2022 Zero DS - Massive CEL fail after first firmware update

Kyle_Fails_Kyle

New member
Hi everyone

New to the forums and trying to decide what to do here. I bought a 2022 DS with 5 miles on it as a daily commuter and loved every second of it until…

Saturday May 29 2022 (approx 18 days of ownership) and roughly 600 miles of driving (I enjoy the bike very much as you can tell) I had a service appointment to check things after the first 500 miles as I’m used to With ICE bikes just to be cautious. Drive belt checked and tightened, tires and brake fluid all good … and a new firmware update.

Drive it home , park it, wake up Sunday and drive to meet friends at the movies, park it again (at this point roughly 20-25 miles driven after firmware update), movie ends and I hop on the bike.

Lights turn on , instrument panel lights up, I push out, and crank the throttle … nothing … check the kick stand all good, still nothing … at this point I’m just thinking I’ve done something dumb and am not thinking straight so I push back into the parking space and get off to look around. Everything looks fine until I really look at the instrument panel (wasn’t my first thought as it just went in for service and was fine).

CEL is on and the Exclamation is flashing, the battery reads zero. Read the manual over the last week so check the error expecting it to be simple cable displacement or something and possible key issue.

7 ERROR CODES FLASH ACROSS THE SCREEN!!!

This is the list of CEL codes : 06, 25, 30, 40, 45, 48, 49

Have the thing towed to the dealer and they are baffled and in need of Zero expert support.

WTH have I gotten into here? Any others with an experience like this? I’m a tried and true ICE rider and have been for years but after test rides galore I just fell in love and have completely mentally just made the switch to this being IT for me moving forward. well at least that was the plan

One very frustrated owner of a 12k dollar bike. I’m not one to complain about cost as I’ve had some big bike buys in the past but this was supposed to be my daily commuter and I cannot be more disappointed so far
 

Justbert

New member
My sympathies for you. I too fell in love with the riding experience on a new 2018 FXS. My issues began on day one and continued on after the only dealer nearby soon dropped Zero. A series of trucking the bike to dealers over 100 miles away (note 200+ miles round trip to drop off and 200+ miles to pick up) only added to my frustration as the issues reoccurred after each dealer's service again and again and again.

Zero corporate customer service will tell you the only resolution is to get the bike to a Zero dealer as they are all trained, qualified and Zero stands by them. When the issue reoccurs and you send Zero the logs, they will say that they are sorry and cannot guarantee the work of independent dealers.

My battery and kill switch issues almost got me killed and Zero never had my back. If your bike is new, I would immediately return it, if necessary via lemon law and spread the word.....buyer beware....Zero does not stand by their products.
 

Ira

New member
Hi everyone

New to the forums and trying to decide what to do here. I bought a 2022 DS with 5 miles on it as a daily commuter and loved every second of it until…

Saturday May 29 2022 (approx 18 days of ownership) and roughly 600 miles of driving (I enjoy the bike very much as you can tell) I had a service appointment to check things after the first 500 miles as I’m used to With ICE bikes just to be cautious. Drive belt checked and tightened, tires and brake fluid all good … and a new firmware update.

Drive it home , park it, wake up Sunday and drive to meet friends at the movies, park it again (at this point roughly 20-25 miles driven after firmware update), movie ends and I hop on the bike.

Lights turn on , instrument panel lights up, I push out, and crank the throttle … nothing … check the kick stand all good, still nothing … at this point I’m just thinking I’ve done something dumb and am not thinking straight so I push back into the parking space and get off to look around. Everything looks fine until I really look at the instrument panel (wasn’t my first thought as it just went in for service and was fine).

CEL is on and the Exclamation is flashing, the battery reads zero. Read the manual over the last week so check the error expecting it to be simple cable displacement or something and possible key issue.

7 ERROR CODES FLASH ACROSS THE SCREEN!!!

This is the list of CEL codes : 06, 25, 30, 40, 45, 48, 49

Have the thing towed to the dealer and they are baffled and in need of Zero expert support.

WTH have I gotten into here? Any others with an experience like this? I’m a tried and true ICE rider and have been for years but after test rides galore I just fell in love and have completely mentally just made the switch to this being IT for me moving forward. well at least that was the plan

One very frustrated owner of a 12k dollar bike. I’m not one to complain about cost as I’ve had some big bike buys in the past but this was supposed to be my daily commuter and I cannot be more disappointed so far
 

Ira

New member
Did you clear the error codes? Do you listen for the "click" before you lift the kickstand and turn the kill switch from off to on?
 

Kyle_Fails_Kyle

New member
Did you clear the error codes? Do you listen for the "click" before you lift the kickstand and turn the kill switch from off to on?
At the dealer now and they are working with zero. Still no definitive answer

kickstand yes

unsure what you mean by clear the codes but no, bike functionality was non existent sans lights and panel. I know with ICE bike you can disconnect the battery to clear a CEL and hope it holds but this tech is beyond my current knowledge base (getting up to speed now) and to be honest even if they somehow disappeared and the bike began working

it would still be in the shop for a diagnostic.
 

Ira

New member
At the dealer now and they are working with zero. Still no definitive answer

kickstand yes

unsure what you mean by clear the codes but no, bike functionality was non existent sans lights and panel. I know with ICE bike you can disconnect the battery to clear a CEL and hope it holds but this tech is beyond my current knowledge base (getting up to speed now) and to be honest even if they somehow disappeared and the bike began working

it would still be in the shop for a diagnostic.
Gotcha the SRS might be different-when you get her back-I was told to charge it too 100% sometimes to make sure all the battery cells are charging-good luck
 

Kyle_Fails_Kyle

New member
BMS replacement needed

I did make it clear to my service department (great group of folks by the way)
That I wanted to know why and they delivered a few answers, one in particular kind of perked my ears up a bit.

So reason for BMS failure was that the bike failed to enter hibernate mode and when the bike was re-engaged (me getting back on to leave the theater) the bike had a critical error trying to figure out what to do next and the BMS decided to call it life , and pass on quietly surrounded by loved ones.

The second thing that stood out here was this:

I was told that although BMS failures are common that replacements are usually a long term fix with no further issues because the replacements are better versions of the stock units.

This raises some interesting questions if true.

One- why not use those in the first place and raise cost of bike to accommodate. Assuming BMS units aren’t cost and distribution killers… I mean they are seemingly replacing these all of the time

Two- if this is a known issue is Zero avoiding recall and rolling the dice that the numbers don’t climb above the acceptable threshold of failure

Estimated time to fix is roughly a week/2 weeks so that sucks… I’m still flipping a mental coin constantly about lemon law and buy back even knowing I may never have another issue

Thoughts from the community here?
 

Ira

New member
BMS replacement needed

I did make it clear to my service department (great group of folks by the way)
That I wanted to know why and they delivered a few answers, one in particular kind of perked my ears up a bit.

So reason for BMS failure was that the bike failed to enter hibernate mode and when the bike was re-engaged (me getting back on to leave the theater) the bike had a critical error trying to figure out what to do next and the BMS decided to call it life , and pass on quietly surrounded by loved ones.

The second thing that stood out here was this:

I was told that although BMS failures are common that replacements are usually a long term fix with no further issues because the replacements are better versions of the stock units.

This raises some interesting questions if true.

One- why not use those in the first place and raise cost of bike to accommodate. Assuming BMS units aren’t cost and distribution killers… I mean they are seemingly replacing these all of the time

Two- if this is a known issue is Zero avoiding recall and rolling the dice that the numbers don’t climb above the acceptable threshold of failure

Estimated time to fix is roughly a week/2 weeks so that sucks… I’m still flipping a mental coin constantly about lemon law and buy back even knowing I may never have another issue

Thoughts from the community here?
IDK but sharing is caring tell us what you decide to go with
 

Jimmy Zero

New member
BMS replacement needed

I did make it clear to my service department (great group of folks by the way)
That I wanted to know why and they delivered a few answers, one in particular kind of perked my ears up a bit.

So reason for BMS failure was that the bike failed to enter hibernate mode and when the bike was re-engaged (me getting back on to leave the theater) the bike had a critical error trying to figure out what to do next and the BMS decided to call it life , and pass on quietly surrounded by loved ones.

The second thing that stood out here was this:

I was told that although BMS failures are common that replacements are usually a long term fix with no further issues because the replacements are better versions of the stock units.

This raises some interesting questions if true.

One- why not use those in the first place and raise cost of bike to accommodate. Assuming BMS units aren’t cost and distribution killers… I mean they are seemingly replacing these all of the time

Two- if this is a known issue is Zero avoiding recall and rolling the dice that the numbers don’t climb above the acceptable threshold of failure

Estimated time to fix is roughly a week/2 weeks so that sucks… I’m still flipping a mental coin constantly about lemon law and buy back even knowing I may never have another issue

Thoughts from the community here?
I have to agree with your sentiment exactly.

why not fit the improved system to prevent failure, and if it is a known issue why not recall and fit the new improved BMS? I gather it's a matter of cost but for a young company here in the UK having consumers wanting to give their bikes up after a short time of ownership, do they not see it is damaging the brand. Invest now and reap the rewards later.

Zero motorcycles are an expensive motorcycle for what they are and should have the best of the best, wether its parts or service.

I am sure having many disgruntled consumers out there really doesnt help them to establish themselves in an expanding market here in the UK and the guys and girls like ourselves who have choosen to invest our hard earned cash into this new tech and brand.

fingers crossed its not to long until its sorted for you and its not a reoccurring issue!
 
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Ira

New member
trying to throttle before that click will do that if you try to ride without clearing the error codes:sick:
 
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