ElectricMotorcycleForum.com
Makes And Models => Zero Motorcycles Forum | 2013+ => Topic started by: Lj66 on April 10, 2017, 04:25:42 AM
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Front brake not switching on brake light even though rear brake did. Decided to investigate even though bike 5 months old and dealer could have done it. Opened wiring loom and traced
white/red wire from rear brake switch to where it joins white/red from front brake switch. It joins a 3rd wire that goes to light the actual brake warning light, all just crimped or soldered together, covered with heatshrink, pressing it brought back the front brake function, i think it's a dry solder joint or badly crimped. I'm going to open the heatshrink and re-solder, hopefully that will cure it, it's a dangerous fault on an electric bike when braking, as there is not even decreasing engine noise to alert a following vehicle you are slowing.
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Nice detective work! Let us know how it goes.
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Take some pictures please.
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Good to know this, thanks!
"there is not even decreasing engine noise to alert a following vehicle you are slowing"
However, this works only with one specific brand of ICE bikes :-)
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Tracked down this fault to the front brake lever micro switch. The rubber dirt and moisture seal around the push button was constricting movement, making the contacts after a few seconds instead of instantly. Not what you want in a switch as slow separation leads to arcing and oxidation on the contact surfaces which is what i found. The switch can be taken apart as the top part clips on to the body that has the mechanism, cleaned it with contact cleaning strips (never use abrasive paper or scrapers) you can use leather for this as well.
Take extreme care when the top is unclipped as the contact is only held by a spring and it's murder to get it back in place, it's so small. It appears that a standard sub minature micro switch is a direct replacement as the mounting holes and push button location match. Its all back working fast now minus most of the seal that was causing the slow down. Incidently the loom wiring connections are sound, Zero have done a quality job on that score.
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Tracked down this fault to the front brake lever micro switch. The rubber dirt and moisture seal around the push button was constricting movement, making the contacts after a few seconds instead of instantly. Not what you want in a switch as slow separation leads to arcing and oxidation on the contact surfaces which is what i found. The switch can be taken apart as the top part clips on to the body that has the mechanism, cleaned it with contact cleaning strips (never use abrasive paper or scrapers) you can use leather for this as well.
Take extreme care when the top is unclipped as the contact is only held by a spring and it's murder to get it back in place, it's so small. It appears that a standard sub minature micro switch is a direct replacement as the mounting holes and push button location match. Its all back working fast now minus most of the seal that was causing the slow down. Incidently the loom wiring connections are sound, Zero have done a quality job on that score.
Can you provide any illustrative photos? This seems worth documenting.
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Had the same problem with my 2014 FX, the micro switch is a generic one and cost
less than 10$...
Better change it then mess with all small parts inside :)
Regards,
Eran