ElectricMotorcycleForum.com
Makes And Models => Zero Motorcycles Forum | 2013+ => Topic started by: peterwarm on August 04, 2025, 03:35:24 PM
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Hi, I've got a 2019 SR/F premium with a 6kW charger on board, so I've got a 3kW, another 3kW, and the 6kW chargers all on board.
At home I use a granny cable to charge from 240 V ac (UK), but it never seems to charge above 96%. I have just accepted this as annoying.
However, now I've got the extended range option, charging to 110%, its more than irritating as it just doesn't work.
Going to a 3 phase (22kW) unit It all works fine, I can get close to 110% as expected.
I think there's some thing wrong with the base 3kW charger. I would like to diagnose it by swapping the wiring with the other 3kW charger.
Anybody got an idea of how to do this?
Thanks, pete
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I suspect you could rewire the phase inputs in the charging cable more easily than the bike, sending the normal 3kW into the other unused one.
But really - yes your charger is finally dying, this is a classic symptom from the older bikes, they just stop charging sooner and sooner as they finally wear out and then one day, poof, they stop altogether. The Gen3 chargers seem a lot more robust but I guess they can't last forever.
Cas :)
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I suspect you could rewire the phase inputs in the charging cable more easily than the bike, sending the normal 3kW into the other unused one.
But really - yes your charger is finally dying, this is a classic symptom from the older bikes, they just stop charging sooner and sooner as they finally wear out and then one day, poof, they stop altogether. The Gen3 chargers seem a lot more robust but I guess they can't last forever.
Cas :)
That is what happened to the OBC of my 2018S and my daughter's 2014S. They both would slowly charge to a lower and lower %. In the case of my daughter's bike, it finally wouldn't charge past 88%. Upon replacing the OBC, charging went back to 100% for both bikes.
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Thanks Cas and Richard. I did indeed rewire the charging plug, (which is wired in permanently to the bike under the seat), swapping L1 and L2. Hey presto, charging striaght to110% off a 13A plug.
Of course this just proves that the first 3kW charger is on the way out, I wonder if I can get a second hand one?
fully charged now ;D
pete
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The chargers are a bit rare 2nd hand (there are hardly any in circulation), besides, chances are it'll be half worn out anyway... best to just get a new one.... they're quite pricey though: https://shop.englishelectricmotorco.com/shop/electric-bike/battery-chargers-and-electrical/onboard-charger-3kw-zero-sr-f-sr-s/
Cas :)
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Here is a photo of what my OBC looked like when it finally stopped charging. I might add that the replacement charger had an updated part number as shown on the second photo.
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yep, dc flashover is a mudderfubber that's for sure! We used to have an ups on the FFG's i was stationed on, long story short had a very critical control board right above an ammeter shunt that was waaayyy stupid designed. When the thing got low voltage, instead of shutting off, the scr's would misfire, drawing a few thousand amps thru a shunt that probably could handle 150 amps at best, end result was a huge green fireball of vaporized copper and tens of thousands of dollars of btfu board. Trying to explain to the engineers in mechanicsburg, if you MOVE this stupid board away from the fireworks in the DC area, yah you can replace the scr's, a few hundred dollars and readily available, but would save the controller assy, many thousand dollars and 6 month lead time. or better yet, put a 200 A fuse in the GD dc side of the thing, and catch it before it goes nuclear. nope, uh nuh, no way, you can't modify the official design bla bla. What momma don't won't hurt her ;D ;)
Aaron