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Messages - zero jim

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Zero Motorcycles Forum | 2012 and older / Re: 2011 zero ds upgrade to sur Ron battery help

« on: February 11, 2022, 12:50:34 AM »

Side view
Anderson connector for bike side
6 gauge wire nickle plated small strands flexible
Supra x connectors for sur ron battery
Pro D6 supra X 8-10 gauge
Part number 201120234309.9
Ebay, audio shop for wire

Zero Motorcycles Forum | 2012 and older / Re: 2010 S Would not charge and brake repair

« on: February 11, 2022, 12:32:15 AM »

Up date update on the brakes.

I did manage to find a kit for the Hayes master cylinder and rebuilt it for the back brakes.

For the front brakes I went with mountain bike brakes from Magura,
the MT5E (and MT7E) have a brake light connector, it seems to work fine and is expensive $130 but it includes brake master, brake line and caliper with pads so not terrible either.
I bought a wire with two of the plugs for $20 to connect it.

You will need a bleeder kit if your are bleeding the brake system out. Magura uses mineral oil
Hayes used dot brake fluid

if I could have waited there were some clones at about half the price

Zero Motorcycles Forum | 2012 and older / 2011 zero ds upgrade to sur Ron battery help

« on: February 11, 2022, 12:25:00 AM »

I have a 2011 with low battery everything else seems to be working fine.
The range is something like 12 miles and little groan heard from controller when under load.

I bought a sur ron X battery to replace the original zero battery.
and slowly gathering sur Ron parts (motor controller harness) since most of the parts for these older zeros are not available and not supported.

For now I have the battery installed diagonally in the original location with connection at the right rear.'

Last night I started the connection process *(not working yet) and did not short anything out.

With the original battery installed and BMS connected-when you power on the bike, there's a short voltage of 58v think it's to charge the controller then it drops to about 9v. The 9v is for the throttle from what I have read.

I read somewhere on a forum that a guy simulated the throttle power with a 9v battery. I tried this with a fuse but it did not work.
It gave an error message and no response. I also tried with a fuse the full 60v to the two wires and no reaction but flashing code think was 8 flashes which is "throttle response from bus inactive"

Fortunately my lizard brain did not burn up the motherboard which is no longer available. I reconnected the original battery/bms and works except of course with it's low battery.

I'm thinking of making a timed circuit to simulate the original BMS.
It would first give the 60v then drops to 9v after 2 seconds. I would use the power on to enable it.
timing module with one relay terminal NO timed for the 60v for 2 seconds and one NC to buck converter power supply the 9v to throttle.
seems like allot but might work.

Gosh if there's an easier way to bypass this let me know. My other option is buying the molicels online and rebuilding the original zero one battery pack which I really didn't want to do since the rest of the components are super obsolete.

will try to post some pictures later

Zero Motorcycles Forum | 2012 and older / 2010 S Would not charge and brake repair

« on: November 16, 2021, 11:02:08 PM »

Hi all, second post Just got a 2010 S and fixing it up.

The previous owner had it stored and did not leave the charger on so it had a low battery and would not charge.
Turned on and 6 flashes on power light.

I read 20v at the big plug on the battery box, charger just showed AC but not charging.
disconnected the charger then used a high voltage low current (0-400MA) power supply to get the battery up to about 38V then connected the charger.
The charger then showed it at the "high bars" solid charging on battery charger.

I may need to refurbish the battery pack later as the previous owner said the range was about 15 miles.

Brakes-
Searched the forms did not see much on my antique bike.
This bike has mountain bike hydraulic masters and calipers. They are Hayes super strokers.

My bike has both front and rear brakes on the handle bars.
There are lever microswitches for brake lights mounted on the master cylinders.
The calipers I think are both four piston.

One master cylinder needed rebuilding and the parts are still available for the piston and the seals about $20-22 online
I also found a spare master cylinder body online $38 prices are high, would rather replace the whole front brake master brake line and caliper but wanted to keep brake light as this is dual sport.

The front caliper I found last night was seeping fluid so will need a kit, probably replace the brake line too.

I guess my question is are there any bolt on newer model brakes that will bolt on the 201 Zero without too much modification?

Thanks J

Zero Motorcycles Forum | 2012 and older / Re: 2011 Zero S no throttle response

« on: November 16, 2021, 10:41:03 PM »

Not sure if someone did not mention it, but the 2010 S BMS has a small white plug that locks out the throttle.
I just read this last night while working on mine.
Hope this helps