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Messages - Eccelerate

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Zero Motorcycles Forum | 2013+ / Re: FX Front Sprocket
« on: October 01, 2020, 08:17:06 AM »
On my 2020 FX the front sprocket "shattered" according to the dealership, which caused damage to the splines on the motor output shaft, and necessitated a motor replacement.  Fortunately it was covered under warranty, but makes me wonder if this could happen again once the warranty has expired.  I don't see any markings on the front sprocket, but there are no holes drilled like in your JT diagram.  Has anyone else had their sprocket fail on a new Zero FX?  It broke when I drove over a small pothole.  I upgraded to the chain kit after the belt broke when I fell in some sand.  I thought the chain would hold up to dirt riding, but mine didn't last more than a month.  The new sprocket has a couple months of riding on it, so maybe it is better, but maybe I should put an aftermarket sprocket on that has a good reputation.

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Just an update after picking my bike up from the dealership today.  First, thanks for all the comments.  I'm glad at least a couple other owners agree on some areas for improvement.  And I agree, the mirrors, fenders, turn signals, and belt drive all could be considered consumable, and I'll take responsibility, because those are not my primary complaint.  Today I found out Zero denied my warranty claim to replace the battery which won't accept a charge.  Yes  the battery with the big yellow decal that says 5 year warranty on the side.  The only explanation provided was denied due to damage.  Nothing specific, and no option to service the battery.   According to Zero, my only option is to buy a new battery for $2895.   I tried to argue, that if there is damage to the battery, then without knowing any details about what specific damage they are referring to, then wouldn't the most likely cause of damage to the battery be related to the 3 motor failures that were replaced under warranty, as opposed to something that I could do to the battery as the operator?  The motor is the consumer of the battery output, and if the motor failed 3 times (one time it started to run the bike in reverse, and another time the temperature indicator would skyrocket as soon as the throttle was applied without power going to the wheels, so internal short with excessive battery drain to instantly overheat..) those correlate as related to the battery where failure of motor could cause damage to battery.,  How could I as user damage the battery?  Sure there are a few minor scratches on the case, but there are no cracks, and no specific damage cited by Zero.  I could swallow my anger and frustration, had they denied my claim because of something specific, such as had they found evidence I performed deep water crossings, or rode in the rain, or rode when it was 110 degrees, had any of those reasons be listed in the Owner's manual as abuse, and had there been evidence I committed those acts.  But there is nothing in the manual describing limitations that I exceeded.  I actually drive the bike pretty tame compared to the advertising videos.  I don't jump the bike, ride wheelies, or do burnouts.  I ride as fast as I can on trails, which is about half the speed of the marketing videos (I'm 56 years old and only been riding for 4 years.)  I haven't been injured on the Zero, and the only damage I did to the bike was cosmetic and those consumables.  I probably do ride it harder than most riders, and I can keep up with some of the riders half my age, but I don't think I deserve this treatment from Zero.   The Zero FX would be the perfect bike for me, if only it would live up to what it is marketed as.. a dual sport that kicks the pants off of the KTM E-XC.   And Alta went out of business, so not a viable option.  Zero might be heading towards the same fate unless they make some improvements, starting with building trust in their brand.  Right now, on a scale of 1 to 10, based on my experience... well a lot can be said in just a name, and maybe the name speaks for itself.  ha ha.. ok not funny.

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I purchased a 2020 FX with two removable battery modules in October 2019.  I have driven 2450 miles on it, and have had the following issues:
The motor replaced 3 times under warranty, and one time "recalibrated" after being stranded each time
I upgraded to the chain kit after the belt broke (long tow from a KTM back to staging area)
The drive sprocket that came with the chain kit "shattered", according to the dealership mechanic, which necessitated one of the motor replacements due to spline damage.  It happened after driving over a small pothole on a dirt road at 50 mph.
9 spokes broke on the rear wheel, then a week after replacing them, 3 more spokes broke.  A full set of spokes are on order (not a warranty item).
One of my batteries stopped working, and dealership was unable to "login" to the battery and obtain fault information.  Currently waiting for Zero to respond to multiple phone calls placed by my dealership.
Both my mirrors became loose and won't tighten, so i removed them (one of them I damaged when I dropped the bike).
The battery retainer piece that has a lock on it fell off 3 times while riding, and 3 times I recovered it the next day.  The latch frequently needs to be adjusted and monitored.
I've lost my license plate twice, due to rear tire contacting the license plate when suspension is compressed.
I dropped the bike once attempting a hill climb on a rocky trail, so forward speed was almost zero, and this caused:
  All six screw fasteners broke on the hole side of the fasteners that hold the upper and lower rear fender together and attached to the frame
  The rear upper/outer fender broke in half
  Rear turn signal broke off
  License plate snapped off
  Horn bent and disconnected
  Seat bolt on one side stripped the nut part that is welded to the frame
  Speedometer sensor wire cut to front wheel
For the 9 months I've had the bike, over half of the days the bike was at the dealership waiting for parts and service (including 1 1/2 months waiting for dealership to reopen after COVID-19 outbreak).  Does this sound excessive?  I'm hoping a reasonable person would agree so that I can return it for a refund.  I love the acceleration, the stealth, the attention, the lack of oil changes and gas station stops.  But for nearly $15,000 for a dual sport dirt bike, it is not living up to expectations, and I cannot put faith that the sprocket will not fail again causing another motor replacement, or some other part to fail.  I ride it about 50/50 offroad every day it is not in the shop, including in the desert like today when it was 109 degrees.  I know it's only a matter of a short time before my next stranding experience.  I carry extra drinks, an emergency locator beacon (never used), and try to ride with friends when venturing farther into the desert than I am prepared to walk.  I miss my KTM 500EXC that was stolen after 3rd catastrophic engine failure in 3 years left me stranded on side of freeway 2 miles from home.  The KTM's reliability looks quite superior to Zero FX in retrospect.  Hopefully Zero works out the bugs by the time I've worn out my future 790 Adventure R into the dust.

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