Makes And Models > Zero Motorcycles Forum | 2012 and older
2011 XU total rebuild, need batt advice
BrianTRice@gmail.com:
--- Quote from: honey_badger on January 20, 2018, 11:11:44 PM ---Hi ZNRL,
I left everything original (original BMS and original Charger) on the bike except the battery. I had to re-wire the Nissan Leaf battery cells exactly the same way the original zero battery was wired to the bms, so I suggest taking your time marking all the wiring if you change the battery. I am quite happy with the results as bypassing the internal Zero controller or "brain" would have meant more work to rewire everything, more parts to be added and bought, loosing the original display and some safety features.
I would strongly suggest to consider 18650 (or the new standard 20700 if available) cells for an off road bike as you can easily fit them into the original battery box (no engineering/making external or additional battery boxes). I choose Nissan Leaf cells as I live in Canada and I was lucky to find a supplier that would ship the cells to me at reasonable cost. 18650 cells would have doubled my cost for the same capacity but the job would have been cleaner.
--- End quote ---
Word is that 18650 cells have a much lower discharge rate limit that could be exceeded on a Zero. Anyone following this advice should look into the matter carefully.
honey_badger:
--- Quote from: BrianTRice on January 22, 2018, 06:18:49 AM ---
--- Quote from: honey_badger on January 20, 2018, 11:11:44 PM ---Hi ZNRL,
I left everything original (original BMS and original Charger) on the bike except the battery. I had to re-wire the Nissan Leaf battery cells exactly the same way the original zero battery was wired to the bms, so I suggest taking your time marking all the wiring if you change the battery. I am quite happy with the results as bypassing the internal Zero controller or "brain" would have meant more work to rewire everything, more parts to be added and bought, loosing the original display and some safety features.
I would strongly suggest to consider 18650 (or the new standard 20700 if available) cells for an off road bike as you can easily fit them into the original battery box (no engineering/making external or additional battery boxes). I choose Nissan Leaf cells as I live in Canada and I was lucky to find a supplier that would ship the cells to me at reasonable cost. 18650 cells would have doubled my cost for the same capacity but the job would have been cleaner.
--- End quote ---
Word is that 18650 cells have a much lower discharge rate limit that could be exceeded on a Zero. Anyone following this advice should look into the matter carefully.
--- End quote ---
True. When working on a project one should always assemble/engineer according to the requirements for power, torque, capacity, discharge, charge etc... Only a few 18650 cells models will satisfy the specs to withstand the discharge rate of a 2011 zero mx/xu but it's still possible to do. I would have gone that way if I were able to find the right 18650 cells at reasonable price. I should have clarified better on my previous reply. This bike is not my first build/fix/rebuild.
MrDude_1:
What makes you think the leaf modules are hard to wire? they're 2cell modules, with both posts and center-tap easily connected... I use them in my gokart.
Mattbastard:
How many of them leaf cells could you fit in the original aluminum battery box? I've been interested in this, and from the looks of things you made 5 fit (with the other two under the seat).
honey_badger:
--- Quote from: Mattbastard on April 27, 2018, 11:02:55 AM ---How many of them leaf cells could you fit in the original aluminum battery box? I've been interested in this, and from the looks of things you made 5 fit (with the other two under the seat).
--- End quote ---
Five modules in the box but they will not fit in the original one. I had to rebuild the box entirely for the modules to fit. The other two modules are under the seat/above back wheel.
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