Zero FX FXS FXE Swingarm Compartment Covers

prusaprinters

<h4>Changelog</h4><figure class="table"><table><tbody><tr><td>2022-08-23</td><td style="width:70px;">v1.01</td><td>increased infill and perimeters for all caps</td></tr><tr><td style="width:110px;">2022-08-21</td><td style="width:70px;">v1.0</td><td>initial public release</td></tr></tbody></table></figure><h4>Unused space in Zero Motorcycles XMX swingarm?&nbsp;</h4><p>Create sealed storage space for warning vests, emergency candy, charging cable, tools, …</p><p>Optional feature: graphics to show basic maintenance information:</p><ul><li>Tyre inflation front and rear&nbsp;<ul><li>for both, road- and&nbsp;</li><li>off-road tyres.&nbsp;</li></ul></li><li>Belt tension limits for both, Krikit load or Gates app frequency measurement.</li></ul><p>I have mounted the tyre inflation values to the right side, as this is where I approach when the motorcycle rests on its kick stand. Belt tension limits for the left side, as its measured there.&nbsp;</p><p>The maintenance values are from the 2022 FX/FXS/FXE manual. <a href="https://www.zeromotorcycles.com/en-gb/owner-resources">Please check</a> if they are valid for your model.</p><h4>Choice &amp; file prefixes</h4><figure class="table"><table><tbody><tr><td><figure class="image"><img src="https://media.printables.com/media/prints/261018/rich_content/86c046bb-eb4c-4015-8730-203d3fdd10bb/a.png#%7B%22uuid%22%3A%221e5c48f9-09b7-458d-8c09-68e3ad3606e5%22%2C%22w%22%3A640%2C%22h%22%3A633%7D"></figure></td><td><figure class="image"><img src="https://media.printables.com/media/prints/261018/rich_content/440f0900-2ddb-41a4-b1e3-e09683fe7a32/b.png#%7B%22uuid%22%3A%227b103cbe-f165-4c7a-b25f-5e22cfd8e4ee%22%2C%22w%22%3A639%2C%22h%22%3A633%7D"></figure></td><td><figure class="image"><img src="https://media.printables.com/media/prints/261018/rich_content/ede11165-6124-4165-96a5-174b6d923bac/c.png#%7B%22uuid%22%3A%22462045d6-1d3d-4450-92ed-10fc7b2600fd%22%2C%22w%22%3A639%2C%22h%22%3A633%7D"></figure></td><td><figure class="image"><img src="https://media.printables.com/media/prints/261018/rich_content/d146895a-d4ec-45a1-b99e-42c798063b29/d.png#%7B%22uuid%22%3A%224db347a5-c1aa-44c5-8b0d-8daf5e1f991e%22%2C%22w%22%3A638%2C%22h%22%3A633%7D"></figure></td></tr><tr><td style="background-color:#f9cd4218;text-align:center;"><strong>A</strong></td><td style="background-color:#40C8E818;text-align:center;"><strong>B</strong></td><td style="background-color:#65C90018;text-align:center;"><strong>C</strong></td><td style="background-color:#E8404018;text-align:center;"><strong>D</strong></td></tr></tbody></table></figure><figure class="table" style="width:380px;"><table style="border-style:groove;"><tbody><tr><td>cap type</td><td style="text-align:center;"><strong>FX</strong></td><td style="text-align:center;"><strong>FXS</strong></td><td style="text-align:center;"><strong>FXE</strong></td></tr><tr><td><strong>plain</strong></td><td style="background-color:#f9cd4218;text-align:center;">A</td><td style="background-color:#f9cd4218;text-align:center;">A</td><td style="background-color:#f9cd4218;text-align:center;">A</td></tr><tr><td><strong>belt tension</strong></td><td style="background-color:#40C8E818;text-align:center;">B</td><td style="background-color:#40C8E818;text-align:center;">B</td><td style="background-color:#40C8E818;text-align:center;">B</td></tr><tr><td><strong>tyre inflation</strong></td><td style="background-color:#65C90018;text-align:center;">C</td><td style="background-color:#E8404018;text-align:center;">D</td><td style="background-color:#E8404018;text-align:center;">D</td></tr><tr><td style="text-align:center;" colspan="4">all cap variants use the same gasket</td></tr><tr><td>gasket</td><td style="background-color:#F5F5F5;text-align:center;">G</td><td style="background-color:#F5F5F5;text-align:center;">G</td><td style="background-color:#F5F5F5;text-align:center;">G</td></tr></tbody></table></figure><h4>Fit</h4><p>I have printed two dozens of variants during development of the caps. I had them too lose, and I also had variants that I needed to destroy to get them off again. The ones published here are ideal on my bike!</p><p>Dimensions are vital to the function of the gasket; sealing, and most important: holding force.</p><p>There may be some tolerances in the production of the swingarms. I have designed them to fit vertical height= 75mm/2.95" and horizontal width= 75.6mm/2.98"</p><p>It is unknown to me how stable these dimensions are through ZMC's pipe forming and welding processes. You may measure your bike's openings before, and scale the prints accordingly.&nbsp;</p><p>I recommend to print one side first, and see if the holding force is right for you; adjust the next print if necessary.</p><h4>Production</h4><h5>&nbsp;plain &amp; graphics type</h5><p>Each cover consists of the plug and the gasket. I have printed the plug in ASA, and the gasket in TPU. Should print fine with a 0.40mm nozzle. Cap's 3mf-files have settings for ASA, and also shrinkage compensation (100.65%) for the filament I used. Remember to adjust to your filament choice.</p><h5>&nbsp;graphics type</h5><p>The graphics look better printed with a 0.25mm nozzle. The files contain the settings for manual colour change: all you have to do is change the filament between housing and graphics colour when the printer asks you to.</p><h5>&nbsp;gasket</h5><p>The gasket needs to be printed with FLEX material. I used TPU to have it elastic enough to mount it on the cap and to squeeze it into the compartment.</p><h4>Assembly</h4><p>The gasket is directional - it needs to be assembled with the smaller sealing lip in direction of the bottom.</p><figure class="image"><img src="https://media.printables.com/media/prints/261018/rich_content/e5e087e4-6578-4462-b4dd-22224b8c8ab7/gasket_x-sec.png#%7B%22uuid%22%3A%2248723720-b031-47c7-9c46-5aec257ffc21%22%2C%22w%22%3A914%2C%22h%22%3A286%7D"></figure><p>It's a tight fit, and not supposed to come off the cover after assembly.</p><h4>Development</h4><p>Please feed back in the comments, and share your makes!</p>