Print

Please login or register.
1 Hour 1 Day 1 Week 1 Month Forever
Login with username, password and session length

[volt]

I got home today, another regular comute, SOC was 9%, plugged into the wall (120VAC @ 60Hz) and boom:

A sound like that of a popcorn machine started inside
Smoke started to flow profusely from somewhere above the motor

As soon as the brain understood what was happening, the power was disconnected and it all stopped.
I tried to turn the bike on to capture logs and everything seems fine, in fact the bike still runs.

I think the rectifier or something related to the AC-to-DC portion of the charging subsystem fried.
Have anybody seen anything like this?

I took the "tank" and seat off just to see if there would be anything obvious on the top of it, but it all looks normal from there. The charging stuff seems to be under that cable mess on top that I'm not willing to play with.

Now I'm afraid to but this back into the garage because of the fire, don't want my house to go down because of Zero.

Thanks!

[TheRan]

The charger is underneath the bike, you need to unbolt the bellypan to get to it but you should be able to see the wires going into it from the rear of the bike.

[DonTom]

I got home today, another regular comute, SOC was 9%, plugged into the wall (120VAC @ 60Hz) and boom:

A sound like that of a popcorn machine started inside
Smoke started to flow profusely from somewhere above the motor

As soon as the brain understood what was happening, the power was disconnected and it all stopped.
I tried to turn the bike on to capture logs and everything seems fine, in fact the bike still runs.

I think the rectifier or something related to the AC-to-DC portion of the charging subsystem fried.
Have anybody seen anything like this?

I took the "tank" and seat off just to see if there would be anything obvious on the top of it, but it all looks normal from there. The charging stuff seems to be under that cable mess on top that I'm not willing to play with.

Now I'm afraid to but this back into the garage because of the fire, don't want my house to go down because of Zero.

Thanks!

Sounds like something shorted out in your OBC (On Board Charger). If you have a Delta-Q charger around, you should still be able to charge the bike that way, just don't use the OBC. The OBC cannot be repaired because of the way it is all sealed up. You will have to replace it.

If you use a Q-charger without the OBC, you will have to key on the bike for the QC to start charging, but it should work.

Several people in this forum have replaced the OBC. It's not all that difficult, but a bit pricey.


-Don-  Reno, NV

[volt]

Thanks for the replies, much appreciated.

Does anybody here has the wiring diagram for the onboard charger?
I'm willing to do this replacement myself, got the part number in hand (45-08253). I'm getting a quote on it today.
May as well just not use it and get a Delta-Q instead, going directly to the battery it should still get me going and for 600 likely the cheapest way out of this situation.

[TEV]

Thanks for the replies, much appreciated.

Does anybody here has the wiring diagram for the onboard charger?
I'm willing to do this replacement myself, got the part number in hand (45-08253). I'm getting a quote on it today.
May as well just not use it and get a Delta-Q instead, going directly to the battery it should still get me going and for 600 likely the cheapest way out of this situation.

Sam will help you with that:

[volt]

Excellent video! That's it!

Looks like there's no need to reprogram anything when replacing the OBC, is that so?
I'm about to order one from the dealer.

[BrianTRice@gmail.com]

You don’t need to reprogram the charger, but because the location of the smoke doesn’t match the location of the charger, you should identify what was damaged before replacing it.

It may have only damaged something between the C14 inlet and the charger on the AC side, or there may be damage on the DC side somehow.

[volt]

Thanks for all the help. Ordered a new OBC through dealer (800 bucks). Besides the OBC itself, all you need is a handful of nylon straps to hold the cables in place.
Bit of a pain to reconnect everything but definitely not the worse maintenance to execute on Zeroes. I was given another one from the same manufacturer (the one with that green logo), same hardware version and all, which is a bummer, there's nothing that makes me believe this new one won't fail again at some point.

[PeuNeu]

Well, I guess it is my turn now. I plugged my 2018 DSR this weekend and got the "pop corn" sound as well as the smoke from the OBC. I will need to contact the dealership in Reno to order the part and replace it.
Thanks for the info on this forum though