ElectricMotorcycleForum.com
Makes And Models => Zero Motorcycles Forum | 2012 and older => Topic started by: Camresearch on February 01, 2015, 10:36:19 PM
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Hi Guys,
First post here.
I am getting a dead Zero DS 2010 to restore from my brother.
The problem is that I haven't got any documentation for the bike as he has lost it!! I was hoping to get a PDF of at least the owners manual. I have looked through the forum and found some links but they had all expired. A service manual, schematic wiring diagram or any other info would be welcome too. Not that I have any real hope of finding such information. I did get a pdf for the motor though so that is a start. :)
Thanks in advance,
Cam
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I don't have the 2010, but I do have the 2011 manual as pdf if that is any help.
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Thanks Jateureka. I would love to have a look at the 2011 manual. I think they are quite similar if not basically the same bikes as the 2010. Best to email me anything you guys have in pdf stuff. I can use all the help I can get on this one.
Thanks Guys and a special thanks to those who have already provided some critical help.
If anybody has anything at all that may help in pdf form about these Zeros, really any model may help give me a few ideas, please email me at camresearch@dodo.com.au
Thanks again people. 8)
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The 2011 S/DS are a little bit different. The battery is the same voltage but has more Ah, the motor uses ducted cooling, the styling is a little different, and Zero switched to belt drive.
But the powertrain should otherwise be identical, so for example error indicators are likely to be the same.
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When I bought my 2010 DS the owner's manual came as a printed booklet (ah - the good old days). At that time they didn't have it in digital form but maybe they did that later. I got one of the first 2010's because I had been waiting for two years with a deposit on my order.
Trikester
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Yeah my brother had the manual "somewhere", which doesn't help me much. He is looking for it and may yet find it. I am not holding my breathe on that one anyway. I have a good idea about the bike now and it's construction and wiring, thanks to people sending me stuff. Thanks again to all those who have aided in the restoration so far.
Cheers,
Cam 8)
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Wish I could help. When I sold my 2010 DS the manual went with it.
Trikester
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Thanks for the thought Trikester. I am sure I have enough info now to make more than a decent start on repairing the DS.
This forum itself is a valuable store house of useful information and the group is really helpful. I am sure if I run into any problems that most of my questions, if not all can be answered by the great people right here. :D It seems like many in the group know their various bikes down to their last nut and wire. Some like me, are even the nut attached to the handle bars ;)
Cam 8)
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You can also download the controller manual from the Alltrax website and the Agni motor manual from Jozztek I think. Jozztek also have service and repair videos for the Agni.
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Thanks Jat for the heads up. I have a couple of sources of info now. I am always happy to get more. Knowledge is power :D and that sounds about right with an EV bike :)
Cam 8)
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Thanks to everybody who has sent me information. I really appreciate all the help that has been given so freely by people on this forum. You guys are a great bunch. I won't name names about who sent me exactly what, for various reasons but you all know who you are, and thank you all very much, there is now a DS here that should live again thanks to you all.
I wish manufacturers of any equipment would give more technical information about their products freely. Other manufacturers don't need their service manuals to reverse engineer their stuff, they would just buy one and take it apart, nut by nut. It only hurts the end users.
I think too, their reputation for reliability would improve, if people knew just how their bikes were put together. Many minor repairs could be done before becoming major issues. Lets face it too, there would be many people who would look at the manual and decide they don't have the time, inclination or special tools to do the job themselves but wouldn't then wonder why the service to fix a problem had cost what it did, when they understood what would have to be done to fix a problem. Win - Win as far as I see it for the manufacturers. They still get most of the service business but they have happier customers, who can keep their own bikes on the road more, rather than sitting dead somewhere waiting to be fixed when they can be taken for service somewhere (often 100s of Kms away!!!) My nearest dealer is towards the North side of the state (Australian States = BIG) NSW in my case, for those who know that is Gosford way north of Sydney for the dealer and I am in Mittagong, in the southern highlands, way south of Sydney. If a zero was your only vehicle and you needed it fixed, then you are stuffed.
If they are worried about people electrocuting themselves, then wouldn't it be less likely if they actually had a wiring diagram. People are often going to try themselves to fix a problem, with or without the information to do the job. It would be much safer if they could actually know what it is they are touching!!!
Anyway guys, thanks again for all the information. I feel right now for info.
Cheers,
Cam 8)
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Great news, Cam! I think the issue is the same for most small "startup" companies that are funded by private investors and do not have a lot of patents on their designs (or a lot of lawyers) yet. They are just worried about other companies using their designs for their own products and want to minimize any chance of that happening by keeping as much of their designs hidden from public view, including their customers. Such is life in the manufacturing business.
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Plus I think Zero is hopping to get everything done and manufactured... for example they don't have the 2015 owner's manuals, rack instructions, etc out yet. At a small company still on a thin margin, you can't hire tons of people, as much as you might need 'em.
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Plus I think Zero is hopping to get everything done and manufactured... for example they don't have the 2015 owner's manuals, rack instructions, etc out yet. At a small company still on a thin margin, you can't hire tons of people, as much as you might need 'em.
The 2015 S/SR/DS manual is up on their website. The FX manual is not, at least of a few days ago.
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Plus I think Zero is hopping to get everything done and manufactured... for example they don't have the 2015 owner's manuals, rack instructions, etc out yet. At a small company still on a thin margin, you can't hire tons of people, as much as you might need 'em.
The 2015 S/SR/DS manual is up on their website. The FX manual is not, at least of a few days ago.
Lmao
If only the true came out what happened to the manuals
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The 2015 S/SR/DS manual is up on their website. The FX manual is not, at least of a few days ago.
WHOO! IT IS! And it includes a table of the error codes!! Most awesome!
SILLY SNOOPY DANCE!!
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That is great news that they are putting up manuals on their site!! Now if they would only be as forthcoming with the service manuals, we could all benefit from those. Cam 8)
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I have scanned a copy of the Alltrax flow chart that the previous owner of my 2011 Zero S gave me from when he was fault finding a faulty contactor I think (which it still has!)
May help you and others.
The limit on attachments is 600kb, so PM me if you need a better copy.
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I have scanned a copy of the Alltrax flow chart that the previous owner of my 2011 Zero S gave me from when he was fault finding a faulty contactor I think (which it still has!)
May help you and others.
The limit on attachments is 600kb, so PM me if you need a better copy.
;D ;D ;D ;D ;D ;D ;D ;D ;D We need a like button!!
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Thanks again Jat, for all the help... The information that you and "others" have provided is invaluable.
Cheers,
Cam 8)
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No worries, glad to help.
Just be sure that while you have it apart you replace that 200A contactor with one rated for 400A! See this thread for details http://electricmotorcycleforum.com/boards/index.php?topic=3441.30 (http://electricmotorcycleforum.com/boards/index.php?topic=3441.30)
Oh, and some photos of your progress would be nice too!
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Thanks for the heads up on the contactor... that is useful info... I will post some photos when I have it apart and know what is wrong. I have been busy putting my Lathe/Mill combo back together for now. In the mean time you can check out my brothers old blog about the bike before I took on the responsibility for it, it has some good photos of it and the history of the bike.
http://zerods.blogspot.com.au/2010_09_01_archive.html (http://zerods.blogspot.com.au/2010_09_01_archive.html)
Cheers,
Cam 8)
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Hello!
I bought two zero motocycles 2010, but 0km. They were plowed for a long time. In this way the batteries are in trouble and do not receive more charge.
Please send me the manuals and documentation that have to help me solve the problem.
In my country to zero does not support nor sells parts.
Thanks!
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I don't think the manual will help. You need a new battery or a battery company that can try to revive it.
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Hello!
I bought two zero motocycles 2010, but 0km. They were plowed for a long time. In this way the batteries are in trouble and do not receive more charge.
Please send me the manuals and documentation that have to help me solve the problem.
In my country to zero does not support nor sells parts.
Thanks!
Where are you from?
Brazil???
Sound like the sour deal no one knows about finally coming out... Let's see how he got the bike? Off a shipping container full of dead bikes.... What a blunder!
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Hello!
I bought two zero motocycles 2010, but 0km. They were plowed for a long time. In this way the batteries are in trouble and do not receive more charge.
Please send me the manuals and documentation that have to help me solve the problem.
In my country to zero does not support nor sells parts.
Thanks!
Where are you from?
Brazil???
Sound like the sour deal no one knows about finally coming out... Let's see how he got the bike? Off a shipping container full of dead bikes.... What a blunder!
Yes, i am from Brasil!
Exacly, this bikes came in a container... unfortunately
No way to unlock the batteries?
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Hello!
I bought two zero motocycles 2010, but 0km. They were plowed for a long time. In this way the batteries are in trouble and do not receive more charge.
Please send me the manuals and documentation that have to help me solve the problem.
In my country to zero does not support nor sells parts.
Thanks!
Where are you from?
Brazil???
Sound like the sour deal no one knows about finally coming out... Let's see how he got the bike? Off a shipping container full of dead bikes.... What a blunder!
Yes, i am from Brasil!
Exacly, this bikes came in a container... unfortunately
No way to unlock the batteries?
Those batteries do not have an "unlock". They have a simple control module called a BMS. The BMS takes measurements of each cell bank to make sure that they are all charged evenly , or charged properly( if the cells are too high or too low the BMS will not send an enable signal) . If those batteries in that container sat for longer than six months without a charge then those batteries are junk. The only repair is to purchase a new set of cells for each of those batteries from that container or build a custom battery that will make the altrax controller happy whilst powering the motor. I would try to build a complete custom bike as it would've easier than getting a new battery built by Zero. There are only a couple dealers that know about the pre MY13 stuff. You probably have a great boat anchor though
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The 2010's had a much higher parasitic current drain, when the bikes were off, than later models. Those batteries were probably drained to nothing and are no good anymore.
As long as I had my 2010 DS it was plugged in at all times unless i was riding.
Trikester
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There is a company in the UK that is re-packing the Zero battery box with new cells, http://electricmotorcycles.co.uk/on-road-street-electric-motorcycles/contact-electric-motorcycles/ (http://electricmotorcycles.co.uk/on-road-street-electric-motorcycles/contact-electric-motorcycles/)
And I guess Zero themselves would re-pack the battery also, but both of these options don't really help you in Brazil...
If you are up to re-packing the Zero battery yourself and wanted to stay with 60Ah then 7 Leaf modules (14s2p) should just fit width wise stacked in the original Zero battery box.
I am planning to upgrade my 2011 Zero to 14 x Nissan Leaf modules (14s4p) to get 120Ah battery pack, but this project is a little ways off yet and will need quite a few modifications to get it to fit, including a CBR600RR tank cover.
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No progress on the bike yet. I am still setting up a spot to take it apart properly.
Cheers
Cam
Here is a photo of it now anyway. :) I hope to start on it this week. I had a lot to finish first.
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I have a 2010 manual - tryied to post but woudlnt work - let me know if you need it
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I just found a paper copy of a 2010 Zero manual in my library. Send me a PM and your mailing address if anyone needs it.
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Zero now offers owners manuals for all consumer bikes going back to 2010 in PDF:
http://www.zeromotorcycles.com/owner-resources/ (http://www.zeromotorcycles.com/owner-resources/)
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Cheers, Thanks for that. A very useful link. 8)