View source for Calex Charger Replacement

This describes removing and replacing the Calex 1200 onboard charger.

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Since some generations of Calex chargers seem to develop faults relatively often, being able to replace a charger on one's own might save someone a lot of grief who doesn't live near a dealer.

;Video Guide
: [https://www.youtube.com/watch?v=DFHQgTOMxO8 How to Remove the Zero's Onboard Charger by NewZeroLand on YouTube] shows very clearly how to remove the charger from his Zero SR.
:: {{#ev:youtube|DFHQgTOMxO8}}

;Notes
: Adapted from [http://electricmotorcycleforum.com/boards/index.php?topic=4424.msg28648#msg28648 these instructions].
: Possibly JAE MX23A18NF1 or MX23A18NF3 for harness connection [https://www.mouser.com/datasheet/2/206/B-0094-2E_MX23A-1132557.pdf MX23A18SF1 (datasheet via Mouser)]
: Charging enable hack (by [http://electricmotorcycleforum.com/boards/index.php?action=profile;u=1531 EMF user Liveforphysics])
:: [[File:LW_ZeroChargerEnableAtHarness_2018-09-25.jpg|thumb|100px|none|Zero Charger Enable At Harness]]

;Tools
* 3mm Allen key.

;Steps
# Unplug the motorcycle, and key it off. Wait for at least 10 minutes to ensure any residual charge has dissipated.
# [[Lower Plastics Removal|Remove the lower plastics]].
# [[Belly Pan Removal]]
#: Unbolt the belly pan (2 rows of 4 3mm Allen head bolts on each side of the pan, and 2 smaller bolts) and remove it.
# Unplug the wiring at the rear of the charger area.
#: There are three plugs (looking left to right at the rear of the charger):
#* One on the AC end of things that's bolted to the bike (your charge plug)
#* The comms connector (enable signal, CAN comms etc...)
#* One plug on the DC side that goes up to the charge wiring harness.
## The comms plug just has a tab; push in the tab and pull that one out.
##: Both of the other plugs are really difficult.
## Removing the DC plug.
##: The plug is an [[Anderson_connector|Anderson]] [http://www.andersonpower.com/us/en/products/sbs/sbs-50.aspx SBS50-BRN], but it seems to be a narrower pin pitch with no center data pin set.
##: The DC plug is located in front of the motor against the back side of the battery on the bike's right.
## The cables are tucked up between the battery and a frame member, so cut the zip ties (including the zip tie holding the plugs together) and pull the plastic zip-tie mount clips on the lower half of the cable going to the charger.
## Pull down on the charger side of the connector from the bottom while pulling up on the top connector.
##: Sometimes this requires a "flesh donation" to the motor, so covering the motor with a rag would be smart.
## Pull the terminals out of the plug housing (see [[Anderson_connector|Anderson disassembly]]), and pull it down thru the hole between the motor and frame.
## Removing the AC plug.
##: It loops up under the seat and is zip tied on in a handful of places.
##: There are two small bolts on the backside that are difficult to reach, so use a decent set of hex drivers with handles.
## There is a fuse holder plug that connects the ground to (somewhere...).
##: Squeeze some tabs to get the green locking piece out.
##: Then squeeze more tabs to get the plug apart.
# Now with the cables out, use the 3mm Allen key to loosen (but not remove) the 6 bolts on the tabs holding it up.
# Remove the charger to the side (recommend the right side) by removing the 3 bolts on the side intended for removal.
#: On removing the last bolt, support the charger so it doesn't fall out, and carry it to the ground or elsewhere.
# Remove the remaining 3 bolts using the 3mm Allen key if not installing a new charger.
;Assembly
* Assembly is the reverse of disassembly! Really.
;Suggestion
: You can extended the DC wires on the replacement Calex charger, and put the plug set sideways, and up higher to make it easier to get at.

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[[Category:Repair]]
[[Category:High Voltage Procedure]]