Hi all,
I recently acquired a 2012 Zero DS ZF 9. I'm in the UK.
It seemed fine at first, but it began cutting out on me
Then when I occasionally turned it on, it would just stutter a bit or even try to go in reverse.
Cutting out in traffic was very bad news.
I googled the problem and discovered that it was a known problem, requiring a free firmware upgrade.
I booked in at my local dealers - eventually after non returned emails, I called them up.
My problem had been passed to the most junior Mechanic, who could not connect to the bike to do the firmware upgrade.
After a call to the States, the Mechanic told me "bad news I'm afraid: It has a sensor problem - you need a new motor, £2000"
I was not too pleased to hear this, even less pleased to hear the some parts would have to be sent to Holland for reprogramming... But I would gain a 20% power increase. I asked did I have any other options and got told "you can trade your bike in for a new bike" I am still waiting to hear what the discount is.
I went home and decided that maybe Google was my friend after all, as I discovered that the Zeros had used Lynch motors, then Motenergy motors. My bike had a Motenergy motor. I contacted John Fiorenza at Motenergy and he told me that they had replaced the old error-prone sensor with a new sensor that would probably fix my problem. I would cost me $30 plus shipping. I liked the sound of that - it just made sense. I bought one and when it arrived fitted it myself - having lost faith in dealerships etc.
With some help and advice from John (a great guy) I had the confidence to switch out the old sensor for the new one John sent me - more importantly - it has worked - NO MORE PROBLEMS!
Read on for the step-by-step
Undo the rear brake and pedal
Slacken motor mounts so the belt is loose
Slacken rear wheel.
Jack the bike up so the rear wheel leaves the floor.
Remove the rear wheel.
Remove the rear suspension / shock absorber
Swingarm removal - this is unfortunately necessary...
Locking in place the 24mm nuts on the inside of the swingarm are two 2.5mm allen/hex bolts - remove these both sides.
Using a 24mm wrench/spanner on the inside of the swingarm and a 10mm allen key/wrench, drop the swing arm.
Now the motor has clearance to be moved rearward for access.
Leaving the motor connected, The sensor is mounted under a circular rear cover that is about 3 inches in diameter, held by three phillips head machine screws. Remove this cover, and you may see some white potting compound on the sensor board (or not on older models)
(DO NOT disturb the motor timing by touching the 4 allen bolts!)Dig out the sealant from around the old sensor, if present (newer motors)
remove the 4 screws holding the sensor board and unclip the connecting wire.
Prise out the old sensor. Cleanup the old sealant remains, if present.
Replace with the new sensor - same orientation of course.
Congratulations! the new sensor works by virtue of the quantum effect known as the Giant MagnetoResistance (GMR) effect which earned its discoverers the Nobel Prize in Physics in 2007 - yes, your zero is now a quantum vehicle.
https://en.wikipedia.org/wiki/Giant_magnetoresistanceI'll attempt to upload some pics...
.