Kickstand Switch Replacement

From Unofficial Zero Manual
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This removes and replaces the kickstand sensor switch.


Warning Warning:
Kickstand Sensor Electrical Equipment Hazard
The connector is three pronged and needs to be connected correctly or can damage the MBB irreparably.
Do not disconnect or reconnect while the vehicle is keyed on or contactor is shut to be safe.
Do not short any wires together to bypass.
This is a Hall effect sensor usually containing or using sensitive measurement IC's and therefore not a simple switch.


Notes
Made using MY2016 SR, should apply to 2014+ S/SR and probably DS/DSR
Parts
  • HALL SENSOR SIDESTAND SWITCH ZERO P/N 45-02413-01 for ~$30 USD
    It looks like an Asahi Denso CE122 sensor used on some KTM bikes.
    Ensure it has a blue, pinkish red, and a black wire
Tools
  • 2.5mm Allen key (for switch)
  • 3mm Allen key (for battery side cover)
  • Side cutters for zip ties
  • Long slender fingers to reach connector
Steps
Removal
  1. Ensure bike is powered off and contactor de-energized.
  2. Remove the three 3mm hex bit fasteners with plastic washers holding the left-hand plastic battery side cover on.
  3. Using a fine slotted head screwdriver, remove both upper and lower "bite clamps" on sheet metal on left side of battery.
  4. Cut zip ties attached to the bite clamps.
  5. Unfasten both 2.5mm hex bit fasteners securing old switch.
  6. Disconnect the old 3 wire switch's connector located above half-circle cutout on left side of battery.
    It has a white triangular female housing.
    It helps to lay on one's side and reach up along the battery wire management area/tray.
    Use one finger (left hand) to hold white, bike-side mating connector in place and take note of the side of the triangle containing the clip.
    It helps A LOT to push both sides of connector together before depressing retaining clip or pulling connector out.
Replacement
  1. Connect 3 wire weatherproof connector to sensor connector.
    Take note of which side of the triangle connector for the new switch has the clip.
    Full-seating makes an audible click.
  2. Replace zip ties on the cable management bite clamps.
  3. Route the switch cable the same way (above frame cross member to not encounter as much road debris).
  4. Clean the switch mount of debris.
  5. Carefully hand-tighten fasteners in and out to clean threads and get a feel for not-cross threading them.
  6. Fasten the side switch in with both 2.5mm hex bit fasteners.
    It's a countersunk plastic housing, and soft aluminum mount.
    Don't over-torque!
  7. Ensure there is no strain on cable especially where it joins the sensor housing.
    This is a common place for it to break.
    You may want to place extra heatshrink insulation here to protect.
  8. Replace side cover.
    Do not over-torque or cross thread.
Left-over parts
  • The old sensor.