Changing Charger Connections, September 11, 2021

So after a few months of using the SAE connection on the charger there’re a few shortfalls I figure I need to change connection type to address.

First problem was having the rubber protective cover to put over then ends slide off sometimes. Not really a big deal if the end of the cable is on the ground but not really good if the end is above the batteries and the exposed metal touches frame or battery metal.

Second problem was noticing that every time I plug it in there’s a spark between when the metal connectors meet.

Third problem is that the SAE connectors are only rated for 30 amps at 12v/24v, not for 30 amps or even 10 amps at 84v, which is the charging voltage. While the connectors held when charging at 10 amps, and the batteries charged faster, the plastic/rubber ends became soft and really warm to touch. When charging at 5 amps the plastic/rubber ends become really warm, but not melty warm.

The C13/C14 connectors are rated for 10 amps at 250V so not thinking there should be a problem using in this application as the 5/10 amp charger came with one with 16 ga leads to use as an adapter to other connectors – and unlike the SAE connectors it did not get melty warm when charging at 10 amps or even warm when charging to 5 amps.

SAE connector with rubber cover, meet Mr. Melty Connector
C14 male connector to mount on bike somewhere and C13 female adapter placed on charging cable direct
Finished connector beside open connector pictured by male C14 plug to be installed on bike