2012 Zero X with no battery

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mcintyretj   100 W

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2012 Zero X with no battery

Post by mcintyretj » Jun 21 2022 3:42pm

Saw a street legal 2012 Zero X with no battery on Craig's List for $895 and thought it would make a good project. From what I read, the original battery was a 14s, 3 kw pack. Not sure this is correct. I hooked up one of my 15s batteries charged to 58 volts and all the 12v electronics (lights, display) seem to work just fine. The controller and motor look to be in good condition. I have seen some YouTube videos where the the original battery was replace and the BMS unit was bypassed so I know it can be done. Looking for more information and possibly a wire diagram for the 8 pin connector (to the BMS?). I have 4.2Kw of 15s batteries to do a test run but plan to build a 4.5 kw (14s?) battery. Here are some photos:
2012 Zero X.jpg
2012 Zero X.jpg (198.51 KiB) Viewed 789 times
zero w 1.5 kw 15s battery.jpg
zero w 1.5 kw 15s battery.jpg (237.07 KiB) Viewed 789 times
zero display on.jpg
zero display on.jpg (93.95 KiB) Viewed 789 times
zero controller and contactor.jpg
zero controller and contactor.jpg (188.13 KiB) Viewed 789 times
zero controller info.jpg
zero controller info.jpg (59.61 KiB) Viewed 789 times
zero motor.jpg
zero motor.jpg (242.26 KiB) Viewed 789 times
120 amp connector.jpg
120 amp connector.jpg (269.48 KiB) Viewed 789 times
8 pin connector.jpg
8 pin connector.jpg (54.4 KiB) Viewed 789 times

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liveforphysics   100 GW

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Re: 2012 Zero X with no battery

Post by liveforphysics » Jun 21 2022 3:47pm

Interfacing with that 8pin would require a bunch of work, as its meant to carry the coms data from the BMS to the vehicle controller computer.

I don't think its worth messing with if the battery you're going to power it with has its own BMS. That motor controller isn't hard to make run.
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mcintyretj   100 W

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Re: 2012 Zero X with no battery

Post by mcintyretj » Jun 26 2022 10:33pm

Thanks for the encouragement Luke. I was able to get the controller, motor, and throttle to work. I do not have garage so I work at the bottom of my condo stairs and push the bike out to a carport at night. Here is my first test without the throttle bypassed.

[youtube]https://www.youtube.com/watch?v=PaXwgIack0g[/youtube]

There is a lot of information about the ALLTRAX AXE7245 controller on line. Just needed to connect the battery positive to the key switch (+57v), the throttle blue/white and white wires direct from the throttle cable to the 2 controller inputs. I used a small 24v battery to activate the relay (this used to turn on when I turned the key), but, I think I can just connect the battery negative to the right side of the relay. Here are the controller inputs and throttle wires.
controller inputs.jpg
controller inputs.jpg (68.58 KiB) Viewed 671 times
throttle wires.jpg
throttle wires.jpg (107.7 KiB) Viewed 671 times
throttle- only WhiteBlue and White wires connected.jpg
throttle- only WhiteBlue and White wires connected.jpg (71.48 KiB) Viewed 671 times

The relay below is rated for 200 amps and and a maximum of 30 volts to activate. I think there is a resistor that drops the voltage to allow the battery minus to be attached to the right side but am not sure.
200a relay 24v coil.jpg
200a relay 24v coil.jpg (87.92 KiB) Viewed 671 times

Tomorrow I plan to bungee my 3, 15s batteries (4 KW total) and go for a test run.
4kw of 15s batteries.jpg
4kw of 15s batteries.jpg (229 KiB) Viewed 671 times

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skeetab5780   100 MW

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Re: 2012 Zero X with no battery

Post by skeetab5780 » Jun 27 2022 6:05am

Nice score on the Zero with no Batt, every time I see them pop up online they are across the country from me!

Are those 15s batteries Kuberg Freerider batteries? Looks the shape lol

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mcintyretj   100 W

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Re: 2012 Zero X with no battery

Post by mcintyretj » Jun 27 2022 9:30pm

Today I loaded up the Zero with 3, 15s ebike batteries. This is about 4 KW of battery. My first run, I hit 45 mph on about 3/4 throttle. After that, I could only get the bike up to 35 mph. I figured that I had blown a fuse. I continued riding around the neighborhood for another mile at 25 mph. When I checked later, 2 of the three battery fuses had blown. I was still stoked with hitting 45 mph.

The battery box dimensions are 15"x 10"x 7" but it can be easily extended to 15"x 12"x 7 or even wider. My question is what voltage battery should I build? Should I stay with 14s or go 15s, 16s or 18s? I would like more speed (for PCH) but the Zero was put together by some people that know what they are doing, and, I do not. I plan to visit the scrap metal store and get some aluminum and start working on a battery box. I am thinking 540 Samsung 30q cells (15s x 36p). I am open to ideas for a battery for this bike.
Zero with batteries bungeed on.jpg
Zero with batteries bungeed on.jpg (141.77 KiB) Viewed 627 times
blown 40 amp fuse.jpg
blown 40 amp fuse.jpg (84.56 KiB) Viewed 627 times
blown 30 amp fuse.jpg
blown 30 amp fuse.jpg (39.61 KiB) Viewed 627 times

mcintyretj   100 W

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Re: 2012 Zero X with no battery

Post by mcintyretj » Nov 04 2022 2:10pm

Update 11/4/2022

Final finished a battery and got out for a ride. This bike is a blast! I just did short spurts in the neighborhood but was able to hit 52 mph a few times. Here are some screen shots:
battery with top.jpg
battery with top.jpg (126.25 KiB) Viewed 249 times
bike with battery.jpg
bike with battery.jpg (130.72 KiB) Viewed 249 times
50 mph screen shot.jpg
50 mph screen shot.jpg (264.86 KiB) Viewed 249 times
2012 zero ride 11-3-2022.jpg
2012 zero ride 11-3-2022.jpg (63.68 KiB) Viewed 249 times

So far all I have done is connect the throttle directly to the controller (with 60v plus). Also, while trying to figure out the wiring, I shorted out the 12v system. It now is on when I plug in the battery (with no key). In addition, I broke the 200 Amp, 24v activated relay which I replaced with a the same 200 amp relay but 60v activation. Now I have to route the key, shutoff switch along with the 12v system and the relay and get this bike to the DMV. They have to view the Vin to complete the registration. Any wiring tips or help are welcome. I have been dreaming about riding and owning this bike for a few years.


For those interested, here are some details on the battery build.

After looking at larger used cells like the Nissan Leaf, Chevy Volt and Toyota Prius. I decided to go with Samsung 25r cells and ordered 500 cells from Dhgate delivered for $1250.00 The final pack is a 30p,14s. On paper it is about 3.8KW. The 14 7/8" x 10" x 6 3/4" battery space is a challenge. Here are some photos:

5s battery section.jpg
5s battery section.jpg (147.31 KiB) Viewed 249 times
battery box.jpg
battery box.jpg (104.51 KiB) Viewed 249 times
battery box in bike.jpg
battery box in bike.jpg (107.86 KiB) Viewed 249 times
starting on the 30p, 14s battery.jpg
starting on the 30p, 14s battery.jpg (127.75 KiB) Viewed 249 times
5s section.jpg
5s section.jpg (169.78 KiB) Viewed 249 times
battery sections in box.jpg
battery sections in box.jpg (136.67 KiB) Viewed 249 times
connecting sections together.jpg
connecting sections together.jpg (135.1 KiB) Viewed 249 times
ground strap and copper pipe busbar.jpg
ground strap and copper pipe busbar.jpg (114.11 KiB) Viewed 249 times
adding BMS.jpg
adding BMS.jpg (195.13 KiB) Viewed 249 times
Now I need to figure out how the wire this bike. I am a novice at this and have already messed up creating sparks and shorts. Any advice is welcome. Here is where all the wires meet. Thanks for all the help!

wire connection.jpg
wire connection.jpg (259.53 KiB) Viewed 249 times

mcintyretj   100 W

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Re: 2012 Zero X with no battery

Post by mcintyretj » Nov 23 2022 7:43pm

Update 11/23/2022

Got the Zero to the DMV for an inspection (Vin and Motor number check). Had to take off the bottom panel so the DMV official could view the motor number.
Zero getting inspected at the DMV-VIN and motor number.jpg
Zero getting inspected at the DMV-VIN and motor number.jpg (148.41 KiB) Viewed 134 times
Since then, I have about 200 miles, mostly around town with some short road trips. My longest trip is 25 miles. Top speed starts to drop along with the battery voltage and I was topping out at 45 mph after 20 miles.

Also, since I live in a 2nd floor condo, I have been parking the bike under the stairs and charging at night. This is in violation of our HOA rules but my neighbors are are fine with it, so far. I just need to run an extension chord out the front door and down the stairs. I also rent part of a car port and tested out my Harbor Freight solar panel straight to battery. This work fine but is less than 100 watts. There is no place to plug in near the car ports. I would put the panels on the roof if I was the owner.

charging at home.jpg
charging at home.jpg (148.55 KiB) Viewed 134 times
solor charging with w a harborfreight 100 watt 4 pannel system.jpg
solor charging with w a harborfreight 100 watt 4 pannel system.jpg (136.9 KiB) Viewed 134 times

Still working out my onboard charging setup. I picked up a J1772 adapter on Ebay and have been using a pair of Meanwell HLG-320H-54A set to 58.8 volts and Max Amps.

J1772 to meanwell 240v adapter.jpg
J1772 to meanwell 240v adapter.jpg (102.99 KiB) Viewed 134 times
charging on the road.jpg
charging on the road.jpg (159.03 KiB) Viewed 134 times
charging with paralleled meanwell HLG 320H 54A power supplies.jpg
charging with paralleled meanwell HLG 320H 54A power supplies.jpg (219.09 KiB) Viewed 134 times



My plan is to mount these MeanWells on the bottom of the frame and the plug under the back of the seat. Then pick up a MeanWell NPP 1200 that I could throw in a backpack on road trips to get 1.8KW of charging. Each can do 120vac or 240vac. If you know of a better charger setup, let me know.


Meanwell NPP 1200.jpg
Meanwell NPP 1200.jpg (63.58 KiB) Viewed 134 times

Wattster   1 mW

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Re: 2012 Zero X with no battery

Post by Wattster » Nov 24 2022 8:15am

Very cool! Thanks for sharing!!!

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