ElectricMotorcycleForum.com
Makes And Models => Zero Motorcycles Forum | 2013+ => Topic started by: Keith on November 17, 2017, 09:12:36 AM
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I've created a complete wiring diagram for my FX and have uploaded it to the Unofficial Service Manual here https://zeromanual.com/index.php/Unofficial_Service_Manual#Schematic. It is too large to attach so here's a link to the pdf https://zeromanual.com/images/8/8f/2016_FX_Wiring_1-1.pdf I will keep this thread uploaded with any revisions as Burton has done with his diagram.
EDIT - One significant error found, DC/DC Converter Input- should connect to Battery- as well as MBB 34-7, corrected in revision 1.1, svg attached. Added charger pin descriptions, improved print appearance.
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Nice job there[emoji122]
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Outstanding - thanks very much !!
Ray
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This is awesome. Let's do our best to take details from this to update relevant sections of the wiki manual.
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Thanks for the comments. If someone can document the battery connection for the S models, that's probably the only real difference. I'd be happy to make another version to show that. And it seems likely that wiring for the more recent model years are also mostly the same, but for example I see that the ABS unit has a canbus connection that is not used, wonder that is still the case. MBB is still mostly a black box but many connections are obvious. Dash connections also could be better understood. And thanks are due to Burton, I applied a lot of his diagram's information, it was very helpful.
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This is great!
I was hoping someone would simply let me take their wire loom apart on the newer models or the FX models and or train someone to do what I previously did so they could do it themselves just so we had this documented.
If you wanted to make this look fancier I would be willing to take the time to make it look similar to mine with all the fancy plugs / colors etc. If you had visio you could manage it from there if you liked.
Thanks for the hard work :) These things not only take time to make but time to confirm :D
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A new version done today, Unofficial Manual is updated. https://zeromanual.com/images/8/8f/2016_FX_Wiring_1-1.pdf I added function descriptions to the Dash and MBB pins. I still don't have that information for the pack connectors. I'd also like to know more about how the S model pack connects.
Burton's fine work inspired me to do this. But I have to say having a harness to work with is a whole lot easier than checking continuity with a meter with the wiring on the bike!
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This is a great diagram. Thanks for your hard work. I have a dumb question though. How do I know what the proper readings are for a circuit?
Example: MBB 1, pins 11and 27 are to the kickstand switch. How do I tell if the MBB is sending or receiving the correct signal on these wires? Would I be looking for 5V or 13.5V? Should I be connecting the switch wire to chassis ground, or the ground connection (pin 12 on MBB) for diagnostic?
Or, DC/DC converter is enabled on the MBB 1, pin 20. So would I connect a VOM to measure DC voltage at pin 20 and again at pin 1 on the DC/DC connecting the negative meter probe to ground? What voltage would be appropriate, 5V, 13.5V ?
Thanks to anyone for helping me to understand how to better use this diagram for diagnostic without shorting something out.
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Good questions. My strong advice, be very careful! There are separate isolated power circuits on the Zero. Shorting the wrong things together can cause very costly damage, like requiring a replacement MBB (~$400) or BMS(~$500) or even controller ($$$$). If I knew the voltages they would be on the diagram, so I can only guess or probe them myself which I hesitate to do because it is risky. I did all my work on the diagram with no power anywhere, just an ohmmeter. Nothing on the Zero electronics is connected to chassis except one wire from the packs, shown in green, probably used to measure isolation. The 12V stuff shown in blue has its own "ground" shown in brown but it is not connected to chassis. The rest is mostly referenced to the battery negative shown in violet but it can be 5V, 12V or 100V circuits. Battery negative could be any voltage relative to chassis due to leakage or low isolation in the packs.The MBB needs to know about the 12v things like the brake light, but I think it uses opto isolators to do that. The MBB runs on 100V power that is ALWAYS ON from the pack (pin 18). That makes it really easy to do damage because it is live even when the bike is keyed off. Even with the packs removed, there will be stored charge in the motor controller. So for safety you should both remove the packs and discharge the system before checking any wiring issue. I use a light bulb across the aux charge port. It is possible to probe circuits while they are on of course, but it must be done with extreme care. The high DC voltage and potential high fault currents make doing that much more difficult and dangerous than on a conventional 12V gas bike.
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I've added this pin layout image for the pack connectors to the unofficial manual schematic section. Pin numbers match my wiring diagram. Pin descriptions are sketchy but probably close. https://zeromanual.com/index.php/Unofficial_Service_Manual#X-Platform_Schematic
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Awesome thanks. Very generous of you.
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But wait, there's more. Here's what things look like from the wire side. The inserts have mold numbers for pins and sockets. However, since the inserts are used in two different housing "genders" the numbers change but they are the same signals on the wiring diagram. Hopefully this clarifies which pin/socket is what signal everywhere.
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And here is the FX power pack wiring from connector to BMS and contactor. This is in the BMS section of the unofficial service manual.
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Keith, thanks a lot for this great work!
Considering the + AUX CHARGE PORT, from the diagram (orange wires), it seems that it is directly connected to the + of the battery (via a fuse JLLN100).
But in the legend the orange wires are labelled "battery + contactor". Where is the contactor ?
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The contactor is inside the pack connector housing and is controlled by the BMS circuit board in the pack. So power to or from the aux charge port only connects to the battery itself when the MBB and BMS processors together decide to close the contactor. That involves CAN bus communication triggered by the key switch and/or the onboard charger.
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OK. I did not realize that the contactors where inside the battery packs.
But this raises another question. I thought that the contactor was the piece that makes a loud click when we start charging, or key the bike,... I have a FXS with 2 batteries. If there is one contactor in each battery pack, why do I never hear 2 clicks ?
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I do hear two clicks on my FX, but they are sometimes so close together that they sound like one. I've had broken connectors and used my ears to reassure me that both packs are on. You'll know they are not if you get half the range or lose power at high speeds. It can also happen that the two packs' SOC are very unequal and that should cause the bike to use only one pack until the SOC's are close enough to be connected together. The harness connects the packs directly in parallel so the voltages need to be close or a large current will flow as they equalize when connected by the contactors.
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OK, I just tried to key the bike ON and OFF several times and listen more closely to the clicks. Difficult to hear 2 clicks. They are probably very well synchronized!
My 2 packs have always worked together. They should have the same voltage. The bike works fine and has a pretty good range, meaning that both batteries work fine.
Thanks !
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Do you know if this diagram will work for an 18 SR?
I need to rewire my kickstand, but have been unsuccessful. If this doesn't work, do you know of a resource to find the proper wiring diagram?
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I have a FX14 and on a mission of building a replacement dashboard since mine has had gone bad...
I tried to compare my dashboard wiring to the diagram and found that the wire colors and numbering are not the same, it thought it would be similar except for the ABS light but it doesn't seem to be the case.
How did you figure out which wire does what for the dashboard?
I attaching pictures of the wires on the dashboard and the connector hoping someone might be able to help.
https://photos.app.goo.gl/Ah96GYwGtcZQHPvf9
Thank you so much!
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hi,
was wondering if anyone had mapped the wiring for newer models since these ones were done?
just curious is all and am happy to make a donation for anyone willing to take some time out for this as i want to see what differences, if any, are made between iterations of each generation of bike that is released.
thanks