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[ricku425]

Long story short, my bike has been having intermittent keyless issues, to the point where I could no longer reliably use the bike so it's been sitting in a corner of the garage for a bit under a year. I was waiting until Energica reopened service in the US, but now that looks unlikely (especially anywhere near Indiana). So, I decided to just throw wrenches at the bike because what else did I have to lose. Turns out, two of the tiny wires coming in to the Zadi keyless module are broken. I believe they were packed in there so tight that they would occasionally complete the circuit, thus allowing the bike to sometimes be powered on and driven, but not always.

Now I'm stuck again. How in the world do I get the Zadi module off the bike and/or get inside of it to fix the wires? The angle is really awkward and it looks like there's a hex bolt up inside the bottom of it, but I have been unsuccessful in getting any tool to grab on to the bolt. The unit has a part number of "XCB0330" but searching for that turns up nothing. Figured I'd pop the question here to see if anyone has any advice (or even a suggestion for repair).

[jotjotde]

Can't exactly help you here, but try googling 'Zadi keyless start'.

You can find manuals for Zadi modules there with a few pictures which could lead you on finding out how to dismantle the unit.
https://device.report/m/bcdd76093de891590898bd419fe0f1c1a9ca59b71739ce3a28f4d044aedd437a.pdf
https://device.report/m/976527bf5feec5c2b25f44d026ed0c3734820e46c87cb65b7c93ca30393b5a03.pdf

Interestingly, Zadi is the mother company of the lamps manufacturer ECE. That suggests that Energica outsourced more or less the complete front unit of our bikes to Zadi.

[ESokoloff]

Your best bet would be to contact the manufacturer here….

https://www.zadi.com/en/contact-us/


A little searching indicates that other motorcycle manufacturers use this or similar unit (KTM Super Duke for one) so ask over on ADVrider as a last resort?
Here’s my best speculations.
In the last image I see two small roll pins in the lower section.
Perhaps those are key to removing the bottom piece?

In the middle image in guessing that the hex fastener is in the upper right area of the unit?
Can’t make out much detail but perhaps a thin wall socket is needed?

A last resort MIGHT be to remove the rubber grommet to gain (better) access to the two severed wires & repair in place?

Here’s what the insides (might) look like https://device.report/zadi/klgmzadi02

The manufacturer will have made it difficult to access the insides for obvious reason so perhaps you’ll have to visit a different motorcycle manufacturer dealer that uses this unit for a proper fix?
Jam a staple into the severed wires to form a sketchy temporary repair that gets you to that dealer (hopefully).

Good luck.

[ricku425]

I was able to track down an EE9 Workshop Manual (page 291), and it appears as though the "key-operated switch" is affixed with shear rivets, not a removable fastner. From what I can descern, I'd need to drill out the shear rivets to get the Zadi off the bike. Not willing to go that far! Since I'd probably have to cut off the rubber gromet anyway, I did that instead. There was enough slack in the wires that I was able to carefully resolder them. Wrapped it up in heat-shrink and put a small dab of silicone sealant in the hole. If this fix doesn't last, I'll try the more destructive route next.

[PWM]

Nice work.

[ESokoloff]

Post mortem analysis…..

Is this an issue (pinched wires due to tight radius routing of cables) that other owners might encounter or had your motorcycle been subjected to unique forces that caused wire severing?

[ricku425]

I'm 48 years old but I ride this bike like I'm 70. Bought it for the "electric" part, not for the off-the-line speed 

There's about 6500 miles on the bike. It has fallen over once while standing still and was "muscled" to the ground (as well as you can muscle a 600 pound bike to the ground), and this problem didn't appear until the next riding season from that incident. Can't totally rule it out I guess, but I'd say the probability of that being the cause is low. Otherwise, it's just a daily commuter bike and occasional errand pony.

[ESokoloff]

Geeez, I’m damn near 70 & unfortunately still ride I did when I was 17 (well, maybe 27)

Sounds plausible that a “muscled” drop could cause wires to be pulled/over stressed).
Hopefully then yours is a unique case so other owners needn’t worry.

[FlyMig]

I would find an electrician who can join those two wires together.  That stuff seems like it can be repaired fairly easy