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[2020_SRS_Commuter]

Im building a mild load tester to check the battery.
It draws 2a.
Im going to check the battery over time with it, dont want to replace it needlessly. Ill be back sometime in a day or so

[2020_SRS_Commuter]

Hi, I'm adding a separate power system for my accessories, a 12aH battery that I charge separately from charging the bike. I'll use a little charger for it and plug it in when I get home. Should be enough. This will be for very loud horns, and my riding lights only.

I found the reason, probably, why the battery light flashes when powering my added riding lights ( They are 72W. 36w each )
Its because my bike doesn't have a 500w 12v converter, its a 300w. I found this by reviewing video of when I took it apart for another reason, and getting a screenshot. Its marked 300. See attachments showing the one on mine, and the one I think its supposed to have.

I also found with my load tester that the original battery was very degraded, and could only power a 2a load for about 5 minutes until voltage was down to 10 something, from the fully charged 13.4 . I replaced the battery.

There could be four reasons for it being 300 instead of 500:
1) they built some this way, then changed their minds and started putting 500w ones in
2) a factory error
3) the dealer stole mine and swapped a 300w in when they had it in for service when a firmware update bricked it
4) its supposed to be this way and I'm wrong about the 500w

[TheRan]

That is very interesting, the gen 2 bikes have used the 500W converters since 2015 with the extra capacity mainly needed to run the ABS pump. I can't imagine them going back to 300W for the gen 3 bikes when even considering the switch to an LED headlight they probably require more power in total. The unofficial manual makes no mention of a power change, it does give the component location on the gen 3 bikes so it's not like it hasn't been updated at all.

Also interesting is I assume the serial number on the converter is a date code with that 500W model being from 2015 which would make sense, but if that's the case then you have a 300W from 2019 which is very unusual. It's not like Zero had an old stock one laying about at their factory that somehow accidentally got put in your bike, nor did the dealer put one in that they pulled from an old gen 2 bike. All I can think of is maybe the dealer meant to order a new 500W model to put into someone else's bike but got the 300W by mistake, so they took yours instead. But that seems like such a scummy and risky thing to do and I don't know why they wouldn't just return it and get the right part.

[2020_SRS_Commuter]

First if you look at the last two attachments again:
500w its part number is 622/11213 . That's a screen grab from unofficial zero manual website
300w on my bike is 622/11202. Not the clearest pic but that's what it is

Now if you look at these two attachments here, Koups, the place I've been ordering parts from, they are listing the replacement part as 622/11202.
Also from a Zero pdf, the part number also is 622/11202. (non emc, whatever that is )

I'm not saying you're wrong. I'm saying Zero fkd this up somehow and doesn't have clear documentation. Im convinced it should have a 500w and doesn't. I  believe you. There aren't even 72W available from accessory to reliably drive some lights. 

[TheRan]

I have a spare 500W module and just checked it and it also has the 11213 part number, and a 2020 serial number which lines up with the guy I bought it from saying he ordered it back in 2020. Mine has a different white sticker though. So that pretty much confirms those two bits of information are both correct. If your part had a 2021+ date code then that would be a sure sign that it had been swapped out.

With Zero also listing the part number as being for that of the 300W module I'm inclined to believe that what you have fitted is correct, for whatever reason Zero decided the bikes didn't need 500W. Perhaps because they now have the 12V battery to share some of the load, I don't know if it's only used for stuff like the cellular module and always on diagnostic port or if there's other stuff connected to it. Still, if you can get hold of a 500W and it seems like it's more accessible than on the older bikes and so an easier swap it wouldn't be a bad idea and can't do any harm.

[2020_SRS_Commuter]

In the "Front Pulley Trashed" thread someone mentioned the service manuals were available. I downloaded mine.
Here a screen grab of the service manual pdf shows a 300w unit, so the answer to my question is #4.
They dont have 500w units. They have 300w.

[2020_SRS_Commuter]

Here's a "fix" for having more power than accessory provides. This provides 12a, and you still have whatever accessory provides for other things if you want it.
Battery from amazon, and old switch, fuse, and some wiring. Around 50 dollars.
This lasts a couple trips then needs to be topped off with a Lipo charger. The switch turns on the display so I can check when it needs a charge.