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Author Topic: Onboard charger failed, bike still thinks it's charging, can't ride  (Read 1351 times)

Auriga

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Re: Onboard charger failed, bike still thinks it's charging, can't ride
« Reply #30 on: May 01, 2021, 08:55:42 AM »

I would not recommend adding more resistors, unless something is not working. I think one of those might be an output, and that follows different rules.

Instead of cutting it off, I'd see if I could find the connector the charge used, crimp a resistor into it(with wire and heatshrink).

Cutting it off would be a giant pain if you ever try to sell it or want to add an onboard charger again(you never know, Zero might release an upgraded charger that plugs in there).
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herculeesjr

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Re: Onboard charger failed, bike still thinks it's charging, can't ride
« Reply #31 on: May 01, 2021, 09:46:29 AM »

I would not recommend adding more resistors, unless something is not working. I think one of those might be an output, and that follows different rules.

Instead of cutting it off, I'd see if I could find the connector the charge used, crimp a resistor into it(with wire and heatshrink).

Cutting it off would be a giant pain if you ever try to sell it or want to add an onboard charger again(you never know, Zero might release an upgraded charger that plugs in there).

No no, I mean I'm getting the Dremel out and cutting the portion of the on-board charger circuit board that has the wiring connector out. I'm not cutting into the bike's wiring harness. That way I have its waterproof connector and can seal the back of it up with something after I solder the resistor to the correct pins.
That way if I ever decide to replace the on-board charger I can just unplug my creation and plug a new charger in.
Since you don't recommend adding a resistor to pin 12 I will hold off for awhile to let the bike go through a few charge cycles to verify no issues randomly pop up. If nothing bad happens with only a resistor on pin 11 and no resistor on pin 12 I'll seal it all up and call it good.
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2017 Zero DS ZF13.0 (Charge Tank, no on-board charger)

herculeesjr

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Re: Onboard charger failed, bike still thinks it's charging, can't ride
« Reply #32 on: May 04, 2021, 03:02:10 AM »

I would not recommend adding more resistors, unless something is not working. I think one of those might be an output, and that follows different rules.

Instead of cutting it off, I'd see if I could find the connector the charge used, crimp a resistor into it(with wire and heatshrink).

Cutting it off would be a giant pain if you ever try to sell it or want to add an onboard charger again(you never know, Zero might release an upgraded charger that plugs in there).
I'm seeing this pop up in the logs whenever the bike is turned on. Which is further leading me to think I'm needing that second resistor installed for the charger enabled pin. Thoughts? The bike runs fine otherwise, just this shows up every time the key is turned on.
Code: [Select]
07006     05/02/2021 14:30:10   INFO:  Enabling External Chg 0 Charger 2   
 07007     05/02/2021 14:30:10   INFO:  Enabling External Chg 1 Charger 3
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2017 Zero DS ZF13.0 (Charge Tank, no on-board charger)

Auriga

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Re: Onboard charger failed, bike still thinks it's charging, can't ride
« Reply #33 on: May 04, 2021, 05:14:28 AM »

I would not recommend adding more resistors, unless something is not working. I think one of those might be an output, and that follows different rules.

Instead of cutting it off, I'd see if I could find the connector the charge used, crimp a resistor into it(with wire and heatshrink).

Cutting it off would be a giant pain if you ever try to sell it or want to add an onboard charger again(you never know, Zero might release an upgraded charger that plugs in there).
I'm seeing this pop up in the logs whenever the bike is turned on. Which is further leading me to think I'm needing that second resistor installed for the charger enabled pin. Thoughts? The bike runs fine otherwise, just this shows up every time the key is turned on.
Code: [Select]
07006     05/02/2021 14:30:10   INFO:  Enabling External Chg 0 Charger 2   
 07007     05/02/2021 14:30:10   INFO:  Enabling External Chg 1 Charger 3

It always says that. You're still good.
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herculeesjr

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Re: Onboard charger failed, bike still thinks it's charging, can't ride
« Reply #34 on: May 22, 2021, 07:01:34 AM »

A possibly final update, I used a Dremel and cut out the connector from the back of the onboard charger, trimmed the pins down, soldered a resistor to it, then weatherproofed it with a hot glue gun.
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2017 Zero DS ZF13.0 (Charge Tank, no on-board charger)

herculeesjr

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Re: Onboard charger failed, bike still thinks it's charging, can't ride
« Reply #35 on: May 22, 2021, 07:02:21 AM »

Second picture with it sealed up, because annoying tiny file size limits.
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2017 Zero DS ZF13.0 (Charge Tank, no on-board charger)
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