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[Richard230]

Here is the backstory:  About 3 years ago my 2014 Zero S with PT started to not fully charge to 100% on both he dash and app. It would stop charging at 98%.  A year later it had stopped charging at 93% and 113 Volts. That was when I bought my new 2018 S and gave my 2014 S to my daughter.  After riding it for 18 months, the 2014 model would stop charging at 89%.  So I figured that one or more cells were bad and reaching a cutoff voltage faster than the other cells. I just couldn't understand how an electronic device like the charger could fail like that.  I expected it would just stop charging, not just fade away like General MacArthur.    As usual, I was wrong again. 

Anyway, I broke down and brought my daughter a new stock (and updated) Zero charger.  Today, I and my son-in-law, replaced the old charger with the new one (see photo).  The entire process took 2 hours and we consulted NewZeroland's charger removal video, which was very helpful. Removing the charger was easier than reinstalling the new one and its connectors. Re-plugging the Anderson connector was a real hassle and the new charger had, what my son-in-law called, a "choke" box on the cable leading to the AC power plug. The old charger did not have this rubber-covered box.  That was also a bit of a hassle feeding it through the gap in the frame.  It just barely fit.  Fortunately, we had my bike to refer to and was we were able to see how the cable and the box was run between the charger and the back of the frame.  (My son-in-law did most of the work.  It is not really a two-man job and one person can do just about as much as two.)

Anyway, I was completely surprised when we plugged the power cord into the bike and it immediately started charging. (Something that I didn't expect as most of my repairs don't work the first time.    )  I stuck around long enough to see the display reach 100% charge for the first time in years.  The Zero app showed 117 volts, compared with 116 volts of my 2018 model when the display reads 100%.  So there was nothing wrong with the battery pack after over 5 years of operation, the problem was entirely with the charger.  Hopefully the new version will be more reliable. 

[NEW2elec]

Great job I'm glad to hear it's going full power again.

I can't remember did the 2014 have the Meanwell 4 units or had they gone to the single Green Watt yet?

Also by "improved" do you mean it's a completely new unit or the one from the 15MY and up to 2019?

[Richard230]

Great job I'm glad it hear it's going full power again.

I can't remember did the 2014 have the Meanwell 4 units or had they gone to the single Green Watt yet?

Also by "improved" do you mean it's a completely new unit or the one from the 15MY and up to 2019?

My 2014 S, manufactured in December 2013, had a Green Watt model EVC-116-1200. It was exactly like the new charger in the photo,  except for a different model number (increased from 1200 to 1300) and the installation of the "choke" box on the charger's AC plug wire.

[hubert]

Hello, that's exacltly what I fear will happen to me sooner or later. My charger stops between 92 and 95%, but I can get it up 100% with an external charger plugged at the same time. Thinking of an upgraded solution by diginow or so.

[Richard230]

Hello, that's exacltly what I fear will happen to me sooner or later. My charger stops between 92 and 95%, but I can get it up 100% with an external charger plugged at the same time. Thinking of an upgraded solution by diginow or so.

Either one of those ideas is probably a good option.  What I don't understand is what causes a charger to just die a slow death.  Why doesn't it just stop charging, instead of cutting off at a lower and lower voltage?    I expect electronic devices to just stop working, not to slowly give up the ghost. 

[alko]

What did the new charger cost? Im assuming it came from Zero.

[Richard230]

What did the new charger cost? Im assuming it came from Zero.

I bought it from AF1. It cost $800 and it is a stock Zero charger. It was an exact replacement for the original charger, just an updated model that hopefully will be more reliable than the original device. I figured it wasn't a bad price, compared with other charger solutions, as the bike's BMS seems happy to have it onboard. 

[alko]

What did the new charger cost? Im assuming it came from Zero.

I bought it from AF1. It cost $800 and it is a stock Zero charger. It was an exact replacement for the original charger, just an updated model that hopefully will be more reliable than the original device. I figured it wasn't a bad price, compared with other charger solutions, as the bike's BMS seems happy to have it onboard. 

Seems reasonable. That good to know. Good luck