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Zero Motorcycles Forum | 2013+ / Reverse switch addition
« on: October 23, 2015, 11:08:51 AM »
I've been getting PM's lately asking about the reverse switches I've added to my 2013 FX and e-trike (2013 drive-train). So I'm going to post the information that I have sent people here. I'm showing only what I did and I'm not making any recommendation to anyone to do this (just replying to questions). It may have an effect on your warranty and it may injure or kill you if not used correctly. One person has said that his wire colors were different than mine so there may be a difference between models (mine was MX/FX harness and his was S).
Here are the wiring changes but the Sevcon also has to be programmed to recognize the reverse input signal. Harlan did that software change for me.
From Sevcon (Motor Controller) pin 19 is a Org/Blu wire going to the MBB pin 19. Cut that wire and connect Sevcon pin 19 to the terminal of the SPDT switch that will become the reverse terminal. Connect the MBB pin 19 Org/Blu wire to the wiper of the switch. There is an Org/Gry wire connected to the Sevcon pin 18. Cut it (the other side of the cut wire is left unconnected) and connect Sevcon pin 18 to the terminal of the switch that will become the forward connection when the switch is thrown to connect the wiper to this terminal.
So, when the switch is in FORWARD it will be connecting MBB pin 19 to Sevcon pin 18. When in REVERSE it will be connecting MBB pin 19 to Sevcon pin 19.
If I were to do it over again I would use a DPDT switch and wire a warning beeper to the other side to provide a warning when the switch was in the reverse position. Or, I may use a momentary push-button switch on the left bar that would have to be held down by my index finger to keep it in the reverse position.
I haven't done this mod to my 2014 DS yet so I don't know if the wire colors will be different on it.
NOTE! IF YOU ARE CONSIDERING THIS MODIFICATION BE SURE TO READ ALL OF THE ADDITIONAL POSTS FOLLOWING THIS ONE. THERE IS MORE INFORMATION ABOUT THE CONNECTIONS TO THE SEVCON CONTROLLER AND SUGGESTIONS TO NOT USING PREWIRED SEVCON PIN 19 AS THE INPUT. THE 2014 IS DIFFERENT THAN 2013 AND THE 2015 IS DIFFERENT THAN 2014.
Trikester
Here are the wiring changes but the Sevcon also has to be programmed to recognize the reverse input signal. Harlan did that software change for me.
From Sevcon (Motor Controller) pin 19 is a Org/Blu wire going to the MBB pin 19. Cut that wire and connect Sevcon pin 19 to the terminal of the SPDT switch that will become the reverse terminal. Connect the MBB pin 19 Org/Blu wire to the wiper of the switch. There is an Org/Gry wire connected to the Sevcon pin 18. Cut it (the other side of the cut wire is left unconnected) and connect Sevcon pin 18 to the terminal of the switch that will become the forward connection when the switch is thrown to connect the wiper to this terminal.
So, when the switch is in FORWARD it will be connecting MBB pin 19 to Sevcon pin 18. When in REVERSE it will be connecting MBB pin 19 to Sevcon pin 19.
If I were to do it over again I would use a DPDT switch and wire a warning beeper to the other side to provide a warning when the switch was in the reverse position. Or, I may use a momentary push-button switch on the left bar that would have to be held down by my index finger to keep it in the reverse position.
I haven't done this mod to my 2014 DS yet so I don't know if the wire colors will be different on it.
NOTE! IF YOU ARE CONSIDERING THIS MODIFICATION BE SURE TO READ ALL OF THE ADDITIONAL POSTS FOLLOWING THIS ONE. THERE IS MORE INFORMATION ABOUT THE CONNECTIONS TO THE SEVCON CONTROLLER AND SUGGESTIONS TO NOT USING PREWIRED SEVCON PIN 19 AS THE INPUT. THE 2014 IS DIFFERENT THAN 2013 AND THE 2015 IS DIFFERENT THAN 2014.
Trikester