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[talon]

Hello all, I was wondering if anyone here had recorded the connector information for the motor controller and on board chargers anywhere for the 2016 (and likely up) Zero's. Specifically S&DS platforms. I need to rebuild the housing and seal for my onboard charging connector (the harness side luckily).

Additionally, I might've posted this before but the Elcon chargers' [terrible (IMO)] typical gray AC input line connector is a "DJ7031-4.8-11" and "*-21" which is commonly referred to as an automotive fan connector used by Toyota Corollas and Camrys (2000s) and in that use case, the non-clone version of it seems to be made by Sumitomo in their TS-187 TS sealed series of connectors.

Here's the part numbers of the "official":
sumitomo TS (TS187) (TIC 6189) 3WF SLD HSG GRAY sealed series 4.8mm
FEMALE:      6189-0165 HOUSING, 8100-0466/0467/0468 FEM_TERMINAL, 7165-0346/0347/0348/0356 SEAL, 7165-0145 PLUG
MALE:      6188-0129 HOUSING, 8100-0463/0464/0465 PIN_TERMINAL, same seals           , same plug

Somewhere I've recorded the connector the kickstand uses when I made my emergency bypass kit that sits in my on-bike toolbox (just in case a kickstand sensor dies and tries to strand me (I have big boots))--I'll try to find it.

http://prd.sws.co.jp/components/en/detail.php?number_s=61890165

[talon]

Looks like I'm walking in the footsteps of others. I couldn't find this initially but trying a different approach yielded GreenWattPowers website with datasheets, which funny enough eventually led me back to the unofficial manual that already had this information.

https://zeromanual.com/wiki/Gen2/Calex_Charger/Connections

The CAN connection for the onboard charger is a JAE MX23A18NF1 wire to board connector.

so JAE MX23A series connectors are used for ECU connections on many motorcycles (Suzuki's?) and apparently equivalent pitch/diam metripack open barrel crimpers will work for wire seal and crimp if you want to avoid the >$300-$4000 OEM connector crimping tool by JAE. Sadly only wire to board and no male wire-to-wire option exists according to my research, so for a DIY harness this would mean soldered connections in a pigtail (not ideal) or small box.

"MX23A series 040 contact 2.5mm pitch, 18 pos, 3A 7A partial on some connectors, only 50 cycles
AVSS AVS partially wire... #22 to 16AWG with 1.6 to 2.2mm insulation diameter #20AWG to #18 w/AVS wire"

male internal pin side (extending latch part):
   full assembly MX23A18NF3 or -NF1 or -NF2
female pin side (orange socket):
   front cap               MX23A18XF1
   seal ring                included in front cap?
   socket housing       MX23A18SF1
   rear grommet        included in hsng?
   rear cover              included in hsng?
   dummy pin            M120-55780
   socket contact 0.5-1.25mm^2   M23S05K351
   socket contact 0.3mm^2      M23S05K4F1
-NF1=standard pin header...
-NF2=reverse pin header....
-SF3 bulk???
-SFG bulk??? reel?

I ordered the 18P and 18S kits from Corsa-Technic, along with some extra socket contacts to verify good crimps.

[talon]

Just so I have it somewhere. In a Sumitomo 3-pin connector I have TWO 4.3kOhm 5% resistors in parallel sealed well in liquid electrical tape between the red and black wires as an emergency kickstand sensor bypass (yellow-blue-red-gold for reference). With the latch facing downwards and the connector (with the socket contacts leading to the sensor) mating surface facing you:  the top is red wire, the bottom left is black. I included this information in the unofficial manual (maybe not the resistor values). These values were picked arbitrarily based on the resistor that is inside the J1772 pigtail supplied by diginow that I used successfully to get home one night.

some ktm's claim that the sensor produces a 50% duty cycle square wave
https://slavensracing.com/shop/emergency-side-stand-sensor-bypass-dongle-ktm-1090-1290-hqv-701/

Sumitomo TS 090 series 3 Way seems correct, look for the non-keyed version?