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[BrianTRice@gmail.com]

Don't forget the contacts, people. If you get heat at a connection, you've got resistance in your connection. So get some electrical cleaner spray and clean up those contacts.

Another clue- flickering or touchy connections. Don't tolerate that stuff. Clean those contact points.

Confirmed to work for me. I've added this to the wiki:
http://zeromanual.com/index.php/Common_Problems#Stuck.2FWarm_Charging_Cord

[SR2016]

I lived with hot cord too long. Started to smoke.  Big mistake.
Resistance builds up where there is a weak connection.  This causes heat.
I removed the AC plug (male) from motorcycle and dissembled it at the heat source.

After cleaning and soldering the connection and covering everything with liquid tape and epoxy the plug is cool when charging now.

Job is easy .  About an hour with a day for epoxy to dry.

[SR2016]

BTW this motorcycle is the best thing in the world.  This is the only major issue I ever had in six years.  I ride almost every day. 

[Richard230]

BTW this motorcycle is the best thing in the world.  This is the only major issue I ever had in six years.  I ride almost every day.

I just did a quick calculation using a Kill A Watt meter when fully charging my Zero S this morning after riding 74 miles to my daughter's home and back this weekend. About 1/3 freeway travel and 2/3 surface streets. The cost, at my home's electric rate of 40 cents per KWh was 2.3 cents per mile.

[ESokoloff]

Here is my fix for hot connections. https://www.electricmotorcycleforum.com/boards/index.php?topic=10514.0

[RightRudder]

If the line voltage is low for any reason the switching converter in the charger will happily just draw more current to get the same input power.  This could make all the difference for a light cord which is borderline at 120v.