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[erensi]

 Hi everyone, I have not been on this forum for a while because I've been busy but I finally want to get around to this project.

I bought a used 2016 SR w/ power tank almost two years ago and a few months after I got it the lights, turn-signals, etc (12V circuit) started randomly not working after I changed out an old aftermarket LED that seemed to be malfunctioning, with a new fan-less LED.    Then I got really busy and didn't have time to do anything with it.   So I have been riding this bike with no lights or turn signals for over a year now.   I avoid riding at night but I carry a flashlight in case I'm out when it gets dark.   Sometimes the 12V circuit and lights will spontaneously turn on for a few minutes every now and then, but it's not reliable at all.   Also the ABS is on the 12V as well so I have no anti-lock brakes either.

At this point I am pretty sure the problem is a faulty DC-DC converter.   I have worked on ICE motorcycles before but high-voltage electronics is unfamiliar to me.  Is there anyone in the area who'd be willing to meet up with me at MotoGuild (https://www.motoguild-sf.com) and assist me with this project?  I would also like to make a mod to allow for an always-on 12V dc socket.  I've read in the manual that this would be where to put it.   I am not rich but I can pay you $100 + beer/food for your time.  I don't want to take this bike to the shop and leave it there for weeks.  I think this can be done in an hour or two.  All the tools and everything are there.  All you'd need to bring is experience and knowledge.  Thanks in advance and DM me if you want to do it some time in the next few weeks.  Thanks!

Efrem



   

[MVetter]

I am somewhat local, I am quite familiar with the DC-DC converter on these bikes, and I like beer. UNFORTUNATELY I have sworn never to dig into the godforsaken piece of garbage bracket that houses the DC-DC on that bike again. The last time I had to do it I ended up disconnecting all of the leads on the controller just to get to the damn thing and its impossibly angled allen screws. Whoever designed the bracket that holds the MBB and DC-DC should be taken out back and beaten for an extended amount of time.

This thread does, however, afford me an opportunity to see if anyone else remembers: a year or two ago on either this board or one of the FaceBook groups, a user posted pictures and video of a replacement/alternative for the stock SevCon DC-DC that was a.) cheaper and b.) more robust. Does *anyone* else remember who did this and where that thread is? A friend of mine's 2014 SR has a failing DC-DC and I don't want him to have to buy another crappy SevCon unit.

[Richard230]

I had the same experience when replacing my DC-DC converter. My son-in-law had to help me and it was a miserable job. While we were able to remove the defective part, we could never get the converter back the way it originally was. I still have about 8 bolts sitting around that we could not get screwed in again. Eventually, we just hooked up the new converter and jammed it into the rat's next of wiring. So far that is still working and I figure that the converter is secure and cushioned in the middle of the nest. 

Here is my write-up regarding my struggle replacing the DC-DC converter. It is a mystery to me why it could not have been installed under the seat at the rear of the chassis, instead of where the sun don't shine.    https://www.electricmotorcycleforum.com/boards/index.php?topic=11689.0

[MVetter]

I had the same experience when replacing my DC-DC converter. My son-in-law had to help me and it was a miserable job. While we were able to remove the defective part, we could never get the converter back the way it originally was. I still have about 8 bolts sitting around that we could not get screwed in again. Eventually, we just hooked up the new converter and jammed it into the rat's next of wiring. So far that is still working and I figure that the converter is secure and cushioned in the middle of the nest. 

That's absolutely the correct solution. If you can manage to get the bracket out, melt it down and send it back to hell. Just shove the MBB and new DC-DC back into the rat's nest. They'll be fine.

[erensi]

I had the same experience when replacing my DC-DC converter. My son-in-law had to help me and it was a miserable job. While we were able to remove the defective part, we could never get the converter back the way it originally was. I still have about 8 bolts sitting around that we could not get screwed in again. Eventually, we just hooked up the new converter and jammed it into the rat's next of wiring. So far that is still working and I figure that the converter is secure and cushioned in the middle of the nest. 

Here is my write-up regarding my struggle replacing the DC-DC converter. It is a mystery to me why it could not have been installed under the seat at the rear of the chassis, instead of where the sun don't shine.    https://www.electricmotorcycleforum.com/boards/index.php?topic=11689.0

Richard, thanks! I checked out your thread.   I guess I'll go ahead and order a new converter. I just found this too, btw. 

@mvetter it looks like the converter you are looking for is one of these: https://www.dmcde.de/index.php?option=com_content&view=category&layout=blog&id=35&Itemid=62

It's in the video I linked above.  The caveat is that you have to swap some connector pin locations.

[MVetter]

Richard, thanks! I checked out your thread.   I guess I'll go ahead and order a new converter. I just found this too, btw. 



@mvetter it looks like the converter you are looking for is one of these: https://www.dmcde.de/index.php?option=com_content&view=category&layout=blog&id=35&Itemid=62

It's in the video I linked above.  The caveat is that you have to swap some connector pin locations.

Dude, great sleuthing! I knew it wasn't Hans but a different European guy. I could not, for the life of me, find it. But for some reason I failed to search YouTube. I am less clever than I thought it would seem.

[Skidz]

Love the fact he included a blooper part at the back