2018, 05:18:01 AM »
Can you describe how you made your obd comnection?

Your issue sounds a lot like mine but I was getting a repetitive motor clunking at initialization.  The alltrax green light routine eventually failed but was normal for a while which made it confusing.  I got a used alltrax which made the bike operable but not completely happy as it was for a zero s and mine is a zero x

12
Zero Motorcycles Forum | 2012 and older / Re: 2010 DS MBB bad and not available need Bypass
« on: August 29, 2018, 06:59:27 AM »
I thought the MBB would be potted but it does look fixable if you had the right component.

If you bypass the mbb and wire it like a golf cart, a programmable controller could provide some of the features of the mbb.  I'm not sure if the bms and or charger would work independently without the mbb, though.

13
Zero Motorcycles Forum | 2012 and older / Re: 2010 DS MBB bad and not available need Bypass
« on: August 27, 2018, 04:58:15 PM »
Can you explain how you arrived at the "burnt board" diagnosis?  What controller is in there?  How many of the functions of the MBB/BMS combo can you live without?

https://advrider.com/index.php?threads/fixed-a-zero-xu.1293998/

http://electricmotorcycleforum.com/boards/index.php?topic=7232.0




14
Zero Motorcycles Forum | 2012 and older / Re: Is the 2012 UX Battery same as the recalled DS battery puoches?
« on: August 19, 2018, 05:42:53 PM »
I believe they are.  XU has a zf3 battery and the recalled units are zf6 and zf 9 units, which are just 2 and three of the zf3 bricks stacked together.  Maybe the issue lies in the areas where the bricks connect with and sit upon eachother.  Or possibly the case built around the stacked batteries is the weakness.  Obviously they determined that the zf3 battery wasn't worth recalling even though it looks like the same pouch cells and architecture.

15
Zero Motorcycles Forum | 2012 and older / Re: Father/Son duo with no knowledge of this 2012 Zero XU, battery options?
« on: August 14, 2018, 08:42:55 PM »
You should be able to measure pack voltage at the charging port.

if you read the manual link shown above you will see that the 2012 battery is  18 cells in series.  The post I linked  was to rebuild a 14S battery.  The concepts are the same for you but you need to build an 18S battery instead.

The people that know most about these older zeroes have probably moved on to bigger and better things but the info is still here in the archives for us latecomers to unearth.  I bought two dead Zeros and after lots of reading I was able to fix them both and am having fun in the process. 

If you want to look into freight shipping charges, I could rebuild yours for a fee.  Otherwise, start by taking yours out and apart to see how much room you have to work with as far as finding appropriate replacement cells. 

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