Performed -most- of the install today.
For the most part taking the old charger out was OK. Taking apart the anderson connector was a little tricky, and reaching the two bolts behind the power plug was extremely frustrating. I ended up taking off the passenger peg just to help reach the bottom one.
The little green wire (charging cutoff switch) coming off the plug goes up underneith the seat.
I had never taken the seat off before, and in my case it was more annoying than it should be. I had to remove the top case and the quick release plate for the top case in order to slide the corbin seat enough to get it off.
The little hole that the Anderson connector goes through is frustrating. It is really almost wide enough for the connector to fit though, but at the bottom of the connector it gets caught up on the welding, forcing it to angle right into the battery cover so it won't slide in any further.
I'm a little bit more nervous about taking apart the connector on my new charger than I was the old one. I haven't taken it apart yet, I don't want to damage it in the process.
The differences between the old and new charger are minor but noticeable. The new one is waterproofed with silicon at all the seams. The old one is not. There are little capsule shaped rubber spots on the top of the charger. The new one has a plastic adhesive sealing those as well.
The other noticeable difference is a big block sealed in with the cable, near the plug. I'm assuming this is the "additional ferrite" mentioned in the notes. It's big, and the last 4 inches of the cable are much stiffer after it. This makes it difficult to form the cable back to where it needs to be to install the plug in the stock position. Luckily I'm not doing that anyways.
There is a much easier way to get the charger on and off the bike than what new zeroland did in his video. Instead of shimming up the charger and removing all 6 bolts, only loosen the 3 bolts on the left side a little bit. Then take off the three bolts on the right side while holding that side up. Then you can easily slide the charger towards the right and take it off. The reverse to put the new charger on. Slide it onto the three bolts on the left and then quickly put in one bolt on the right, now it's in place and you can add the other bolts and tighten everything up.
EDIT: IT LIVES!
After looking up a video on how to take apart the anderson connector I felt I had a better understanding and went for it. Easy as could be. Plugged it in, and the bike charges normally.
Still need to button everything up, put new zip ties on the cables, etc. but the charger install is a success so I'm thrilled.
Author
Topic: Charger seemingly dead? What are my options? (Read 1309 times)