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[pacificcricket]

Folks,

Calex charger stopped working on 2014 DS. What are the current options for replacing or upgrading it ?

[Richard230]

Folks,

Calex charger stopped working on 2014 DS. What are the current options for replacing or upgrading it ?

A couple of years ago I bought a replacement updated OBC from RF1 Racing for around $800 USD and it has been working well ever since I installed the new one in my garage (an extra pair of hands helps).

[TheRan]

The 2016 onwards revisions are meant to be more reliable. Installation is fairly easy even by yourself, the trick is to install a couple bolts on the left side first and then because the mounting points on the charger are slotted you can just slide it in and the bolts hold it on that side and you can support it fine with one hand while you put a bolt in on the right side. The trickiest part is getting the connector out from between the motor and battery pack.

[pacificcricket]

Yeah, installation isn't a problem. I was mostly just wondering if alternative chargers emerged similar to how Elcon and DigiNow stuff was being developed in the past. I came across this Chinese offering : https://www.aliexpress.us/item/3256805701219095.html

It's not clear if it's correctly programmed to interface with Zero though despite the claims and also the wiring interface isn't described.

[T.S. Zarathustra]

This page has couple of links to the onboard charger. Personally I'd look at the 3,3 charger you found. Note the Canbus connection, ask the seller to confirm the canbus is as intended and you can limit the charge current where the wall outlet cannot provide 3,3.
https://zeromanual.com/wiki/Gen2/Calex_Charger

[pacificcricket]

Looking at that Ali listing a bit more I've noticed that for Zero S/DS they propose using Enable signal instead of CANBUS. So I guess it would be usable through the AUX charging port and not the main charging port where Calex was connected with CAN.

[pacificcricket]

I've pulled the charger out, and noticed that the connector charger was plugged into is now energized when the bike is keyed. I guess all the power connections are routed via the MPC and there is no separate charge path ?

[MVetter]

On the comms connector for the Calex, jump the following wires to put the bike into charge mode. You can just wire in a toggle switch.

[pacificcricket]

Very nice! Is there an advantage to hooking up the external charger via original Calex DC path versus the aux DC path ?

[pacificcricket]

Here is another Chinese charger that may work. Lower output current (similar to original Calex) but also much lower cost : https://www.aliexpress.us/item/3256806711097498.html

[TheRan]

They both go through the same route. Using the connector for the on board charger means you can salvage the one from the busted charger as they're two different sizes, using the auxiliary connector means you can use the charge enable connection built into that so the bike continues to charge after you key it off if you don't want to do what MVetter suggests.

[pacificcricket]

Understood, thank you!

[MVetter]

You get what you pay for. Cheap chargers have been known to catch fire. And never mount something on the bike that isn't shockproof, vibration resistant, and IP67 rated.