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[karlh]

Zero Motorcycles has announced a recall, NHTSA ID 20V640, for subject motorcycles to replace the DC-DC converters.  It seems the original converters cannot keep up with the demand when all DC systems are operating at once, causing them to shut down.  I don't know what the capacity of the original converters is, but the replacements are rated at 500W.  Documentation can be found on the NHTSA web site at https://www.nhtsa.gov/recalls?nhtsaId=20V640.  Click on the recall title and scroll down to Associated Documents.  The documentation is periodically updated, so check back occasionally if you're interested.
 

[Fran K]

Potential Number of Units Affected 64

[Crissa]

Guess not all revisions work out.  Wonder if it's just a bad factory run?

-Crissa

[UlsterZero]

Probably a cost reduction exercise that didn't go to plan!  I wonder will Sevcon have to pick up the tab on this one?

It's fortunate they found out so early, only 64 to recall, most of which may still be in dealer stock.

[DonTom]

Zero Motorcycles has announced a recall, NHTSA ID 20V640, for subject motorcycles to replace the DC-DC converters.  It seems the original converters cannot keep up with the demand when all DC systems are operating at once, causing them to shut down.  I don't know what the capacity of the original converters is, but the replacements are rated at 500W.  Documentation can be found on the NHTSA web site at https://www.nhtsa.gov/recalls?nhtsaId=20V640.  Click on the recall title and scroll down to Associated Documents.  The documentation is periodically updated, so check back occasionally if you're interested.

Did they reduce the DC2DCC power rating for 2021?  Or have a larger 12 volt load? Why does the older bikes not have this problem?

-Don-  Auburn, CA

[Crissa]

Why does the older bikes not have this problem?

Because that was a different batch of parts, Don.

-Crissa

[carldev]

Someone on the reddit forum speculated that the 300W units from the SR/F were accidentally installed instead of the 500W units typically used on the FX/S/DS bikes
I guess the power supplies are the exact same size.

Thankfully it was caught quick

-Carl

[DonTom]

Someone on the reddit forum speculated that the 300W units from the SR/F were accidentally installed instead of the 500W units typically used on the FX/S/DS bikes
I guess the power supplies are the exact same size.

Thankfully it was caught quick

-Carl

OIC. So a factory screwup with using the wrong part.

-Don- Auburn, CA

[ESokoloff]

This begs the question of how many watts does it take to run say a 2016DSR?
I curious how many free electrons (watts) are available for farkles (accessory’s).

[Curt]

This begs the question of how many watts does it take to run say a 2016DSR?
I curious how many free electrons (watts) are available for farkles (accessory’s).

Every winter I run a heated vest (70 W) and heated grips (35 W) from the provided accessory plugs, so 105 W of accessories on my 16 FX is no problem.

[ESokoloff]

I have heated grips (not sure wattage) as well as a 48w Warm n Safe shirt.
Also I have aux driving lights (selective yellow), 16 @ 1 or 3 watt aux LED’s for run, stop, turn as well as LED’s in the front signal pods for run/turn (360° coverage).
I shoehorned two additional horns in the voids of the tank sides but those get their power from a SPDT relay that interrupts the heated grips/shirt so as to limit current to one or the other load. 
I have replaced all incandescent bulbs with LED’s but still will have a considerable load with my planed J.W. Speaker LED headlight install (66w).

Hope I don’t let the smoke out of the wires

[UlsterZero]

Someone on the reddit forum speculated that the 300W units from the SR/F were accidentally installed instead of the 500W units typically used on the FX/S/DS bikes
I guess the power supplies are the exact same size.

Thankfully it was caught quick

-Carl

OIC. So a factory screwup with using the wrong part.

-Don- Auburn, CA

The Sevcon part number for the SR/F DC Convertor is different, it's 622/11202 which appears to be specifically designed for battery charging.  The recall notice shows the Revision B model as being part number 622/11213, which according to the Sevcon website is definitely a 500 Watt unit.

If there was a screw up, it would have to be during manufacture at the Sevcon factory, which I think is in Poland - wrong labelling or wrong components!

I wonder will other brands using the same DC convertor as Zero be issuing their own recall soon?