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The most probable reason for the failure is the nominal voltage rating of the original part, which is 80 VDC. This is below the nominal voltage of the system. Even though it is within its operating range, it is still near its limits and for example an ABS system can have large current demands. A revenue minded design, lower cost to produce, higher revenue through selling more spare parts.

wind plays also a big role in the range....but in good riding weather and having fun, the range will not be as limiting as the overheating of the bike. If I rode my FXS the same way as a gas bike, it took only 30 minutes to make it overheat at 25 Celsius ambient temperature. As far as I know, the Zero app does not show the battery temperature, only the controller/motor temperature. The battery temperature is only visible in the logs.

For that speed and that weather I think it is normal.
With normal summer weather you can expect 45 miles at 55 mph according to my experience.
You would have to stay at 35-40mph to get app 60 miles or little less, but it is dependent also on how you accelerate.
Don't forget to factor in the wind, that is also a big factor.

You will have fun with the bike if you stay within a radius of 20 miles  of your charge location (40 miles there and back).
Hypermiling these small bikes makes no sense, their strong point is the agility.

Hi Guys,

has anyone else noticed how on the home page and every review they blatantly clame to be able to charge the 17.3 battery in one hour?

To substantiate that claim:

they mark the nominal capacity as 110%.
They give the charge target as 95%
The charger setup gives 12.6kW

So 95% of 110% (usable capacity 15.2 kW) is about 13kW.
This is just absurd.

I am even sceptical about getting those 13 kW into that battery  with that 12.6 kW charger, as the efficiency for sure isn't 105%.

I find it to be false advertising with the aim to desperately catch up to the competition with manipulated numbers.

charging up a 17.3 battery in 1 hour with a 12 kW charger is the new magic charging (and if no charger is around, you can use the old magic charging instead)

The information regarding charging and the battery capacity on the Zero website is rather confusing (I suppose intentionally). Max capacity is  17.3 kWh, nominal 15.2 kWh, but supposedly charged to 95% within 60 minutes with a 12.6 kW charging setup. Not to mention the times to 110%. ...I know that this is their way of masking the pay to unlock features and all I can see is a tried and proven tactic....if you can not convince them, confuse them. BTW. they forgot to mention the continuous power of 48 HP.

If a capacity of a battery is given, that should be 100% and that is the maximum literally and not 110% and with no mention to which value this percentage is related to.

The charge time to 95% within an hour at 12.6 kw suggests a 14.4 battery. As does the range (80 Miles at 70 MPH) compared to a 14.4 DSR (78 Miles at 70 MPH).
The 14.4 is also the max capacity so I really do not understand the 17.3 and 15.2 claims.

They should clearly state the Ah value or kWh value, which you get with the price paid for the motorcycle and simple and clear information on the charge time to that value (which is 100%) at the time of purchase.

when I left the bike on the charger longer for it to balance, the contactor clicked after charging was done, the green light stayed on and the BMS was balancing the battery with burning off the excess voltage in the higher charged cells. This will result in a lower overall state of charge. When I checked the next day, the  SOC was 98% and when unplugging and plugging the charger back in, the contactor clicked again and the charger charged the battery back to 100%.

This is my layman observation from what I saw and read from the logs, as I have no inside information about the architecture.

my understanding is that it balances only at full charge when the charger is connected. Usually I also have between 5-12mV. In my case regen braking seems to increase the imbalance.