You might want to look at...

https://www.hdlivewireforum.com/threads/bike-wont-charge-or-start.5569/

No resolution was posted in that thread, but maybe you could reach out to the OP to see what fixed the bike. Sounds like neither a new battery nor OBC did it.

 

I decided to remove OBC but before I did that, I wanted to check something - I plugged li-ion adjustable voltage/current charger parallel with 12V battery, I set 4-4,5A current to match idle power consumption of bike, and........ bike charging at DC

this means, external dc-dc converter 200-300VDC to 14VDC should help and will be a lot cheaper solution than new OBC

NEXT STEP
tear down OBC, after I opened it, I smell burned electronics

one mosfet burned but for now i only openmetal underplate,

more to come

 

GAZYLION screws later

burned area near mosfets

I sent an emai to OBC manufacturer - current ways tech - but i dont expect much

 

Thanks for sharing and fotos, very interesting to see OBC insides! Good luck and keep us updated!

 

I found 3kW OBC with integated 500W DC-DC converter
but it is "dumb" one - probably without any canbus singals

to make it work (in theory) I will have to be replicate CANBUS signal to RESS to wake it up

if RESS will wake up can close HV contactors for HV OUT/IN to DC-DC then it should work

problem is - OBC has also integrated charging controller for AC/DC this is small PCB inside - question is if I only need this one small pcb to make it work or whole original PCB should be present

of course its possible to make it work withou tbut then it have to be a lot more signals to replicate so it making it a lot more complicated

since hardware parts should be under 1000USD - so maybe even for one bike it is worth to try, especially failing OBC are common problem with our bikes

 

I started bike without OBC and without 12V battery - simply by external 12V 8A brick - HV of course disconnected bcoz there is no signal from OBC to RESS to wake it up


EDIT
HV disconneted error was probably by tilted BCM (complety forgot about that) with normal position I dont get this error

stillin diagnostic menu i got RESS error (sth with power)

 

UPDATE:
1. proffesional eye - first look

shortcut on igbt transistors - (4 pieces) - probably overheated
burned elements - its will be EASY fix if i have any pdf to it - next week its going to lab to look under microscope and we will see after that

so in my case DC-DC not work as OBC as well - I can live without AC charging but dc-dc hase to be present - for cheap fix - probably standard AC/DC 12V(13,5V) PSU will work as DC(RESS) input but it has to be proper insulated physically and 30-40A psu will be challenging to fit somewhere

2. I bought livewire one 2021 OBC for cheap - different part number but I hope it will work- seller dont want to ship over sea so I have to arrange US-USshipping at first and then US-PL

 

unfortunanelty shipping from US to PL cost a lot so I have to wait till december when my cousin will visit me, he can take it in registered luggage - not worth paying 150-200$ to get it month earlier - and probably I will can;t ride anyway due the colder weather

 

Hello, szczur333!
I can't help you, but I'd like to let you know that several H-D LiveWire riders in France are following your post closely, along with the Electric Bikers Association and a specialist from Revolt garages (which repair electric vehicles). Thanks for sharing!
Greetings from Colmar, Alsace.

 

new ideas:

as new OBC will be here in december, in meantime I will try to remove/unsolder burned igbt from pcb - and then I will check for shortcircuit - if there will be not any - I will install OBC into bike again - for sure AC charging will not work, but I want to restore 12V OUT from dc-dc - not having ac charging isnt problem for me

if I am not getting 12v out, I will try to connect 20-30A powersupply in parallel with failed OBC - AC powersupply should work with DC input - of course proper DC-DC will be much better but it cost too much (200-250$) - PSU 20$


EDIT
after soldering out mosfets, there is not shortcircuit anymore - this is good sign - mounting in bike in 2 weeks

 

i dont know if OBC from ONE will work in ELW - but I also ordered charge port mount/bracket as my friend sending package from USA so this will not change price much - ship it separaletly later will be more expensive

also I found this part for 27$ with shipping

 

ok, so....... OBC is repaired (sort of) - burned igbt soldered out (no more short circuit), and one 12V mosfet for some driver/controller reverse engineered and replaced, rest of burned parts are untouched bcoz its required to rebuild PCB traces/area which will be A LOOOOLT of work - I will not use AC charging anymore bcoz at home I have DC so not worth to do it (althoutgh i think its possible)

OBC is still teared down, not tested in bike yet

assembly and mount in bike - thursday/friday

 

Good luck!

 

unfortunanetly sth is still not ok, first switch on was ok, but after switching off and on again 10A fuse blowed, after replacing it, second fuse blowed immiadatelty

second tear down and same situation - sth fried again

so I have to wait for LW1 charger -my friend will ship it to me on monday