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[Verichai]

Hi Team,

Looking for instructions on to swap out the on-board charger on my '18 FXS. I have the part, and I know where it goes, in front of the battery, but was hoping someone could point me towards a walkthrough or manual for replacing this. Thanks!

[DerKrawallkeks]

https://zeromanual.com/wiki/Calex_Charger_Replacement

This is for a different bike, no idea if this helps you. Always check the Unofficial Zero Manual:)

[Bodo]

Maybe you find something in here? http://zero-legacy-service-manual-site.s3-website-us-east-1.amazonaws.com/2018-F/2018%20Zero%20FXS%20Service%20Manual.htm
Look for #Repair Procedures and then #Power Pack Charger Replacement. Originally linked here: https://www.electricmotorcycleforum.com/boards/index.php?topic=11899.0

At the same time, there is a useful video for coming closer to the components. It's for a 2022 FXE, but the architecture should not have changed much from an '18 FXS:

[Verichai]

Wow, thanks! This just might do it...

[staples]

This other thread might also be helpful.

I am not sure if anyone noticed this before, I found an AWS bucket with the service manuals. wget'n now. If it goes offline, let me know and I'll send you the archive.

http://zero-legacy-service-manual-site.s3-website-us-east-1.amazonaws.com/

I've tried iterating on the url to get current ones but haven't been able to guess it. (ie, not legacy)

If one were so inclined, ask your parts guy to print out the bolt torque values for latest model. The bucket url will be at the bottom of the page. Share the root URL!

Specifically http://zero-legacy-service-manual-site.s3-website-us-east-1.amazonaws.com/2019-FX/2019%20Zero%20FXS%20Service%20Manual.htm

[Verichai]

Okay, the online service manual is incredibly helpful here, but it references a "High Voltage Discharging" procedure and I can't find these instructions anywhere. Does this just mean to run the battery down to near zero before swapping the on board charger?

How dangerous is this? Is there a chance I electrocute myself? There are some pretty serious warnings in the manual. 

[Verichai]

The required tools listed also include "PN 85-05665 Controller Discharge Tool" which is something I obviously do not have...

[Curt]

If you run the battery down the battery would be ruined. The tool would be to discharge the output capacitors on the charger. I think it would suffice to measure the VDC on the pins before touching them, and wear insulating gloves. But it sounds like you might be better off finding a shop to do it.

[Richard230]

When I replaced the OBC on both my daughters 2014 S and my 2018 S I didn't do anything to deal with possible voltage shock. I didn't even wear gloves. I just removed the charger, disconnected its three wires, installed the new charger and reconnected the new charger's wires to the bike's wiring loom (which was the toughest part of the job). No sparks and no problems. 

[Verichai]

And your battery SOC was at what % during this operation?

[Richard230]

And your battery SOC was at what % during this operation?

I don't recall for sure as I didn't pay any attention to the SOC at the time. However, I hadn't ridden the bike for a couple of weeks while I was waiting for the new OBC to arrive, so it was likely around 70-80%.

[Verichai]

Appreciate the insight! Did you need to remove the battery?

[Richard230]

Appreciate the insight! Did you need to remove the battery?

Not on the S/DS models. The OBC is located directly under the battery pack. All you need to do is to remove the bell pan, unbolt the OBC box, then it drops into your lap. Then you just bolt up the new one. Easy to do. The hard part was reattaching the wiring connectors as they are mashed into the side of the bike and very hard to access well enough to push the new OBC's connectors back together. Attached is photo of the latest version of the OBC.

[Verichai]

Okay, thanks. That OBC is different from the one I received for my FXS. I just completed this operation, by the way and I appreciate everyone's advice. I have virtually zero mechanical experience but I found my way through and the bike appears to be charging normally. Hopefully it charges to 100% and full range is restored.

On the FXS, I think you are supposed to remove the battery, although the service guide did not mention this, in the illustrations, the battery had been removed. I left mine in and it required working nuts, washers and bolts in a space I could barely get two fingers into, let alone a whole hand or a couple tools. Patience persevered.

[Verichai]

Very happy to report that full charging capability and range have been restored. Bike is as good as new.