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[cheerad]

Dear all,

I'm riding a 2011 DS for a couple of month now, and it drove quite well. Some weeks ago, the motor didn't start anymore after stopping at a traffic light for example. Sometimes it started after a couple of times switching on and off the ignition, sometimes I had to wait till the next day. I started checking everything, the motor, the connectors, reading out the MBB and the controller - no errors. I then measured the resistance of the throttle at the connectors to the controller, and realized that it is not connected directly, but through the MBB I guess. So to understand everything now and to find the error, I'm looking for a wiring diagram. My dealer doesn't have one, Zero in Europe tells me, that "we are not allowed sharing any technical details directly with customers regarding safety issues".
Can anybody help?

Thanks, Christoph

[giacomo]

Dear all,

I'm riding a 2011 DS for a couple of month now, and it drove quite well. Some weeks ago, the motor didn't start anymore after stopping at a traffic light for example. Sometimes it started after a couple of times switching on and off the ignition, sometimes I had to wait till the next day. I started checking everything, the motor, the connectors, reading out the MBB and the controller - no errors. I the measured the resistance of the throttle at the connectors to the controller, and realized that it is not connected directly, but through the MBB I guess. So to understand everything now and to find the error, I'm looking for a wiring diagram. My dealer doesn't have on, Zero in Europe tells me, that "we are not allowed sharing any technical details directly with customers regarding safety issues".
Can anybody help?

Thanks, Christoph

This is for a 2013, not sure how much it matches yours:
http://zeromanual.com/index.php/Unofficial_Service_Manual#Wiring_Diagram


Sent from my SM-G950U1 using Tapatalk

[David_Walsh]

Dear all,

I'm riding a 2011 DS for a couple of month now, and it drove quite well. Some weeks ago, the motor didn't start anymore after stopping at a traffic light for example. Sometimes it started after a couple of times switching on and off the ignition, sometimes I had to wait till the next day. I started checking everything, the motor, the connectors, reading out the MBB and the controller - no errors. I the measured the resistance of the throttle at the connectors to the controller, and realized that it is not connected directly, but through the MBB I guess. So to understand everything now and to find the error, I'm looking for a wiring diagram. My dealer doesn't have on, Zero in Europe tells me, that "we are not allowed sharing any technical details directly with customers regarding safety issues".
Can anybody help?

Thanks, Christoph

Chris, when I had a similar problem, swapping out the sensor for the updated one fixed it for me: http://electricmotorcycleforum.com/boards/index.php?topic=7289.msg60715#msg60715

Sent from my SM-N910H using Tapatalk

[cheerad]

This is for a 2013, not sure how much it matches yours:
http://zeromanual.com/index.php/Unofficial_Service_Manual#Wiring_Diagram


Sent from my SM-G950U1 using Tapatalk

Hi Giacomo,

unfortunately the 2013 diagram seems to be quite different to the 2011 diagram.

[cheerad]

Chris, when I had a similar problem, swapping out the sensor for the updated one fixed it for me: http://electricmotorcycleforum.com/boards/index.php?topic=7289.msg60715#msg60715

Sent from my SM-N910H using Tapatalk

Hi David,

I've got an Agni motor, the Lynch design. I've been through your thread already   .

[David_Walsh]

Chris, when I had a similar problem, swapping out the sensor for the updated one fixed it for me: http://electricmotorcycleforum.com/boards/index.php?topic=7289.msg60715#msg60715

Sent from my SM-N910H using Tapatalk

Hi David,

I've got an Agni motor, the Lynch design. I've been through your thread already   .

Oh, OK.
Thought Zero changed in 2010 - apologies.
I don't know too much about those models... You can probably get onto the motor terminals with a meter. See if you can measure voltage when you throttle it? If you do, then it is probably brushes that are the problem. How many miles on the bike?

Sent from my SM-N910H using Tapatalk

[togo]

... I'm looking for a wiring diagram. My dealer doesn't have one, Zero in Europe tells me, that "we are not allowed sharing any technical details directly with customers regarding safety issues".
....

I would recommend calling Zero Customer Service, getting your dealer a wiring diagram and whatever other technical info they need to fix the problem.

I had a problem with my throttle on my 2011 Zero S, it was pulling a little when stopped, I contacted Zero Customer Service, and it turned out to be the throttle itself, Zero shipped me a new one for a self-install.

[cheerad]

Oh, OK.
Thought Zero changed in 2010 - apologies.
I don't know too much about those models... You can probably get onto the motor terminals with a meter. See if you can measure voltage when you throttle it? If you do, then it is probably brushes that are the problem. How many miles on the bike?

The motor is running fine, if I just power up the Alltrax AXE controller with the motor connected to it. And I also used the original throttle. So the problem occurs, when everything is connected to the rest of the bike (the MBB).

[David_Walsh]

Oh, OK.
Thought Zero changed in 2010 - apologies.
I don't know too much about those models... You can probably get onto the motor terminals with a meter. See if you can measure voltage when you throttle it? If you do, then it is probably brushes that are the problem. How many miles on the bike?

The motor is running fine, if I just power up the Alltrax AXE controller with the motor connected to it. And I also used the original throttle. So the problem occurs, when everything is connected to the rest of the bike (the MBB).

OK, the MBB huh...? But no fault code shown by the led flashes?
My understanding is that the MBB checks MANY electrical components before it allows the throttle signal to influence the controller to spin the motor - but you should see a fault code series of flashes. I guess it may be a faulty MBB itself? This (Spanish) guy Manuel shows how to swap one out:
'course, you need a replacement MBB and Spanish to benefit...

Sent from my SM-N910H using Tapatalk

[igorbaldo]

I have taken the wiring diagram from my 2010 DS, which I believe is pretty much the same as the 2011. It's drawn by hand, so I will not post it now, but I will draw it in the computer an post it here, OK?

[yokahoma]

Here are some diagrams that might help. Technically it's for XU but I think the S and DS are similar.

[cheerad]

Here are some diagrams that might help. Technically it's for XU but I think the S and DS are similar.

That's cool, thanks a lot. I will check the bike tomorrow. Funny thing is, that the bike is running sometimes, and sometimes not. The contactor is not switching every time. I have ordered a male and a female 34 pin connector to build a short cable, which I can put between connector and MBB. On this cable I can then do all measurements while the whole system is up and running.

[BrianTRice@gmail.com]

Here are some diagrams that might help. Technically it's for XU but I think the S and DS are similar.

Are these yours, and can I post them to the unofficial service manual website? I'll link the thread for now.

[igorbaldo]

Hi guys,

I've finally finished drawing the schematics. Enjoy! 

[Leroysparky]

Igorbaldo,

That is great, thank you for doing that wiring diagram. I have a question for you.

So I just got my 2011 Zero XU and I got it with a dead battery. So I took about 4 days to slowly charge each of the 7 banks (2 of the cells that are stacked in series on top of one  another). I charged them at 1 amp with a car/motorcycle charger 6v. Until I got each bank to about 6.5 volts with a total of 45.5 volts. I kept those cells that I got to that voltage, using a computer power supply and a step up. After getting to the 45.5 volts I connected it back to the charger on the bike ant started charging!

So the battery is not in the best shape, with it being that low for well over a year. So with the way the battery is it will cut out around 38mph because it doesn't have enough amps to push out when I need it. (I tested it with another battery I built in parallel and it worked with out cutting out). I was also able to travel about 6 miles and then it would cut out completely with original battery.

So this brings me to the next step in my adventure. I took this pack that I made from 14 3.7v 24ah li-ion cells from a Ford C-Max. ( I did this to make it a faster build.)

So I got everything ready but I very sadly hooked up the BMS in  the exact opposite order needed and I fried my BMS.

With that can you, Igorbaldo or anyone else, tell me by chance what the voltage is going from the KSI to the MBB. The Br and B?

Thank you