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[ttshaw1]

I've had a used 2022 FXE for about two years now, taken it from about 700 to 7000 miles. I've usually been paranoid about riding it in the rain but I finally got caught in a thunderstorm last week. I thought everything was fine and made it home no problem, but I'm finally realizing the thing isn't charging. When I plug it in, the charging light and check engine light glow orange briefly, I hear the contactor close, then I get a very quick green flash on the charging light and eight slow flashes before all LEDs turn off. Disconnecting the charger, I get a quick red System Warning Indicator blink, then the contactor opens.

If I turn the key, the charging time stays at 00:00 and I have error codes 45 (Kickstand Switch Disable) and 47 (MBB Charger Connected Disable). I don't think I've seen anyone make this guess but I think the latter is just the MBB saying "you can't turn the throttle, the bike's plugged into the wall," as opposed to the MBB knowing there's some charger problem. So nothing terribly enlightening.

Collecting a bunch of other threads
https://www.electricmotorcycleforum.com/boards/index.php?topic=10197.0 (fuse/holder)
https://www.electricmotorcycleforum.com/boards/index.php?topic=12576.0 (fuse/holder)
https://www.electricmotorcycleforum.com/boards/index.php?topic=11400.0 (fuse/holder)

from r/ZeroMotorcycles

from r/ZeroMotorcycles

(doesn't look related)

So seems like odds are good the problem is the fuse or fuse holder. Annoyingly, in the first thread, the OP mentioned that the fuse didn't measure as bad with his multimeter, so I guess it's hard to be sure that's the problem. Anyway, I'll try to get logs tomorrow or tonight. I set up an ESP32 as a wifi-serial bridge to use with the OBDII port a couple years ago, but it's been a long time since I've looked at it and it'd require some relearning; is there any information that would be useful to pull from the serial port?

I'll update this thread as the situation evolves. Hopefully it'll be another testimony for the fuse/fuse holder pile that someone will find on google in six months. If anyone has any more info, especially the practical aspects of how to find or replace the fuse on my bike, please do share.

[Specter]

caught in the rain.  did something get wet and ground out?  is the bike totally dry now for sure?

sounds like it's trying, then seeing something and saying nope, like  leakage current maybe? or a rotten switch not making good connection.
just a thought.

Aaron

[ttshaw1]

It's been a week in 90F weather, so I'd expect dry by now. I'd be surprised if this didn't stem from something getting wet, but now I think we're sadly in "figure out what's broken" rather than "figure out what's wet" mode

[Specter]

those log files are going to help, need to see what errors are shutting it down.  if it's someting stupid like brake indicator fault pops up, even though that is not in the charging 'sequence' it might indicate something compromised, pulling just enough leakage current or something to trigger a shutdown.  Granted battery is hv, but anything leaking to ground can get picked up and trigger it.  just saying as an example that if something totally goofy comes up, don't immediately discount it.

aaron

[ttshaw1]

Log files attached. Error messages are generally
- `ERROR: Internal Fault on BMS0`
- `DEBUG: Charge Fault Occured. Sevcon trying to close contactor, but one was not closed quickly enough`
- `Sevcon Turned Off`,
-`Shutting Down. Too many Charge faults`

Which looks like what they ran into this thread https://www.electricmotorcycleforum.com/boards/index.php?topic=12576.0 . That thread is absolutely full of fuse/holder people, which bodes well for me. According to the service manual, it seems like the relevant fuse is High-Voltage Fuse 4 - "Charge Fuse (on-board)", which is "ABC10A". Presumably that's the ABC-10A https://divinelighting.com/products/divine-lighting-abc-10a-fast-blow-ceramic-fuse-10-amp-250v-abc10a-abc10-abc-10a-fast-blow-fuse-also-3ab-ceramic-6mm-1-4-in-x-30mm-1-25-in, a $3 part. Fingers crossed.

Interestingly, I had this failure 6/18 before the current spate, and I got hit by the thunderstorm 6/24. Maybe this has been happening intermittently and didn't get bad until the rain.

Also, while downloading the logs with the charger plugged in, the bike eventually realized there was a problem and turned on the Check Engine light. I didn't see a new error code on the dash, though.

[MVetter]

Man that's a weird battery log.

07024     06/30/2025 22:22:46   Disarmed                   PackTemp: h 31C, l 31C, PackSOC: 19%, Vpack: 98.567V, MotAmps:   0, BattAmps:   0, Mods: 01, MotTemp:  38C, CtrlTemp:  28C, AmbTemp:  25C, MotRPM:   0, Odo:11410km
 07025     06/30/2025 22:23:27   Calex 720W Charger 0 Connected   
 07026     06/30/2025 22:23:27   Calex 1200W Charger 1 Connected   
 07027     06/30/2025 22:23:27   DEBUG: Module scheme changed from Stopped mode to Charging mode   
 07028     06/30/2025 22:23:27   DEBUG: Module mode Change Does Not Require Disconnect   
 07029     06/30/2025 22:23:28   INFO:  Enabling Calex 720W Charger 0   
 07030     06/30/2025 22:23:28   INFO:  Enabling Calex 1200W Charger 1   
 07031     06/30/2025 22:23:37   Charging                   PackTemp: h 31C, l 31C, AmbTemp: 25C, PackSOC: 19%, Vpack:  98.56V, BattAmps:   0, Mods: 01, MbbChgEn: Yes, BmsChgEn: No
 07032     06/30/2025 22:30:17   ERROR: Internal Fault on BMS0   
 07033     06/30/2025 22:30:17   Module 00                  vmod: 98.533V, batt curr: 0A
 07034     06/30/2025 22:30:17   Module 01                  vmod: 0V, batt curr: 0A
 07035     06/30/2025 22:30:17   INFO:  Disabling Calex 720W Charger 0   
 07036     06/30/2025 22:30:17   INFO:  Disabling Calex 1200W Charger 1   
 07037     06/30/2025 22:30:17   OBD-II - Set Confirmed DTC: 3 = P0A7B   
 07038     06/30/2025 22:30:17   Dtc set because of BMS internal fault   
 07039     06/30/2025 22:30:17   Module 00                  vmod: 98.56 maxsys: 98.56 minsys: 98.56 diff: 0.000 vcap: 98.687 prechg: 100%
 07040     06/30/2025 22:30:18   DEBUG: Charge Fault Occured. Sevcon trying to close contactor, but one was not closed quickly enough   
 07041     06/30/2025 22:30:18   Sevcon Turned Off   
 07042     06/30/2025 22:30:18   DEBUG: Sevcon Contactor Drive OFF   
 07043     06/30/2025 22:30:18   Retrying contactor close   
 07044     06/30/2025 22:30:18   Module 00                  vmod: 98.534V, batt curr: 0A
 07045     06/30/2025 22:30:18   Module 01                  vmod: 0V, batt curr: 0A
 07046     06/30/2025 22:30:18   DEBUG: Module 00 Contactor is now Open   
 07047     06/30/2025 22:30:21   Sevcon Turned On   
 07048     06/30/2025 22:30:22   Sevcon CAN Link Up   
 07049     06/30/2025 22:30:22   DEBUG: Sevcon Contactor Drive ON.   
 07050     06/30/2025 22:30:22   Module 00                  vmod: 98.549 maxsys: 98.549 minsys: 98.549 diff: 0.000 vcap: 90.875 prechg: 92%
 07051     06/30/2025 22:30:22   DEBUG: Module 00 Contactor is now Closed   
 07052     06/30/2025 22:30:22   INFO:  Enabling Calex 720W Charger 0   
 07053     06/30/2025 22:30:22   INFO:  Enabling Calex 1200W Charger 1   
 07054     05/07/2025 10:32:45   Riding                     PackTemp: h 26C, l 24C, PackSOC: 76%, Vpack:108.003V, MotAmps:   0, BattAmps:   0, Mods: 01, MotTemp:  29C, CtrlTemp:  24C, AmbTemp:  22C, MotRPM:   0, Odo:10459km

See how it starts with you riding it down to 19% SoC or 98.567V? Then you plug it in, it freaks out because of internal fault on BMS0, and then it thinks it's 27 days in the past. I would do a BMS reset.

[ttshaw1]

Yeah, the 5/7 entries did strike me as weird but I assumed it was something to do with how the app formatted the logs. Didn't occur to me that the bike's clock could be messed up.

I checked the owner's manual and service manual but it doesn't look like either actually tells me how to reset the BMS. You know if the procedure here https://zeromanual.com/wiki/BMS_Reset_Procedure applies to my bike?

[MVetter]

yes

[ttshaw1]

Good news and bad news. The good news is it's charging and riding fine again. The bad news is the check engine light is on and I can't figure out why or how to get it to turn off.

Getting it charging wasn't too bad. The charging circuit fuse is indicated by the red arrow. Pointing towards the base of the bike, there's a flathead screwdriver slot. Push in and unscrew ~1/4 turn to get the fuse holder out of the body. The fuse holder with fuse, and body, are sketched in an attached picture. I cleaned the contact on the holder, and scraped the mating contact inside the body clean with a small flathead. Then cleaned out the resultant black plastic shavings. After reassembly it worked fine. The fuse itself read *BUSS*ABC10A, which is a different manufacturer than I expected, but no big deal.

Now, the check engine light had come on a few days beforehand when I was downloading logs. I was assuming it would go away after I fixed the charging problem. But a couple weeks after cleaning the fuse contacts, charging to full and load balancing for 12 hours, and riding a few times, it's still there. I don't see much in the logs of any value. There are errors that existed long before the check engine light came on and so I assume aren't responsible, but nothing that seems to have cropped up at the same time as the check engine light. The manual says the check engine light will bring with it a decrease in torque, but I'm still able to get up to at least 75MPH. I suspect it'll go higher, though I haven't been able to test its old top speed of 85MPH, and it doesn't feel sluggish at lower speeds so maybe there's no actual torque reduction.

Logs to follow in the next post as I'm out of attachments

[ttshaw1]

Logs attached. There's some weirdness in the mbb logs, where we go from 7/4/25 entries, to a bunch of mysterious entries the decoder is confused by, to some 5/16, 6/26, 6/30, 7/4, and "0" entries. Anyone got any ideas or do I send this in to Zero?

[ttshaw1]

Well, a few days after I got the logs, the check engine light turned off and hasn't turned back on since, so problem solved. I forgot to mention in my last post, I also attached the .log of bluetooth communications between my phone and the bike. Wireshark knows how to parse it. If I ever get time I'll try to reverse engineer the communications so I can pull info off the bike in python, since as far as I can tell no one's yet reverse engineered that and open sourced it.