Once upon a time I hit an issue with a client that sounds similar, and
here are some notes from then:

Code:
#Used strace to find /etc/zypp/services.d which had a file causing the error.
> strace -s 999 -ttt -ff zypper dup >zypper.strace 2>&1
Feel free to try out the command above, or just look under
/etc/zypp/services.d to see if something in there is old, and clean it out
from there.


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Good luck.

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