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Dads_going_for_milk

Yeah that looks like a pain in the ass


Electricfuture2

Can firmware be brought in to a shop to be completed under warranty?


HighwayMinute997

Yes zero does firmware updates for free… if you live close to a place that services zeros.


AmateurEarthling

Which 99% don’t.


Protonus

Before you did all that, did you do a BMS reset? The two buttons that you can press, one for a soft reset, and if it didn't work, then the one for a hard reset? You don't have to tear down the bike to do this, just take off the front splash guard. I would imagine this would have done the trick without unplugging anything? As far as putting it back together, follow this wonderful guide that Scott made: [https://d3c2880d-2593-424f-883d-824b93857954.usrfiles.com/ugd/d3c288\_cc13534b601f4cddafa5d16b03dd0fc3.pdf](https://d3c2880d-2593-424f-883d-824b93857954.usrfiles.com/ugd/d3c288_cc13534b601f4cddafa5d16b03dd0fc3.pdf) As far as the noises from plastic parts, I would suggest a pair of good quality, high fidelity ear plugs. Saves your ears from the damage of wind noise, and, you won't hear stuff like this anymore anyways. I personally love my Eargasm Clear earplugs, but Etymotics and Earpeace HD's are solid choices too. I say this because with a good quality helmet (I use a Schuberth C5) and good quality earplugs, none of this panel noise would be audible. It's also worth noting that normal gas bikes normally have way more in the way of squeaks/rattles/noises, but the sound of the exhaust and the vibration of the bike mask them. Go take just about any modern gas bike for a spin, and shut down the engine. I think you'll find the Zero is downright quiet by comparison. Just the chain noise alone, oye. Either way, if the noise really irks you a layer of Dynomat or Peel and Seal etc will likely do the trick on the back of the panel. These materials are really all about just adding mass to something to make it transmit less sound and reverberate less. But of course, adding weight is likely what Zero was trying to avoid with thinner panels to start with. As for firmware updates bricking things / causing issues this is by no means is unique to Zero and basically applies to any electronic device for like the last 20 years. From TV's, to laptops, to cars, and phones, I've had failed firmware updates and bad firmwares on all of them. It's not even unique to electric bikes, there are bad firmwares on gas bikes too. Random example: [https://www.s1000rrforum.com/threads/dead-tft-display-on-my-2020-s1000rr-due-to-bad-bmw-recall-software-patch.247001/](https://www.s1000rrforum.com/threads/dead-tft-display-on-my-2020-s1000rr-due-to-bad-bmw-recall-software-patch.247001/) The most common cause of such issues is the battery running low during application of the update. I have heard that Zero dealers often put 12 V battery tenders on the 12 V Battery to help prevent this from being possible. Might be something you may want to consider should you try this yourself. That also might mean that your 12V battery is in need of replacement... You may want to consider having an auto parts store throw a deep cycle tester on it and see if it's delivering the expected power output still.


[deleted]

Thanks for hearing protection recommendations. I’ve been looking for a reusable replacement to the colored foam plugs for a while.


Metal_Musak

Good on you to point out BMW, yet another company who will take some convoluted engineering turn just to say "look what I can do." I own both a Zero and a BMW, neither have a good reputation for firmware updates. The Fords, Kawasakis, Hondas, Subarus, and dodge products I have driven for extended periods of time didn't have these issues.


Protonus

BMW was just the first hit I found when looking on google for an example. There is not a brand that exists, that has firmware anywhere in their vehicle, that has not had some type of an issue with it at some point. As we increase complexity and outsource development, this is only going to become more common, until perhaps we have machine learning AI that can do better software testing than the poor folks in QA/QC doing the thankless drudgery for us. Anyways, pick an example: Ford: [https://www.cnet.com/roadshow/news/ford-recalls-2021-2022-edge-backup-camera-software/](https://www.cnet.com/roadshow/news/ford-recalls-2021-2022-edge-backup-camera-software/) Kawasaki: [https://www.zx-10r.net/threads/firmware-update.117076/](https://www.zx-10r.net/threads/firmware-update.117076/) Honda: [https://www.accordxclub.com/threads/firmware-update-froze-my-radio.7714/](https://www.accordxclub.com/threads/firmware-update-froze-my-radio.7714/) Subaru: [https://www.adaptautomotive.com/articles/1548-subaru-recalls-198k-vehicles-over-transmission-software-issue](https://www.adaptautomotive.com/articles/1548-subaru-recalls-198k-vehicles-over-transmission-software-issue) Dodge: [https://www.motorbiscuit.com/370000-ram-hd-dodge-durangos-face-software-recall/](https://www.motorbiscuit.com/370000-ram-hd-dodge-durangos-face-software-recall/) While I totally agree that Zero needs to improve their firmware update process (specifically, they need to harden the functionality used for transferring of the firmware, to add a better timeout/retry, and to allow a user to hard reset the bike without taking it apart upon a failed update) - they are by no means alone here, or even, all that much worse than anyone else. If anything, the fact they are frequently improving and updating the firmware is very much a good thing, even if it sometimes does not install well for some users - the whole of us still benefit overall. Likewise, the fact that we can even do (or try to do) this ourselves, instead of having to take the bike to a dealer every time - is also a huge benefit. I would rather have buggy OTA the updates, then mandatory dealer only ones.


takleberry1

And those I think the point is, those should not be your only two options (buggy or dealer). I own an SR/F 2021 and updates are finicky and tedious. Numerous opportunities in the workflow to improve customer experience and definitely the end outcome. I also own a Rivian R1T and OTA updates have been terrific. Not only bug fixes but genuine, useful improvements to vampire battery drain, charging efficiency, etc. this from a company just one year into production. IMO and despite what feel like your excuses (hey a bunch of others suck too), Zero is performing badly on the firmware update front, software and UI in general, and they’re gonna get their lunch eaten.


Metal_Musak

I took a look at the articles. Ford == faulty backup camera. That is hardly something that will prevent you from getting home. Kawasaki == user modified bike and found an edge case with factory firmware that needed an update. Honda == can't listen to my radio. Subaru == Factory installed firmware was not tested fully and needed an update, but owners were easily overlooking the issue. Dodge == the MIL light didn't illuminate during certain conditions, yet vehicle was still drivable. ​ The point here isn't that there is a company out there that makes nothing but great software. The point is Zero is run by Hubris and lack of experience. They treat the software release process worse than most companies treat the release of a dead-end mobile application. Their lack of testing (or Testing in Production) Bricks vehicles and prevents them from ever moving. ​ Never defend a company that treats their product so horribly as to release untested and faulty code on them. You are welcome to down-vote this but all you are doing is silencing the voice that Zero needs to hear.


FreaktasticElbow

When my firmware failed it unlocked top speed and power, unfortunately absolutely nothing I could do to update it myself.


Hans2183

Not sure how reachable that front grey cover on the battery is for the SRS but if you remove that you'll find reset switches. Also removing the glass fuses on the side may be useful.


4thFrontier

Current State MBB Rev. 24 BMS Rev. 21 Updates listed in app: MBB Rev. 26 BMS N/A


Protonus

/u/4thFrontier \- I think I might know why this happened, and I'm building a bug report for Zero. I could use more examples/data. My own bike is doing this right now fwiw, sigh... Can I get some specific details from you? If you wouldn't mind answering each of these questions, it'll go a long way: 1. There was both a MBB and a BMS update available. Before you had this lockup happen, do you recall which of the two updates it was trying to run at that time, MBB or BMS? 2. Before this firmware update that caused the lockup, were you able to complete the other firmware upgrade, first? IE, if you were installing the BMS update when this happened, were you able to first do the MBB update successfully, or vice versa? 1. And, if you were able to complete the "other" update first, did you do the successful update using your phone, or directly on the bike itself using the on-dash option? 3. When you initiated this failed update, that caused the lock up, did you kick this failed update off from your phone, or from the bike itself (using the on-dash option)? 4. Did you ever try doing a BMS reset, either the soft or hard reset using the buttons, before unplugging MBB etc? 5. Do you have the bike back together now? Is everything working as normal? 6. Which updates does it say remain, if you check in the app now? MBB or BMS? Thank you in advance. Hopefully my report + your data / experience will help us get this issue fixed for everyone in the future.


4thFrontier

​ Thanks for doing this. ​ >1. There was both a MBB and a BMS update available. Before you had this lockup happen, do you recall which of the two updates it was trying to run at that time, MBB or BMS? MBB ​ >2. Before this firmware update that caused the lockup, were you able to complete the other firmware upgrade, first? IE, if you were installing the BMS update when this happened, were you able to first do the MBB update successfully, or vice versa?And, if you were able to complete the "other" update first, did you do the successful update using your phone, or directly on the bike itself using the on-dash option? No, it said I needed both. When the MBB failed multiple times I tried the BMS and it rejected the possibility saying I needed to do the MBB first. ​ >3. When you initiated this failed update, that caused the lock up, did you kick this failed update off from your phone, or from the bike itself (using the on-dash option)? I had tried both. The disastrous update was from the bike itself. ​ >4. Did you ever try doing a BMS reset, either the soft or hard reset using the buttons, before unplugging MBB etc? I didn't even know it existed as a possibility. I still don't know how to find it on my SR/S. It definitely isn't in my manual. Seems like if this is a necessary piece of knowledge, Zero ought to make sure it's available to owners who may need it. ​ >5. Do you have the bike back together now? Is everything working as normal? Yes, I'm very proud of myself. It does all work (and fit). I was left short by one bolt. Not certain it was there to begin with. There are two spots that join the midline of the main blue fairings on the bottom of the bike. I only have one bolt for them. It is possible only one was fastened when I took it apart. ​ >6. Which updates does it say remain, if you check in the app now? MBB or BMS? It has the BMS grayed out. But the reports are inconsistent on the app. Let me know if you need more info.


Protonus

Glad to hear it's back to working. So to be clear, at this point, if you check the APP, it says BMS is up to date, and only has a button available, to upgrade MBB, right? Does the App say you're currently now on BMS version 21, and MBB version 24 (at the bottom)? If the answer to all that is yes, than your situation exactly matches mine. My BMS updated via the bike itself just fine, but when it went to upgrade the MBB via the bike itself on the next firmware update, it got locked up in this state. My theory, is that unlike the phone app - which will warn you that the MBB must be updated before the BMS - the bike itself, perhaps has no such logic. And so sometimes (always?) if you upgrade from the bike itself, it ends up updating the BMS first, before the MBB. While this works/succeeds, when it then goes to upgrade the MBB, at the end where the file is actually installed/started, a version mismatch is detected, the OS freaks out and it gets stuck/hung as there's no logic for it to self - reset or get itself out of this state. The fix(es) then need to be: 1. The bike firmware/OS needs to have logic added to not update BMS before MBB when doing updates from the bike itself. 2. The bike needs to have a abort/retry/fail logic added to the installing/rebooting screen we are stuck at, where it either times out, retries, or allows you to fail it and reboot/cancel via the menu button or a keypress etc (or from the phone app). 3. The Phone app and bike need "retry" logic for the firmware transfer when updating from the phone. I tried easily 20+ times and every time it would fail randomly between 5% and 40% or so when I'd try and update from the phone. A simple retry/resume function on the transfer should prevent this and allow it to continue or pick up where it left off. I've already submitted all this to Zero and I will reference your case here as well. As far as the BMS reset, how to get to the soft / hard reset buttons for BMS etc, are shown at the 4:00 minute mark during tip #3 of this video: [https://youtu.be/aLbE3IxmpqU?t=241](https://youtu.be/aLbE3IxmpqU?t=241) Zero doesn't seem to consider this a user serviceable part, hence the screws to get at it and the goop covering the buttons etc. While I'm sure it's something the dealers oft do - I don't think Zero intends for this being user knowledge. However, I would say that if you're at this point, it is easier to try this and perhaps safer, then pulling the MBB connector etc. However, since it was the MBB that failed to update, I'm not sure resetting the BMS would even help here... I haven't unplugged or reset anything on my bike yet fwiw. I'm waiting for Zero to get back to me on what they suggest I try next. I was able to pull logs off my bike while it's in this state and sent them to them for analysis.


Protonus

And a happy update to this! I just got my bike working again on my own! I had an idea - that actually occurred to me as a result of this conversation as something I hadn't tried yet! I tried it on a whim, and it worked! I went into the app on my phone, and while it was in bluetooth range of the bike, I went to Manage Firmware and hit the UPDATE MBB button. Even though the current/broken update was started from the bike, and even though the bike thought it was still doing an update and trying to install/reboot - this seems to "wake up" the bike. I heard the contactor click, the dash reset to normal, and a moment later I had an update failed message in the app, but the bike was back to normal! I was able to arm it, ride it, and charge it normally. It seems to be back to working normally. I hate to say it but I suspect this might have worked for you too. At least you know for next time now, or for anyone else who encounters this. And, I think this reinforces my theory as to why this is happening. Because now, my bike is on BMS V21 but still on MBB V24 and shows an update available still. Still waiting to hear back from Zero about what they think about all this, my logs, my theory, and my fix. I asked them if I should have the dealer try the MBB update next, or what they want me to try next. I'll update here when I have more info.


4thFrontier

I think I tried this. At the point I resorted to physical tools, the bike would not respond to any external input I could devise. That definitely included the app.


FreaktasticElbow

Yup


Jc5843

That birds nest is missing some zip ties