An Important Message To You From...
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Transcript of An Important Message To You From...
TOC-1
Introduction ................................................................. 1-1An Important Message To You From Zero ......... 1-1Introduction ............................................................ 1-1
Index .............................................................. 1-1Useful Information For Safe Riding ............ 1-2
Plug In Your Power Pack .................................... 1-2Owner Information ................................................ 1-3Vehicle Identification Number (VIN) .................... 1-4
VIN Location .................................................. 1-4VIN Break Down ........................................... 1-4
General Information ............................................. 1-6Zero S Technical Specifications .................. 1-6Zero DS Technical Specifications ................ 1-7Vehicle Range ............................................... 1-9Optimizing Your Range By Adapting YourRiding Style ................................................... 1-9Public Charging Stations ..............................1-10Emissions Information ..................................1-10Transporting ......................................................1-11
Safety Information ..................................................... 2-1General Safety Precautions ................................. 2-1
Important Operating Information .................. 2-2Location Of Important Labels ...................... 2-3Power Pack Information Label .................... 2-4Throttle And Speed Control Label ............... 2-5Power Pack Labels ...................................... 2-5Power Pack (Battery) Fuse Label .................2-6Main Power Cut-Off Label ............................ 2-6
Performance Specifications/Operation Guidelines ................................................2-7
Performance Envelope ................................. 2-7Z-Force Air Induction System ....................... 2-7System Error Indicator .................................. 2-8
Controls And Components ....................................... 3-1Motorcycle Controls .............................................. 3-1Left Side View ...................................................... 3-3
Table Of Contents
TOC-2
Suspension ................................................... 5-8Wheels And Tires ......................................... 5-8Tire Inflation .................................................. 5-9Chain ..................................................................5-10Headlamp Alignment ......................................5-13Headlamp Bulb Replacement .....................5-14Turn Signal Bulb Replacement....................5-16Stop/Tail Lamp Bulb Replacement..............5-16Running Lamp Bulb Replacement..............5-17Cleaning ............................................................5-18
Parking And Long Term Storage...........................5-19Maintenance Schedule ....................................... 5-20Parts/Maintenance Items ................................... 5-23Accessories ........................................................ 5-23Fuses .................................................................. 5-23
Troubleshooting .......................................................... 6-1Power Pack And Charger .................................... 6-1
Understanding Beep Sequences ................ 6-3Safety Interlocks ............................................ 6-6General Troubleshooting ...............................6-11
Right Side View .................................................... 3-5Instrument Panel .................................................. 3-7
Indicators ....................................................... 3-8Handlebar Controls .............................................. 3-9
Starting And Operating ............................................. 4-1First Time Set-Up ................................................. 4-1
Uncrating Your Motorcycle ............................ 4-2General Operation ................................................ 4-4
Pre-Ride Inspection ...................................... 4-4Key Switch Positions .................................... 4-5Fork Lock ....................................................... 4-5Main Power Cut-Off ...................................... 4-6Power Pack ................................................... 4-7Operating Your Motorcycle ............ ................4-14Suspension Adjustment ............................. 4-15
Maintaining Your Motorcycle .................................... 5-1Owner’s Responsibilities .................................... 5-1Bolt Torque Table ................................................. 5-2Power Pack ........................................................... 5-5General Maintenance ........................................... 5-6
Motor .............................................................. 5-6Brakes ........................................................... 5-6
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Warranty/Customer Assistance ............................... 7-1Customer Assistance ........................................... 7-1Warranty Information ............................................ 7-2Zero Motorcycles Limited Warranties.....................7-3
Standard Warranty ......................................... 7-3Extended Warranty ........................................ 7-4No Fault Warranty ......................................... 7-5Disclaimers Applicable to StandardWarranty, Extended Warranty andNo Fault Warranty .............................................7-5Proper Use .................................................... 7-6Purchaser’s Responsibilities ....................... 7-7Warranty Procedures .................................... 7-7Transfer Of Ownership And Warranty ..........7-8
TOC-4
NOTES
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Introduction
Congratulations and thank you for purchasing the2010 Zero S/DS electric motorcycle; we welcome youto the community of Zero Motorcycle riders. Thismanual is designed to provide you with a betterunderstanding of the operation, inspection, and basicmaintenance requirements of this motorcycle. Zerocontinually seeks advancements in product designand quality. Therefore, this manual contains the mostcurrent product information available at the time ofprinting. Because of this, your motorcycle may differfrom the information supplied in this owner’s manual.No legal claims can be made on the basis of data inthis manual. When it comes time to sell your Zeromotorcycle, please remember to hand over thismanual; it is, by law, an important part of the vehicle.If you have any questions concerning the operation ormaintenance of your motorcycle, please contact Zeroat [email protected].
IntroductionIndex
A good place to locate information about themotorcycle is in the index in the back of the manual.The terms “right” or “left” refer to the rider’s right orleft when sitting on the motorcycle.
An Important Message To YouFrom Zero
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Useful Information For Safe Riding
This manual contains the word CAUTION to tell aboutsomething that could hurt you or others. It alsocontains the word WARNING to tell about things thatcould damage your motorcycle.
CAUTION: Please read this manual carefully andcompletely before operating this motorcycle. Do notattempt to operate this motorcycle until you haveattained adequate knowledge of its controls andoperating features, and until you have been trained insafe and proper riding techniques. Regularinspections and careful maintenance, along with goodriding skills, will help you to safely enjoy thecapabilities and the reliability of this motorcycle.Disregarding them may render the warranty invalid.
Plug in Your Power Pack
WARNING: Proper care of the motorcycle’s power packis essential! When not in use, the power pack shouldbe left on the charger even if fully charged. Failure todo so could damage the power pack and thereforevoid your battery warranty. See page 4-7 for otherimportant information about the power pack.
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CSC Information Motorcycle Information
Address
Model
Date of Purchase
VIN
Telephone No.
Battery Serial Number
Owner Information
Record important information here pertaining to your motorcycle. When contacting your Certified Service Center(CSC) you may need to provide this information.
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M O
T O
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A
Vehicle Identification Number(VIN)
See Location Of Important Labels on page 2-3.
VIN Break Down
VIN Location The VIN is a 17-digit number stamped on the headtube of the frame. Do not alter or remove this numberas it is the legal identifier for your motorcycle.
A. VIN Label
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S = StreetC = Commuter
538
Motorcycle Type
2 = 168 Cell3 = 2nd Generation4 = 336 Cell
M = MarsP = PermZ = Z Motor ForceA = Agni
05 = 0 - 50 HP51 = 50 - 100 HP10 = 100 + HP
9 = 2009A = 2010B = 2011
Production Number
S 3 9 1M 905 123456
Model Line
Motor Type
Model Year
Net Brake Horse Power
1-6
General InformationZero S Technical Specifications
CHASSIS/SUSPENSION/BRAKES
Front SuspensionTravel
203.2 mm (8 in)
Rear SuspensionTravel
203.2 mm (8 in)
Front Brakes2 Piston Hydraulic, Stainless Rotor,Hand Actuated
Rear Brakes1 Piston Hydraulic, Stainless Rotor,Foot Actuated
Front Tire 110/70-16 in
Rear Tire 140/70-16 in
Front Wheel 16 x 3.0 in
Rear Wheel 16 x 4.0 in
MOTOR
Type Brushed permanent magnetic electric
Est. Top Speed 108 km/h (67 mph)
POWER SYSTEM
Type Patent-pending lithium ion array
Capacity 4 kwh (58 V @ 70 Ah)
Range Up to 80 km (50 miles)
Recharge Time Less than 4 hours
Input Standard 110 V AC or 220 V AC
DRIVETRAIN
Transmission Clutchless one speed
Drive System 16T/53T Sprocket, 420 Chain
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Zero DS Technical SpecificationsDIMENSIONS
Wheel Base 144.3 cm (56.8 in)
Seat Height(Standard)
86.4 cm (34 in)
Low Seat Height(Option)
81.3 cm (32 in)
Rake 22 degrees
Steering Angle +35 degrees, -35 degrees
Trail 82.8 mm (3.26 in)
WEIGHT
Frame 8.16 kg (18 pounds)
Power Pack 43.1 kg (95 pounds)
Curb Weight 123.8 kg (273 pounds)
GVWR 260.8 kg (575 pounds)
Carrying Capacity 136.0 kg (302 pounds)
ECONOMY
Typical Cost toRecharge
Less than $.01 per mile orkilometer
MOTOR
Type Brushed permanent magnetic electric
Est. Top Speed 108 km/h (67 mph)
POWER SYSTEM
Type Patent-pending lithium ion array
Capacity 4 kwh (58 V @ 70 Ah)
Range Up to 80 km (50 miles)
Recharge Time Less than 4 hours
Input Standard 110 V AC or 220 V AC
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DIMENSIONS
Wheel Base 146.8 cm (56.75 in)
Seat Height(Standard)
88.9 cm (35 in)
Low Seat Height(Optional)
83.8 cm (33 in)
Rake 24 degrees
Trail 82.8 mm (3.26 in)
Steering Angle +35 degrees, -35 degrees
WEIGHT
Frame 8.16 kg (18 pounds)
Power Pack 43.1 kg (95 pounds)
Curb Weight 125.6 kg (277 pounds)
GVWR 260.8 kg (575 pounds)
Carrying Capacity 134.7 kg (297 pounds)
ECONOMY
Typical Cost toRecharge
Less than $.01 per mile orkilometer
DRIVETRAIN
Transmission Clutchless one speed
Drive System 16T/53T Sprockets, 420 Chain
CHASSIS/SUSPENSION/BRAKES
Front SuspensionTravel
228.6 mm (9 in)
Rear SuspensionTravel
203.2 mm (8 in)
Front Brakes2 Piston Hydraulic, Stainless Rotor,Hand Actuated
Rear Brakes1 Piston Hydraulic, Stainless Rotor,Foot Actuated
Front Tire 3.25-17 in
Rear Tire 110/90-16 in
Front Wheel 17 x 2.15 in
Rear Wheel 16 x 3.0 in
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Vehicle Range
The range of an electric vehicle is defined as thedistance the vehicle will travel on a single full chargeof the power pack. Just like EPA mileage estimateson an automobile, “your mileage may vary.” Yourrange results are a direct reflection of your ridinghabits. The more conservative you ride the betterrange you can expect from your Zero S/DS Motorcycle.
Some of the factors which affect range include speed,acceleration, number of starts and stops, as well aschanges in elevation. The combination of thesefactors, as you travel from one point to another,defines your trip profile. In addition, tire pressure andpayload are important considerations.
We suggest that you ride conservatively when you firstget your Zero S/DS motorcycle and get to know yourmotorcycle and your commute. Once you becomefamiliar with the range versus performance of yourmotorcycle then you can adjust your ridingcharacteristics if you so desire. This applies mainly toriders with trip profiles which are at the edge of theperformance envelope. Those of you with relativelyshort commutes can expect to ride quite aggressivelyand reach your destination with energy to spare.
An average rider can expect to achieve 64 km (40miles) of average range under normal use (stop andgo traffic), with a maximum range of 97 km (60miles) of steady riding at 40 km/h (25 mph). You canexpect to achieve 48 km (30 miles) of range on thefreeway of steady riding at 89 km/h (55 mph).
Optimizing Your Range By AdaptingYour Riding Style
• Apply the throttle slowly and try to match themotorcycle’s acceleration with your throttleposition.
• Hard acceleration will cause a voltage drop,thereby making the energy gauge dropsignificantly; the gauge should recover when youroll off the throttle.
• If 108 km/h (67 mph) can be reached at 100%throttle, 75% throttle will give you about 89-95km/h (55-59 mph) (a 25% energy savings for anapproximate 12% speed loss).
• Coasting whenever possible makes a significantdifference; the motorcycle will coast for a longdistance (take advantage of this).
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Calculation
EPA Electric vs. Gas Equivalent: 33.705 kwh/galEnergy used riding the Zero S/DS: 3.7 kwhRange of the Zero S/DS: 50 milesMPG= 50 miles/[3.7 kwh/33.705 kwh]MPG= 455.45
Emissions
The Zero S and DS do not require any gasoline and,as a result, do not get ‘miles per gallon.’ For thesake of emissions comparisons, the EPA estimatesthere to be about 33.705 kilowatt hours in one gallonof gasoline (33.705 kwh/gal). When operating a ZeroS or DS we estimate that you will use 3.7 kwh beforerecharging. Based on the EPA estimate, 3.7 kwh isequivalent to .10978 gallons. With that .10978 gallonsa rider can travel up to 80 kilometers (50 miles). Thismeans that the Zero S or DS achieves incredibleefficiency at 455.45 MPG.
the only kind of vehicle which actually gets cleaner interms of air pollution each year, as the electricity gridgets cleaner and more renewable. Zero EmissionsVehicles (ZEV’s) offer greater efficiency, and can helpsolve the serious air pollution, global warming, andenergy security problems facing the country and theworld.
WARNING! Please use only Zero approved parts andaccessories for your Zero motorcycle. Parts andproducts for your Zero motorcycle have been checkedand tested for safety and suitability. Zero is unable toaccept any liability whatsoever for parts andaccessories which have not been approved.
Emissions Information
The Zero S/DS electric motorcycle is a true freewaycapable zero emissions vehicle under California(CARB), U.S. Federal (EPA), and European Unionstandards. It uses no gasoline or other liquid fuel. Ithas no tailpipe and therefore no tailpipe emissions.It also has no exhaust or evaporative emissions.Because the Zero S/DS runs solely on electricity, it is
Public Charging Stations
There are more public charging stations coming on-line every day and there may be some in your area.These stations are often available at a variety oflocations including shopping centers, city parking lots,airports, hotels, government offices, and otherbusinesses. We recommend that you search theinternet for locations in your area. For example,search for “charging stations.”
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A
S FS F
A
Transporting
When the front fork is compressed, the built uppressure must be released to help prevent fork sealleaks. There is a 3 mm Allen “bleed” screw locatedjust in front of the rebound adjuster on each fork leg.This “bleed” screw (A) is used to release the built uppressure. Loosen the screw slowly, but do notremove. Once all the air is out, tighten the bleedscrew.
It is recommended that the motorcycle be tied-downusing ratchet straps and a fork support (A) to preventfork damage. Place the ratchet straps around theframe or a solidly mounted part. Soft straps must beused to prevent scratches or other damage.
AWhen the fork is released, with no weight on the fronttire, the screw must be opened again to allow forstabilization. Ensure that the screw is tightened beforeriding.
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Use two ratchet straps in the front and two in therear. The tie down straps should be at a 45° anglefrom the motorcycle. Follow the manufacturer’sinstructions for the ratchet straps you are using.
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NOTES
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NOTES
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Safety Information
General Safety Precautions
1. This is a performance motorcycle and shouldbe treated with extreme caution.
2. Proper safety gear, including a DOT approvedhelmet, riding boots, gloves, and protectiveclothing should be worn while riding to reduce therisk of potential injury. We highly recommend theuse of full height riding boots since the vastmajority of motorcycle injuries are leg and footinjuries. It is not recommended to ride withoutprotective clothing; this applies to even shortjourneys, and to every season of the year.
3. Read all additional warnings and productinstructions in this owner’s manual, and safetylabels, before operating the electric motorcycle.
4. Never carry a passenger. This motorcycle isdesigned for a SINGLE RIDER ONLY.
5. Never permit a guest to ride your electricmotorcycle without proper instruction. These areperformance motorcycles and should be treatedwith extreme caution.
6. Do not ride on wet, frozen, oily or pitted surfaces.Avoid potholes, surface cracks, and otherobstacles.
7. Never use alcohol or mind-altering drugs beforeoperating an electric motorcycle.
8. Persons unwilling or unable to take responsibilityfor their actions should not use this motorcycle.You assume all responsibility while operating yourmotorcycle. The seller will assume no liability formisuse or operator negligence.
9. Prior to each use the rider must check everythingin the “every ride” column of the maintenanceschedules on pages 5-20 through 5-22, and thepower pack function level as indicated on theinstrument panel energy gauge.
10. Your safety depends in part on the goodmechanical condition of the motorcycle. Be sureto follow the maintenance schedule andadjustment requirements contained in thismanual. Be sure you understand the importanceof checking all items thoroughly before riding.
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11. Modifications of the motorcycle may render thevehicle unsafe and may cause severe personalinjury. Zero Motorcycles cannot be held liable fornon-approved modifications.
12. Be very careful when loading or addingaccessories to your motorcycle. Large, bulky, orheavy items may adversely affect the handlingand performance of your motorcycle.
13. Failure to follow battery storage and charginginstructions, as described in this Zero MotorcyclesOwner’s Manual, may void the warranty of yourZero motorcycle. These guidelines have beenrigorously tested to ensure maximum batteryefficiency and service.
Important Operating Information
1. Always turn the key switch and the kill switch tothe OFF position when not actively riding. It is veryeasy to forget that the motorcycle is powered upbecause it is silent. An accident can occur if themotorcycle is left powered up while getting on oroff the motorcycle.
2. Switch the power OFF when backing up orpushing the motorcycle while dismounted. It ispossible to unintentionally twist the throttle,resulting in unexpected acceleration.
3. Use the rear brake when you are stopped on anincline. Do not hold the motorcycle using partialthrottle or damage to the motor may occur.
4. The Zero S/DS power pack should be plugged inwhen storing the motorcycle for extended periodsof time.
5. Keep your Zero S/DS connected to the chargerwhen your motorcycle is sitting in storage or if itwill be sitting unused for more than 7 days.
WARNING: Charge the Zero power pack with theZero charger.
The power pack must be charged within 24 hoursif fully discharged, and charged within 60 days ifstored fully charged. Zero recommends that youplug in your Zero motorcycle after 7 days even ifcharged. Please leave your Zero motorcycleplugged in whenever possible.
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M O
T O
R C
Y C
L E S
D ACB
Location Of Important Labels
A. Vehicle Certification LabelB. Power Pack Information LabelC. Throttle and Speed Control LabelD. Vehicle Identification Number (VIN) Label. See
Vehicle Identification Number (VIN) on page 1-4.
The Vehicle Certification Label contains the followinginformation:
• Gross Vehicle Weight Rating (GVWR)
• Gross Axle Weight Rating (GAWR) Front and Rear
• Vehicle Identification Number (VIN)
• Rim Size
• Tire Pressures
• Manufactured Date
6. Always firmly apply the rear brake while turningthe key switch ON or OFF. In the event of amalfunction, the firm application of the rear brakewill help keep the motorcycle from running away.
7. The power pack does not require or tolerate deepdischarging. To get the most power pack life,recharge each power pack immediately after eachride. Leaving a power pack in a discharged statewill cause damage. See Charging The PowerPack on page 4-12.
2-4
Power Pack Information Label
7
2-5
There is no engine braking
A
B
Throttle And Speed Control Label Power Pack Labels
A. Power Pack (Battery) Fuse LabelB. Main Power Cut-Off Label
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MAIN POWER CUT-OFF
ON OFFSLIDE DOWNSLIDE UP
Power Pack (Battery) Fuse Label Main Power Cut-Off Label
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Performance Specifications/Operation Guidelines
The Zero S/DS motorcycle is designed to providemany years of trouble free commuting and ridingexcellence. Please read the information below to geta sense for the motorcycle’s performance abilitiesand limitations.
Performance Envelope
• An average rider can expect to achieve 64 km (40miles) of average range under normal use (stopand go traffic), with a maximum range of 97 km(60 miles) of steady riding at 40 km/h (25 mph).You can expect to achieve 48 km (30 miles) ofrange on the freeway of steady riding at 89 km/h(55 mph).
• The Zero S/DS has the ability to start, from astandstill, up a steep 10% grade when fullyloaded. It is not recommended that you stop on agrade of more than 10% with a fully loadedmotorcycle.
Z-Force Air Induction SystemThe air induction system is a compact forced airdelivery system. It consists of a powerful lowmaintenance fan motor (A) located under the rearfender. The fan is connected to the motor by meansof a flexible duct. The system allows the motor to runcooler and increase power by efficiently moving airthrough the motor core. The fan is automaticallycontrolled by the motorcycle control unit and will turnon as the motor temperature increases. In theunlikely event that you exceed the motorcycle’sperformance capabilities, the motor warning systemwill activate. See System Error Indicator on page 2-8.
A
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Stage 1
The brush carrier begins to reach an undesirabletemperature:
• A slow blink is clearly seen on the dash-mountedwarning indicator.
• You can continue to ride without performanceinterruptions.
• You should reduce speed - this will lower poweroutput and the brush carrier temperature toeliminate the blinking warning indicator.
Stage 2
If the brush carrier continues to heat up:
• A fast blink is clearly seen on the dash-mountedwarning indicator.
• The power to the motor begins to drop off,resulting in a noticeable reduction in availabletorque. This provides tactile feedback to the riderand also helps prevent the motor from heatingfurther. As the motor cools again, full-power willbe restored.
WARNING
A
System Error Indicator
The Zero S/DS is equipped with a motor brushcarrier temperature error indicator. In the unlikelyevent that you exceed the motorcycle’sperformance capabilities, it will provide you withan illuminated lamp (A) in three distinct stages:
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• The brush carrier should take no longer thanabout 10 minutes to cool.
• When the warning indicator turns off you cansafely operate the motorcycle again.
• Use the throttle sparingly at first to ensure that thebrush carrier does not overheat.
• At this point it is strongly recommended that youreduce your speed and consider finding a safearea to exit the road.
• You may still have time to back off the throttle toreduce heat. This will restore full power to themotor and eliminate the warning indicator.
Stage 3
If the critical temperature threshold of the brushcarrier is reached:
You will not reach this stage without knowinglyignoring stage 1 and stage 2.
• A ten second sequence of close intervals of rapidpulsing will be visible on the warning indicatorand then power to the motor will be disabled.
• You must quickly find a safe place to park themotorcycle off of the road.
• When power to the motor is disabled the warningindicator goes solid.
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NOTES
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70
60
50
SELECT
ADJUST
40
30
2010 0
80
90100 110
120
A ACB E FD
G IH
Controls And Components
Motorcycle Controls
A. MirrorsB. Fork LockC. Instrument PanelD. Warning IndicatorE. Front Brake Fluid
Reservoir/Master CylinderF. Front Brake LeverG. Left Handlebar ControlH. Key SwitchI. Right Handlebar Control
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A. MirrorsThis motorcycle is equipped with convex mirrors. Aconvex mirror has a curved surface. Convexmirrors offer a greater field of view than a similarflat mirror. However, the greater field of viewmakes objects seem further away than they reallyare. Care must be used when judging thedistance of objects seen in these mirrors.
B. Fork LockFor description and operation see page 4-5.
C. Instrument PanelFor description and operation see pages 3-7 and3-8.
D. Warning IndicatorSee System Error Indicator on page 2-8.
E. Front Brake Fluid Reservoir/Master CylinderFor description and operation see Brakes onpage 5-6.
F. Front Brake LeverThe front brake lever controls the front brake whenthe lever is squeezed. When braking, the throttleshould be in the neutral/returned position. Thestop lamp will illuminate when the brake lever isapplied.
G. Left Handlebar ControlFor description and operation see pages 3-9 and3-10.
H. Key SwitchFor description and operation see page 4-5.
I. Right Handlebar ControlFor description and operation see pages 3-9 and3-10.
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A C DB
E F G H I
Left Side ViewA. HeadlampB. Main Power Cut-OffC. Stop/Tail LampD. Rear Turn SignalE. Front Turn SignalF. AC Charger Power
ConnectionG. On-Board Battery
ChargerH. Kickstand SwitchI. Kickstand
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A. Headlamp
• For headlamp operation, see HandlebarControls on page 3-10.
• For headlamp bulb replacement, seeHeadlamp Bulb Replacement on page 5-14.
• For headlamp alignment, see HeadlampAlignment on page 5-13.
B. Main Power Cut-OffFor description and operation, see page 4-6.
C. Stop/Tail LampFor stop/tail lamp bulb replacement, see Stop/TailLamp Bulb Replacement on pages 5-16 and5-17.
D, E. Turn Signals
• For turn signal operation, see HandlebarControls on page 3-10.
• For turn signal bulb replacement, see TurnSignal Bulb Replacement on page 5-16.
F. AC Charger Power ConnectionFor description and operation, see Charging ThePower Pack on page 4-12.
G. On-Board Battery Charger For description and operation, see Battery Charger
on pages 4-9 and 4-10.
H. Kickstand SwitchThis switch is a safety feature that prevents motoroperation when the kickstand is down. If thekickstand were down when riding it could contactthe ground causing you to lose control of themotorcycle and cause personal injury.
WARNING: Park only on a flat firm surface otherwisethe motorcycle could fall over causing damage.
I. KickstandThe kickstand swings out from the side andsupports the motorcycle when parked. The keyswitch should be in the OFF position whenparked.
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A B C D
A. Rear Brake Fluid ReservoirB. Drive Chain AdjusterC. Rear Brake PedalD. Power Pack
Right Side View
3-6
A. Rear Brake Fluid ReservoirSee Rear Brake on page 5-7.
B. Drive Chain AdjusterSee Drive Chain Adjustment Procedure on page5-12.
C. Rear Brake PedalThe rear brake pedal controls the rear brakewhen the pedal is pressed. When braking, thethrottle should be in the neutral/returned position.The stop lamp will illuminate when the rear brakepedal is applied.
D. Power PackFor description and operation see page 4-7.
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WARNING
A EC D F
G H J KI
B
A. Left Turn Signal IndicatorB. High Beam IndicatorC. SpeedometerD. Main Power IndicatorE. Energy GaugeF. Right Turn Signal IndicatorG. Select ButtonH. Adjust ButtonI. Warning IndicatorJ. Trip OdometerK. Odometer
Instrument Panel
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A and F. Turn SignalsAn arrow on the instrumentpanel will flash green in thesame direction as selected bythe turn signal switch. This willremain on until the turn signalrequest has been canceled.
E. Energy GaugeThis bar graph displays the amount of energyremaining in the power pack, similar to the fuelgauge on a gasoline powered vehicle.
G. Select ButtonBy pressing the select button you can change thedisplay units that appear on the instrument panelbetween English or Metric.
H. Adjust ButtonBy pressing the adjust button you can toggle betweenthe trip odometer settings. Holding it down will clearthe trip odometer resetting it back to zero.
Indicators
B. High BeamWhen the headlamp highbeams are on, this indicatorwill illuminate blue and willremain on until the highbeams are turned off.
C. SpeedometerThe speedometer is an analog and digital display ineither kilometers per hour (km/h) or miles per hour(mph).
D. Main Power IndicatorThe main power indicator is OFF any time the key isin the ON position. If the main power indicator isflashing, the system has detected a fault. Fortroubleshooting, see pages 6-9 and 6-10.
I. Warning IndicatorThis motor brush carrier temperature error indicatorwill blink in the unlikely event that you exceed themotorcycle’s performance capabilities. See SystemError Indicator on page 2-8 for more information.
J. Trip OdometerThe trip odometer displays individual trip mileage, andis reset by pressing and holding the Adjust button.
K. OdometerThe odometer displays the total distance themotorcycle has been ridden in kilometers or miles.
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A B C
ED F G H
A. High Beam Flash-to-PassB. Headlamp High/Low Beam SwitchC. Front Brake LeverD. High Beam IndicatorE. Horn Switch
Handlebar Controls
F. Turn Signal SwitchG. Kill SwitchH. Throttle
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B. Headlamp High/Low BeamSwitchWhen the switch is pushed, theheadlamp will change from lowbeam to high beam. It will stay inthe selected position until it isswitched back. When in highbeam position, the high beam
C. Front Brake LeverThe front brake lever controls the front brake whenthe lever is squeezed. When braking, the throttleshould be in the neutral/returned position. The stoplamp will also illuminate.
D. High Beam IndicatorWhen the headlamp is in high beam position orthe flash-to-pass switch is pressed this indicatorwill illuminate.
E. Horn SwitchWhen the key is in the ON position, the horn willsound when the switch is pressed. Electricvehicles run quietly; the horn can be used to warnpedestrians or other motorists of your presence.
F. Turn Signal SwitchWhen the turn signal switch ispushed in the left or right position,the corresponding front and rearturn signal will flash. When theturn signal switch is ON, thecorresponding turn signal indicator
on the instrument panel will illuminate.
Always signal your turns and other maneuvers asrequired by law. Unlike an automobile, the turnsignals must always be cancelled manually on themotorcycle. Push in on the switch and it will returnto the center or OFF position.
A. Flash-to-PassWhen the headlamp is in the low beam position,push the flash-to-pass switch and the high beam willilluminate and will stay illuminated until the switch isreleased. When released, this switch will default backto the low beam position. The high beam indicatorwill also illuminate.
indicator on the handlebar control and the high beamindicator on the instrument panel will illuminate.
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A
B
A
B
G. Kill SwitchWhen the switch (A) ispressed, it will kill power to themotor controller. The motorcontroller will remain in thisstate until the ON (B) button ispressed. The switch does notturn off all electrical circuits,just the operation of the motor.
H. Throttle ControlTwist the throttle in a counter-clockwise rotation (A) toenergize the motor and start the motorcycle in aforward direction. Release the throttle and it will snapback to the neutral/returned position (B), de-energizingthe motor.
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NOTES
4-1
Starting And Operating
First Time Set-Up
If your motorcycle was direct shipped you will need toperform the following:
1. Remove the motorcycle from its shipping crate.See Uncrating Your Motorcycle on page 4-2.
2. You must charge the power pack before riding themotorcycle. See Charging The Power Pack onpage 4-12.
3. Identify and inspect the wheels and brakes forleaks or irregularities.
4. Check the tire pressure and adjust to properspecifications. See Tire Inflation on page 5-9.
5. Inspect the hydraulic brake system. Follow thehydraulic line from the reservoirs to the calipersand verify that there are no leaks or damage tothe brake lines. Verify that the brakes functionproperly.
6. Make sure the motorcycle key switch is OFF, thentwist the throttle to make sure it’s rotation issmooth and returns correctly.
7. Inspect bolts and make sure they are tight. SeeBolt Torque Table on page 5-2. Double check thefork, wheel, and brake bolts.
8. Insert the key in the key switch, engage the rearbrake and turn the key to the ON position. Theenergy gauge should read fully charged.
4-2
Uncrating Your Motorcycle
The S/DS motorcycle arrives almost entirelyassembled. It is recommended that you have anassistant to help with the uncrating procedure. Weadvise wearing protective gloves and protectiveeyewear when uncrating the Zero motorcycle. It ispossible during shipping that sharp edges or pointsmay occur, please use caution. Retain the crate andall other shipping items for future shipping of themotorcycle.
Note: The shipping crate may differ slightly thanshown, below are general guidelines for uncrating themotorcycle.
1. Remove the crate clamps (A) and remove thecrate end panel (B).
2. With the aid of an assistant, lift and move (C) thecrate off of the base.
A
C
B
4-3
A
B B
A
3. With the assistant holding the motorcycle upright,remove the ratchet straps (B).
4. Fold down the ramp (A) and lower the protectiveplastic.
5. Remove the fork support (A), located between thewheel and front fender.
6. Carefully roll the motorcycle off of the crate base.
7. Secure and adjust the mirrors.
4-4
General Operation
Pre-Ride Inspection
Before operating the Zero S/DS motorcycle, check thefollowing to make sure the motorcycle is secure andintact:
• Power PackMake sure the onboard energy gauge isindicating a charged power pack. If theenergy gauge reads below 6 bars (1/2), wesuggest you recharge before use. Always keepthe charger cord with the motorcycle.
• Drive ChainCheck chain slack and condition. Adjust andlubricate if necessary. The drive chain must becleaned and lubricated at the intervals specifiedin the maintenance schedule; otherwise it willquickly wear out, especially when riding in dustyor wet areas. See Chain on page 5-10.
• BrakesSqueeze the brake lever and press the brakepedal individually while pushing the motorcycle tosee if it rolls. You should be able to lock-up thewheels completely by applying the brakes.
• ThrottleWith the key switch in the OFF position, apply thethrottle and release to verify that the throttle issmooth and returns correctly.
• TiresCheck both tires for condition and tread depth.Check cold tire pressure frequently. Check fordamage and alignment. Maintain correct tirepressure as specified on page 5-9. Replace thetires when the tread height is 2 mm (0.08 in) orless.
CAUTION: Under-inflation is the most common causeof tire failure and may result in severe tire cracking,tread separation, “blowout,” or unexpected loss ofmotorcycle control causing personal injury andpossible death.
• Electrical SystemCheck for correct function of the headlamp, turnsignals, and the stop/tail lamps.
4-5
A
B
Key Switch Positions
This is a two-position switch that is located on thetop/front of the motorcycle below the handlebar. Theswitch positions are as follows:
• OFF
• ON
The key should be removed from the motorcyclewhen parked to prevent theft.
There is a red dot (A) indicating the ON position. Thekey (B) can be folded down.
Fork Lock
CAUTION: Do not operate the motorcycle with the forklocked. This will prevent the motorcycle’s ability tosteer and could cause personal injury.
Using the fork lock when parked will preventunauthorized use and help prevent theft. The fork lockkey is different from the key switch key.
To Lock
1. Turn the fork all the way to the left.
2. Insert the key (A) into the lock (see image onpage 4-6) then turn the key clockwise and removethe key. The fork should not turn.
4-6
MAIN POWER CUT-OFF
ON OFFSLIDE DOWNSLIDE UP
A
To Unlock
1. Install the key and turn counter-clockwise.
A
Main Power Cut-Off
The main power cut-off switch (A) is located on theleft rear of the Z-Force power pack. This is a slideswitch. This switch is used to connect or disconnectthe Z-Force power pack from the motorcycle. Whenthe switch is slid down to OFF (disconnected) allelectricity to the motorcycle is turned off, this includesthe charger. When charging or operating, the switchmust be slid up to the ON (connected) position.
2. Remove the key.Never ride with thekey in the fork lock.
This switch must be in the OFF position whentransporting or shipping the motorcycle.
4-7
Power Pack
The battery is located within the power pack andrequires no special break in period. Under normaluse and correct power pack maintenance, the powerpack should maintain most of its capacity forapproximately 5 years, dependent on use.
The charging time is the same if connected to 110 VAC or 220 V AC; this is an input to the charger. Thecharger output will be the same.
The normal recharging time of the power pack isusually less than 4 hours in ambient temperatures.Out-of-the-normal temperature range charging andrun-time times will vary. The power pack should notbe used outside of the range of -7°C - 71°C (20°F -160°F); the Battery Management System (BMS) willturn off the motor controller outside of this range.
It is recommended that you leave the motorcycle onthe charger if you expect it to sit in storage or unusedfor over 7 days. The power pack must be chargedwithin 24 hours if fully discharged, and charged within60 days if stored fully charged. Zero recommends youplug in your Zero motorcycle after 7 days, even if fullycharged. Please leave your Zero motorcycle pluggedin whenever possible.
Add On Electrical Equipment
WARNING: Do not add anything electrical to yourmotorcycle unless approved by your CSC. Someelectrical components can damage your motorcycle.Some add on electrical equipment can keep othercomponents from working as they should or candramatically reduce the range and or life expectancyof the power pack.
The 6 digit serial number for the battery is located ona label on the top of the power pack.
4-8
• High or Low TemperatureAction: If the BMS senses that the power pack istoo hot, above 71°C (160°F), or too cold, below -7°C (20°F), it sends a signal to disable the motorcontroller and the motorcycle will not run until thetemperature returns to an acceptable level. Thecharger will also be disabled in this condition.
• High VoltageAction: If the BMS detects a voltage that is toohigh, it shuts down the charger to prevent over-charging.
The BMS is sealed inside the power pack. As a rider,you don’t need to think much about the BMS - it justsilently does its job as you charge, ride, and storeyour motorcycle. There are only two things you mightneed to know about your Z-Force BMS:
• Beep-SignalsThe BMS will emit an “OK” beep-tone every timeyou turn-on your motorcycle. The BMS might alsorespond to other internal conditions and errorswith different kinds of beeps. This sectionexplains the different beep-patterns and theirmeanings.
Battery Management System (BMS)
Every power pack contains a Battery ManagementSystem (BMS) which monitors the condition of thecells and optimizes the charging process to providethe highest-performance, longest-range, and longest-life for the power pack.
The BMS also monitors the battery for a host ofpredefined conditions and then takes actionsaccording to these conditions. Some of theseconditions are listed below. Also see UnderstandingBeep Sequences on page 6-3.
• Low VoltageAction: When a low voltage is detected, thebeeper is sounded to alert the rider that theyshould stop riding the motorcycle. This beeperbeeps approximately once every 10-12 secondswhen the motorcycle is being ridden and thenonce every minute when the motorcycle is inactive.
• Dangerously Low VoltageAction: If the voltage drops to the point that maydamage the battery cells, the battery sends asignal to disable the motor controller and themotorcycle will not run until the voltage returns toan acceptable level.
4-9
A
• Safety InterlocksThe BMS can disable the motorcycle’s throttle-control if the power pack is fully discharged, or incase of other errors. The BMS can also disablecharging under certain circumstances. Theinformation below explains the different conditionswhich can cause the BMS to disable the throttle-control or the battery charger.
Beeps
The BMS includes an electronic beeper, sealed insidethe power pack. The beeper is located on the upperfront left corner of the power pack.
The BMS will beep under only two circumstances:
• When the motorcycle key switch is turned from“OFF” to “ON.” When the motorcycle is turned ON,the BMS will perform a self-test. It will alwayssound a beep-signal when the test finishes. Thebeep-pattern reports the self-test result.
• When the key switch is “ON,” and thepower pack is nearly empty. The BMS willcontinuously sound a warning when the powerpack is low. The warning will stop when themotorcycle is turned-off.
Battery Charger
When charging the motorcycle’s power pack (battery)the charger (A) can be left ON, even after the batteryis fully charged. There are two possible cases thatcan occur:
4-10
• When left on the charger the power pack willreceive a full charge. Once fully charged, thecharger will check the status of the power packonce every 72 hours to ensure that it maintains afull charge. When fully charged a green light willilluminate on the charger. Should the charger notread that the power pack is full, it will continue toattempt to fully charge the power pack. In thisevent the green light may not illuminate, however,the power pack may be fully charged. To ensurethat the power pack is charged, check the energygauge prior to riding.
• If the power pack terminates the charge beforethe charger reaches the state above, then thecharger will continue to cycle and will top off thepower pack until the power pack is removed orthe charger reaches the complete state notedabove.
4-11
Charger LED Indicators
Note: The charger must be plugged in for the charger’s indicators to illuminate. See Battery Charger onpages 4-9 and 4-10 for location.
Power Pack LED Indicator Diagram
Ammeter(Amber)
Solid: Displays approximate scale of current output during bulk phase. High internal charge temperature. Current output reduced.
Solid: Bulk charge phase complete, 80% charged. In Absorption phase.
With no power pack connected, indicates algorithm # selected by number of flashes.
Flashing: Also displays algorithm #1-6 for 11 seconds if no power pack is connected.
Flashing:
80% Charge(Amber)
100% Charge(Green)
AC On(Amber)
Fault(Red)
Solid: Charging complete. Charger in Maintenance Mode.
Flashing: Absorption phase complete. In Finish phase.
Solid: AC Power good.
Flashing: Low AC Voltage, check voltage and extension cord length 7.6m (25 FT) 12 AWG
Flashing: Charger error. Reset charger power and see Troubleshooting Section 6.
4-12
A
4. Always connect the charger to a GROUNDEDoutlet. When using an extension cord, avoidexcessive voltage drops by using a grounded, 3-wire, 12-AWG cord no longer than 7.6 m (25 ft).The charger can be used on 110 V AC or220 V AC current. The voltage does not changethe amount of time that the motorcycle takes tocharge.
Charging The Power Pack
1. When the motorcycle’s energy gauge is on thethird or fourth bar when not under load, thepower pack needs to be charged. Frequent topoff charging is good for the power pack’s lifespan, so do not hesitate to charge frequently.
2. Ensure that the key switch is in the OFFposition.
3. Plug the supplied power cord (A) into the on-board charger connector. Always keep the powercord with the motorcycle.
WARNING: Charge the Zero power pack with the Zerocharger. It is possible for lithium ion cells to overheatand burst. It is recommended to charge in a locationthat is away from combustible materials and in a wellventilated area. Avoid outdoor charging of your Zeromotorcycle in the rain.
4-13
5. AVOID connecting the Zero motorcycle charger andanother device to a single 15A/20A or the circuitmay become overloaded.
6. Charging a fully discharged power pack takesabout 4 hours.
7. Your power pack is equipped with an “EmergencyEnergy Reserve Beep.” When your power packmakes an audible beep, it has only a few milesof range left. This beep tells you your power packis dangerously low on energy and needs to berecharged immediately. Your power pack willcontinue to beep even when it’s charging until ithas recovered its “Emergency Energy Reserve.”
8. When the power pack is fully charged, disconnectthe power cord from the charger.
4-14
The front and rear brake should be applied together,with a slight amount more of the braking on the front.
CAUTION: If you apply the front or rear brake hardenough, it is possible lock the wheels. This couldcause you to lose control of the motorcycle. Wesuggest progressive use of the brakes to bring theZero motorcycle to a complete stop without lockingthe wheels. Your Zero motorcycle is a light weightperformance product and therefore practice isrecommended to safely perfect emergency stops.
Stopping
1. With the throttle in the neutral position and thebrake applied, press the kill switch to the OFFposition. This switch can also be used inan emergency to shut the motor off.
2. Turn the key switch to the OFF position andremove the key. To prevent theft, the key shouldbe removed anytime the motorcycle is leftunattended.
3. Be sure to charge the power pack after each ride.See Charging The Power Pack on page 4-12.
2. Turn the key switch to the ON position.
4. With the kickstand up, release the brake and twistthe throttle toward you (counter-clockwise) toincrease speed. When the throttle is twisted awayfrom you (clockwise), the speed will decrease.
Braking
1. On the right handlebar is the hand operatedbrake lever. The brake lever controls the frontbrake when the lever is squeezed. On the rightlower side, next to the foot peg, is the footoperated brake lever. This lever controls the rearbrake. When braking, the throttle should be in theneutral/returned position.
3. Verify that the energy gauge reads fullycharged.
Operating Your Motorcycle
Starting
1. With the brake applied, press the kill switch to theON position.
4-15
Suspension Adjustment
Front Fork Adjustment
A shock has two main actions: compression whenthe shock gets compressed, and rebound when theshock returns back to full length. Compressiondamping is the adjustment that determines how fastor slow the fork compresses. Rebound damping isthe adjustment that determines how fast or slow thefork rebounds.
1. Bleed Screw - The small Allen screw (A) at thetop of the fork leg is the “bleed” screw. The bleedscrew serves two purposes:
• Transporting your motorcycle. See Transportingon page 1-11.
• Bleeding the fork: Bleed the fork regularly, letany excess air out after each ride.
2. Rebound Damping - The rebound damping isadjusted by turning the slotted brass adjusterscrew (B) on the top of both fork legs. Next to itwill be the writing S-F, meaning Slow and Fast.The adjuster has 18 stages of adjustment. Thisdetermines how quickly the fork returns to itsextended position after being compressed.Turning the rebound adjuster screw clockwise willslow the rebound speed down making it better forlarger, rolling terrain or bumps. Turning therebound adjuster screw counter-clockwise willincrease the rebound speed making it better forsmaller, rougher bumps. Adjust each fork legevenly.
A
S FS F
A
BB
4-16
AA
B
B
3. Compression Damping - The compressiondamping is adjusted by turning a screw on thebottom of each fork leg. There is a rubber dustcover protecting the screw and a jam nut (A)securing the screw (B). The adjuster has 12stages of adjustment. Turn the adjuster clockwisefor slower compression. To speed upcompression, turn the adjuster counter-clockwise.Start with a middle setting and fine tune thecompression from there. Proper compression willallow the tire to track the ground over consecutivebumps. Compression that is set too slow willpack-up (feel harsh over consecutive bumps)while compression that is set too fast will causethe fork to bottom out harshly. If the fork isbottoming out, turn the adjuster one click at atime until the bottom-out stops. Adjust each forkleg evenly. Replace the rubber dust cover after theadjustment.
4-17
Rear Shock Adjustment
Spring Adjustment:
Obtaining the correct rear spring rate is critical forproper handling. The spring rate must be set tomatch the weight of the rider. Heavier riders requirestiffer spring rates. A good approximation of your rearspring requirements can be found by measuring therear suspension’s sag. This measurement will quicklydetermine if your rear spring is approximately correctfor your weight. This adjustment is a recommendationguideline; personal riding preference may vary fromthe specifications given.
• Checking Sag
1. Support your motorcycle on a standwith the rear wheel off the ground.
2. Measure vertically from the rear axle tothe rear fender. Mark this spot as it willbe used for other measurements.
3. Record this measurement, this will bemeasurement M1.
M1
4. Remove the motorcycle from the stand.
5. Wearing your normal riding apparel, sit on the motorcycle.
6. Have an assistant hold the motorcycle up, your feet should be on both pegs.
7. Bounce the suspension a couple of times.
4-18
M2
Example:
If the total is between 90 to 100 mm (3.5 to 4.0 in),the sag is correct. If it is not within 90 to 100 mm(3.5 to 4.0 in), the spring pre-load should beadjusted. See Spring Pre-load Adjustment.
M1 600 mm (23.6in)
M2 - 500 mm (19.6in)
Sag = 100 mm(4 in)
8. Have a second assistant take ameasurement using the same locationsas in step 2.
9. Record this measurement, this will bemeasurement M2.
10. Subtract the second measurement (M2)from the first measurement (M1).
4-19
• Spring Pre-load Adjustment
1. Clean any dirt or debris from the threads of the shock.
2. Using a spanner wrench loosen thelock nut (A).
3. For measurements less than 90 mm (3.5 in),decrease the pre-load on the spring byturning the spring nut (B) counter-clockwiseon the shock. If more than 100 mm (4.0 in),increase the pre-load on the spring byturning the spring nut (B) clockwise on theshock.
4. Recheck the sag. If the sag is correct, tighten the lock nut (A).
• Rebound Adjustment - The rebound adjuster knob(C) is at the bottom of the shock. It has 8 stagesof adjustment. Printed on the knob is S-F,meaning Slow and Fast. The rebound adjusterknob controls how slow or fast the shock returnsto its extended position after being compressed.Turning the knob clockwise, or S direction, isgood for big impacts.
C
B
A
Turning the knob counter-clockwise, or F direction, isgood for smaller and more frequent impacts.
4-20
NOTES
5-1
Maintaining Your Motorcycle
Owner’s Responsibilities
1. This owner’s manual should be considered apermanent part of this motorcycle and shouldremain with it even if the motorcycle issubsequently sold.
2. Perform routine care and maintenance of yourelectric motorcycle as detailed in this owner’smanual.
3. Use only genuine Zero approved parts andaccessories.
4. The operator is responsible for learning andobeying all country, federal, state, and local lawsgoverning the operations of an electric motorcycle.
5. Always wear a DOT approved helmet, goggles,appropriate boots, and all other appropriate safetyequipment when operating an electric motorcycle.
5-2
Bolt Torque Table
* or equivalent
LOCATION ITEM TORQUE NOTES
A Handlebar clamp mount bolts 13-15 N•m (10-11 lb ft) Use LOCTITE® 242®*
B Shock mount bolts 13-15 N•m (10-11 lb ft) Use anti-sieze lubricant
C Rear caliper mount bolts 11-13 N•m (8-10 lb ft) Use LOCTITE® 242®*
D Fork pinch bolts 11-13 N•m (8-10 lb ft) Use LOCTITE® 242®*
EFront axle pinch bolts 11-13 N•m (8-10 lb ft)
Use LOCTITE® 242®*Front axle end bolts 18-20 N•m (13-15 lb ft)
F Front caliper mount bolts 11-13 N•m (8-10 lb ft) Use LOCTITE® 242®*
G Charger bolts 5-6 N•m (44-53 lb in) Use LOCTITE® 242®*
H Main pivot bolt/nut (swingarm) 105-110 N•m (77-81 lb ft) Use LOCTITE® 270TM*
I Rear axle pinch bolts 11-13 N•m (8-10 lb ft) Use LOCTITE® 242®*
J Rear axle end bolts 18-20 N•m (13-15 lb ft) Use LOCTITE® 242®*
K Triple tree pinch bolts 13-15 N•m (10-11 lb ft) Use LOCTITE® 242®*
L Headlamp bolts 13-15 N•m (10-11 lb ft) Use anti-sieze lubricant
M Motor mount bolts 30-32 N•m (22-24 lb ft) Use anti-sieze lubricant
5-3
B C JI
H
FED
G
See Bolt Torque Table on page 5-2.
5-4
L
M
K
See Bolt Torque Table on page 5-2.
5-5
A
See Bolt Torque Table on page 5-2.
Power Pack
WARNING: You must leave your motorcycle on thecharger if you expect it to sit in storage or unused forover 7 days.
The power pack must be charged within 24 hours iffully discharged, and charged within 60 days if storedfully charged.
1. The power pack is a lithium ion power system.While it does require charging, it does not requiremaintenance.
2. The power pack should be kept away fromexcessive heat. The lithium ion cells should notget above 71°C (160°F). Do not store in a hot caror trailer, or leave the power pack in directsunlight.
3. Only an authorized service agent is qualified tohave access to and troubleshoot the power pack.
4. Dispose of the power pack according to your stateand local laws. It is encouraged that the powerpack be recycled rather than disposed of inlandfills. Locate a recycling center in your area. Ifone cannot be found, contact Zero [email protected].
Zero recommends you plug in your Zero motorcycleafter 7 days, even if fully charged. Please leave yourZero motorcycle plugged in whenever possible.
5-6
General Maintenance
Motor
CAUTION: Wear safety glasses when usingcompressed air to avoid eye injury.
The motor does not require much maintenance, butdust can collect inside the motor and can causepremature brush wear. If you ride in dusty conditionsit is important to blow the dust out of the motor withcompressed air. Do this only in a well ventilated area.
Brakes
Brake Fluid Level Inspection
WARNING: Do not spill brake fluid on painted orplastic surfaces, the finish could be damaged. Cleanoff any brake fluid spills immediately.
Low fluid levels may indicate worn brake pads or aleak in the hydraulic system. Inspect the brake padsfor wear and or the hydraulic system for leaks. Useonly new DOT 4 brake fluid from a sealed container.
Front Brake
A
B
C
Inspect the level of thefront brake fluid throughthe sight glass (B). Ifthe fluid level is visiblybelow the low levelindicator (C), brake fluidmust be added. Cleanany dirt or debris fromthe cover (A) beforeopening the reservoir.
1. Remove the two Phillips screws, securing thecover onto the reservoir.
2. Add new DOT 4 brake fluid.
3. Inspect the cover seal, ensuring that it is free ofany wear or damage and that it is positionedcorrectly.
4. Install the cover and tighten the Phillips screws.
5-7
B
A
A
Rear Brake
Inspect the level of therear brake fluid byinspecting the levelthrough the reservoirhousing. If the fluidlevel is visibly belowthe low minimum “MIN”indicator (B), brakefluid must be added.Clean any dirt ordebris from the capopening (A) before
opening the reservoir. Unscrew the cap and add newDOT 4 brake fluid. Inspect the cap seal ensuring thatit is free of any wear or damage then reinstall thecap.
Brake Pad Inspection
The brake pads must be inspected when specified inthe maintenance schedule. See MaintenanceSchedule on pages 5-20 through 5-22. Visuallyinspect the brakes by looking at the remaining brakepad material through the sides of the brake caliper.Replace the brake pads if either pad’s thickness is1.35 mm (0.05 in) or less. If the brake pads (A) areworn, replace both brake pads immediately.
5-8
Rear
CAUTION: The shock absorber assembly containshighly pressurized gas.
• Do not attempt to tamper with or open thecylinder or shock.
• Do not subject the shock to high temperatureor open flame.
Doing either of these can cause the cylinder or shockto explode causing personal injury or death.
To adjust the shock, see Rear Shock Adjustment onpage 4-17.
Wheels And Tires
Inspect both wheels for the following:
• Bent, loose, or missing spokes
• Bent or cracked wheels
• Impact marks on the wheels
Suspension
FrontFor maintenance, see Maintenance Schedule onpages 5-20 through 5-22.
To adjust the fork, see Suspension Adjustment onpage 4-15.
For maintenance, see Maintenance Schedule onpages 5-20 through 5-22.
5-9
Inspect both tires for the following:
• Cuts, cracks, splits, missing tread lugs, orbruises in the tread or sidewall area
• Bumps or bulges within the tire body
• Uneven tire tread wear. Wear on one side of thetire tread or flat spots in the tire tread indicate aproblem with the tire or motorcycle.
• Exposed tire tread or cords
If either of the wheels or tires are found to have anyof the above conditions, replace the wheel and tireimmediately.
Tire Inflation
CAUTION: Under-inflation is the most common causeof tire failure and may result in severe tire cracking,tread separation, “blowout,” or unexpected loss ofmotorcycle control causing personal injury andpossible death.
Tire pressure should be checked and adjusted beforeeach ride. Tire pressure is checked using anaccurate gauge when the tires are cold. This meansthat the tires have not been ridden on for 3 hours.Always replace the valve stem cap when finished.
MODEL FRONT REAR
S 248 kpa (36 psi)
248 kpa (36 psi)
DS 220 kpa(32 psi)
220 kpa (32 psi)
5-10
Chain
Cleaning The Drive Chain
CAUTION:
• Wear safety glasses when cleaning the chain toprevent eye injuries.
• Never have the motor spinning the wheel. Turnthe wheel only by hand. Failure to do so couldresult in serious personal injury.
• Never place your hand or any other body partbetween the chain and sprockets. Work with thechain only in the middle between the twosprockets. Failure to do so could result in seriouspersonal injury.
• Do not allow any of the cleaner to get on thebrake rotors or brake pads. If the rotors arecontaminated with cleaner, it will impair themotorcycle’s ability to stop. This could result inserious personal injury.
Follow the manufacturer’s instructions for the chaincleaner you are using; below are the general guide-lines.
1. Remove the key from the key switch.
2. Set the motorcycle on a stand or lift so the rearwheel is free to spin. While turning the wheel byHAND, spray the inside of your entire chain with agood coating of chain cleaner and let it sit for afew minutes.
3. Using a brush, fill the bristles with spray from thechain cleaner. Begin gently scrubbing the chain onthe top of your swingarm using the brush.
4. Do this for the entire length of the chain. Now dothe same thing for the inside/bottom of the chain.
5. Using the brush, clean both sides of the rearsprocket. Let this soak for 5 minutes.
6. Using a hose, rinse the entire chain and using aclean rag wipe any residual moisture from thechain.
5-11
32 mm (1.25 in)
Lubricating The Drive Chain
CAUTION:
• Wear safety glasses when lubricating the chain toprevent eye injuries.
• Never have the motor spinning the wheel. Turnthe wheel only by hand. Failure to do so couldresult in serious personal injury.
• Never place your hand between the chain andsprockets. Work with the chain only in the middlebetween the two sprockets. Failure to do so couldresult in serious personal injury.
Follow the manufacturer’s instructions for the chainlubricant you are using; below are the general guide-lines. Do not allow any of the lubricant to get on thebrake rotor.
1. Turn the wheel backwards slowly and spray theinside of the chain on the inside of the links.
2. Turn the wheel backwards slowly and spray theoutside of the chain on the outside of the links.
Checking The Drive Chain
1. Remove the key from the key switch.
2. Using a ruler, grasp the chain halfway betweenthe front and rear sprockets.
3. The chain should move 16 mm (.63 in) in eitherdirection, so 32 mm (1.25 in) of total free play.
4. If the chain’s free play is not within specificationsit will need to be adjusted. See the Drive ChainAdjustment Procedure on page 5-12.
• Do not allow any of the lubricant to get on thebrake rotors or brake pads. If the rotors arecontaminated with lubricant, it will impair themotorcycle’s ability to stop. This could result inserious personal injury.
3. Let the motorcycle stand for 30 minutes to allowthe lubricant to penetrate the link rollers.
5-12
A
B
D
C
Drive Chain Adjustment Procedure
7. Tighten the 13 mm jam nut on the chaintensioner. See Bolt Torque Table on page 5-2.
8. Test ride the motorcycle.
9. Recheck the chain for proper adjustment after thetest ride and readjust if necessary.
1. Remove the key from the key switch.
2. Loosen both rear motor mount Allen bolts (A).
4. Loosen the 13 mm jam nut (C) on the chaintensioner.
5. Turn the adjuster bolt (D) a 1/4 turn at a time untilthe chain free play is within specification.
6. Tighten all motor mount Allen bolts. See BoltTorque Table on page 5-2.
3. Loosen both front motor mount Allen bolts (B).
5-13
A
A
A
B
Headlamp Alignment
The headlamp should be checked for correctalignment periodically. It must be aligned any time thesag is adjusted because this will affect the headlampalignment. Before the headlamp can be aligned, thesag and tire pressure must be correctly adjusted. Theheadlamp can be adjusted horizontally and vertically. Ifthe horizontal adjustment is off, the beam will pointtoo far off to one side. If the vertical adjustment is off,it will cause the beam to point too close to or too farahead of the motorcycle. With the headlamp on thelow beam position, the motorcycle perpendicular tothe ground, and the operator sitting on the motorcycle,verify the beam alignment.
To adjust the headlamp horizontally, turn screw (B)until the correct beam alignment is achieved.To adjust the headlamp vertically, loosen the housingscrews (A). Move the housing up or down until thecorrect beam alignment is achieved. Tighten thescrews. See Bolt Torque Table on page 5-2.
5-14
Headlamp Bulb Replacement
CAUTION: Halogen bulbs contain gas under pressure.Handling a bulb improperly could cause it to shatterinto flying glass fragments. To help avoid personalinjury:
• Turn off the key switch and allow the bulb to coolbefore changing the bulb.
• Leave the key switch OFF until the bulb change iscomplete.
• Always wear eye protection when changing ahalogen bulb.
• Handle the bulb only by its base. Avoid touchingthe glass.
A
2. Disconnect the main headlamp connector (A).
1. Remove the two screws (A) from the headlamphousing.
5-15
A
3. Working with the headlamp on a bench,disconnect the headlamp bulb connector andcover.
4. Unhook the headlamp bulb spring clip (A) by(1) pushing down then (2) pushing to the side.
5. Lift up on the spring clip and remove theheadlamp bulb.
A
2
1
WARNING: Do not touch the glass portion of theheadlamp bulb. Keep the headlamp bulb free ofcontaminants. Oil from your fingers or contaminateswill shorten the life of the bulb. Thoroughly clean anyfingerprints or contaminates from the bulb using aclean cloth moistened with alcohol.
5-16
6. Install the headlamp bulb into the lens.
7. Install the headlamp spring clip.
8. Install the headlamp bulb cover; ensure that thearrow is pointing up.
9. Connect both connectors and install the headlampscrews.
Turn Signal Bulb Replacement
1. Remove the turn signal lens screw (A) andremove the lens.
2. Push in on the bulb, turn the bulb counter-clockwise, and then pull the bulb out.
3. Insert the new bulb into the socket, push in andturn clockwise until it stops.
4. Install the lens and screw; tighten the screw. Donot over-tighten the screw otherwise the lens maybreak.
A
Stop/Tail Lamp Bulb Replacement
1. Remove the stop/tail lamp lens screws (A) andremove the lens.
5-17
Running Lamp Bulb Replacement
1. Remove the two screws (A) from the headlamphousing.
A
2. Remove the bulb socket (A) from the headlampusing a rocking motion (see image onpage 5-18).
2. Push in on the bulb and turn the bulb counter-clockwise then pull the bulb out.
3. Insert the new bulb into the socket, push in andturn clockwise until it stops.
4. Install the stop/tail lamp lens and screws; tightenthe screws. Do not over-tighten the screwsotherwise the lens may break.
A
5-18
Cleaning
To prolong the life of your motorcycle it should bewashed periodically. Regular cleaning, using correctmethods, is an important factor in maintaining thevalue of your motorcycle. It also ensures that safety-relevant parts remain in full working order.
CAUTION: After cleaning and before starting yourjourney, always test the brakes.
If tar, bugs, or other similar deposits haveaccumulated, wash them off as soon as possible. Donot use high pressure or steam cleaners; they cancause water intrusion of bearing, seals, and electricalcomponents. Avoid spraying water of great forcearound the instrument panel. Avoid using strongacidic wheel cleaners, especially on spoked wheels.If such products are used on hard-to-remove dirt, donot leave the cleaner on the affected area any longerthan instructed. Also thoroughly rinse the area off withwater, immediately dry it, and then apply a corrosionprotection spray.
WARNING: Improper cleaning can damage electricalcomponents, cowlings, panels, and other plasticparts. Use only a soft, clean cloth or sponge withmild detergent and water to clean plastic.
3. Pull the old bulb out of the socket.
4. Push the new bulb into the socket and push thesocket (A) into the headlamp.
5. Install the headlamp housing and screws.
A
5-19
Parking And Long Term Storage
1. It is recommended to always leave the powerpack plugged in. The Zero S/DS charger isdesigned to maintain a balanced and completecharge at all times without wasting any electricity.
After gently washing the motorcycle, be sure to allowall of the electrical components to dry prior tooperation. If the motorcycle is ridden immediately afterbeing washed, apply both brakes several times inorder to remove any moisture from the brake linings.Do not use products such as tire dressings on tiresas this will deteriorate traction.
2. Over extended periods of time the power pack ischecked every 72 hours to ensure that the cellsare balanced and that the power pack is full.Once the power pack is “topped off” the chargerstops charging and continues to monitor thepower pack. This ensures that electricity is notwasted in maintaining an optimized power pack.
3. To prolong the life of your power pack you shouldstore your motorcycle in a cool area. Storing yourmotorcycle in a hot area will cause your powerpack’s life to be shortened.
4. If, for some reason, your motorcycle was notplugged in for several days you should alwayscharge it up before operation.
For more information on the power pack and theelectrical system see Battery Management System(BMS) on page 4-8.
WARNING: Opening of the power packs is for trainedZero Motorcycles technicians. Please be aware thatincorrect handling of a Zero battery can be dangerous.DO NOT OPEN!
Do not use any harsh chemical products on plasticparts. Be sure to avoid using cloths or spongeswhich have been in contact with strong abrasivecleaning products, solvent or thinner, fuel (gasoline),rust removers or inhibitors, brake fluid, antifreeze orelectrolyte.
5-20
Maintenance ScheduleThe scheduled maintenance must be performed in accordance with this chart to keep the Zero S/DS motorcycle intop running condition. The initial maintenance is vitally important and must not be neglected. Where time andmileage are listed, follow the interval that occurs first.
NO. ITEM ROUTINE EVERYRIDE
INITIAL ODOMETER MILEAGE READINGS
1,000 km(600 mi)
or1 month
7,000 km(4,000 mi)
or6 months
13,000 km(8,000 mi)
or12 months
19,000 km(12,000 mi)
or18 months
25,000 km(16,000 mi)
or24 months
31,000 km(20,000 mi)
or30 months
1 Front Brake• Check operation, and for fluid leakage. Replace brake pads if necessary.
2 Rear Brake• Check operation, and for fluid leakage. Replace brake pads if necessary.
3BrakeHoses
• Check for cracks or damage. Replace if necessary.
4 Wheels• Check runout and for damage. Replace if necessary.
5 Tires
• Check tread depth and for damage. Replace if necessary.• Check air pressure. See page 5-9. Correct if necessary.
5-21
NO. ITEM ROUTINE EVERYRIDE
INITIAL ODOMETER MILEAGE READINGS
1,000 km(600 mi)
or1 month
7,000 km(4,000 mi)
or6 months
13,000 km(8,000 mi)
or12 months
19,000 km(12,000 mi)
or18 months
25,000 km(16,000 mi)
or24 months
31,000 km(20,000 mi)
or30 months
6WheelBearings
• Check bearings for smooth operation. Replace if necessary.
7SwingarmPivotBearings
• Check bearing assemblies for looseness.• Moderately repack with lithium grease.• Ensure main pivot bolt is properly torqued. See Bolt Torque Table on page 5-2.
8 Drive Chain
• Check chain slack/alignment and condition.• Adjust and lubricate chain with chain lubricant thoroughly.• Replace worn chain.
Every 1,000 km (600 mi) and after washing the motorcycle or riding in therain
9SteeringBearings
• Check bearing assembly for looseness.• Moderately repack with lithium grease every 25,000 km (16,000 mi) or 24 months.
Repack
10ChassisFasteners
• Check all chassis fittings and fasteners. Correct if necessary.
11Front BrakeLever PivotShaft
• Apply lithium grease (all purpose grease) lightly.
5-22
NOTE: From 37,000 km (24,000 mi) or 36 months, repeat the maintenance intervals starting from 13,000 km(8,000 mi) or 12 months.
NO. ITEM ROUTINE EVERYRIDE
INITIAL ODOMETER MILEAGE READINGS
1,000 km(600 mi)
or1 month
7,000 km(4,000 mi)
or6 months
13,000 km(8,000 mi)
or12 months
19,000 km(12,000 mi)
or18 months
25,000 km(16,000 mi)
or24 months
31,000 km(20,000 mi)
or30 months
12 Front Fork
• Check operation and for oil leakage.• Service/rebuild if necessary. Refer to the service manual for more information.
13Rear ShockAbsorberAssembly
• Check operation and for oil leakage. Replace if necessary.
14 Throttle Grip • Check operation and free play.
15Rear Brake PedalPivot Shaft
• Apply lithium grease (all-purpose grease) lightly.
16 Kickstand Pivots• Check operation.• Apply lithium grease (all-purpose grease) lightly.
17 Kickstand Switch• Check operation and replace if necessary.
5-23
Parts/Maintenance Items
The proper replacement parts, fluids, and lubricantsto use are listed in the chart below.
PART NUMBER
Headlamp Bulb-55 watt H4
Turn Signal Bulb 1156
Stop/Tail Lamp Bulb 1157
Front Running Lamp Bulb 194
Brake Fluid DOT 4
AccessoriesZero accessories are designed to complement andfunction with other systems on your motorcycle. YourCSC can accessorize the motorcycle using genuineZero accessories.
A full line of Parts, Accessories, and Apparel can befound on the Zero Motorcycles website.
FusesWhenever there is an excessive amount of currentflowing through a circuit the fusible element will meltand create an open or incomplete circuit. Fuses area one-time protection device and must be replacedeach time the circuit is overloaded. Replace the fusewith one of equal current rating. If the fuse meltsrepeatedly, have the electrical system inspected byyour CSC.
5-24
B
A
AA
Z-Force Power Pack Battery Fuses
The Z-Force power pack (A) has four MDA slow blowfuses. The fuses are located on the back of thepower pack in front of the rear wheel. These fusescan be checked by removing the fuse and checkingfor continuity. A fuse that has no continuity isconsidered to be melted. Remove the fuse bypushing in on the plastic cap and turning counter-clockwise. Install the fuse by pushing in and turningclockwise. For more information about the fuse label(B), see Power Pack Labels on page 2-5.
Fuse Center Location
The 12-volt fuse center is located behind the frontfork. The fuse center has a protective cover that mustfirst be removed to gain access to the fuses. Toremove the cover, squeeze the tabs (A) together andlift off the cover.
5-25
FUSE # AMP CIRCUITSCONTROLLED
A 10 Headlamp, Flash-to-Pass
B - Not Used
C 10 Turn Signals, Horn
D 5 Instrument Panel, Tail/StopLamp
A B C D 4
2
3
1
#ESUF PMA STIUCRICDELLORTNOC
1 01 )ADM(rotcatnoC
2 02 )ADM(retrevnoCCD
3 52 troPegrahC
4 52 tuptuOretrevnoCCD
5-26
DATEODOMETER
MILEAGEREADING
ITEM SERVICE/ROUTINE DESCRIPTION
Follow the maintenance schedules on pages 5-20 through 5-22. After a scheduled service or routine isperformed, record the information on the chart below.
5-27
NOTES
5-28
NOTES
6-1
Troubleshooting
All of the motorcycles are carefully inspected beforethey are delivered. Even after the motorcycles areinspected, some technical issues can occur. Thefollowing information offers a guide to help you toidentify an issue, and if possible, repair it yourself. Ifyou are unable to solve an issue with your Zero S/DSelectric motorcycle, take it to an authorized CertifiedService Center (CSC) at your convenience. If there isno CSC in your area call Zero Motorcycles CustomerService.
Power Pack And Charger
If a fault occurs during charging, count the number oftimes the red light (A) flashes on the charger inbetween pauses. See the table on page 6-2 for thepossible cause and solution to the issue.
A
6-2
NUMBER OF RED FLASHES CAUSE SOLUTION
1 Power Pack High VoltageReset charger (interrupt AC power for 15seconds).
2 Power Pack Low VoltageReset charger (interrupt AC power for 15seconds).
3
Charge Timeout caused by powerpack not reaching required voltage.Charger output was reduced due tohigh temperatures.
Check connections.Operate charger at a lower ambienttemperature.
4Power pack could not be tricklecharged up to minimum voltage.
Contact CSC.
5Over-Temperature: Charger shut downdue to high internal temperature.
Ensure sufficient cooling air flow and resetcharger (interrupt AC power for 15 seconds).
6 Charger Internal FaultReset charger (interrupt AC power for 15seconds). Contact CSC if fault persists.
6-3
Understanding Beep Sequences
The Battery Management System (BMS) is located inside the power pack and is fitted with a beeper to provideaudible notifications about the status of the power pack. Below you will find information on the meaning of thebeep sequences.
PATTERN WHEN MEANING SOLUTION
1 Short Key-on Self-Test Pass BMS OK. Ready to ride!
1 Trill2 Long
Key-onCharger StillPlugged-In
Unplug charger & try again.
2 Long Key-on Power Pack EmptyCharge power pack beforeriding.
4 Long Key-on Too Hot Let power pack cool down.
5 Long Key-onPower PackUnbalanced
Leave on charger for 72hours.
4 Short1 Long
RidingLow-Power PackWarning
Charge soon.
6-4
Power Pack Empty
If the power pack is completely empty, an error-beepwill sound and the BMS will disable the throttle. Youcannot ride the motorcycle until you recharge thepower pack. If the Power Pack Empty error-beep stillsounds after two hours of charging time, contact yourCSC. Your power pack may need to be repaired orreplaced.
Too Hot
The power pack contains internal temperaturesensors. If the BMS measures excessive internaltemperatures, it will sound an error-beep and disablethe throttle. You cannot ride the motorcycle until thepower pack cools down. Place the motorcycle in acool, well-ventilated location and wait a few minutesbefore riding again. If the Too Hot error-beep stillsounds after the power pack has had time to cooldown, contact your CSC. Your power pack may needto be repaired or replaced.
Power Pack Unbalanced
The power pack contains many individual cells. TheBMS continuously monitors the cells and tries to keepthem all “in balance” (at the same level-of-charge). Ifany of the cells are grossly out-of-balance, the BMSwill sound a Power Pack Unbalanced error-beep anddisable the throttle. You cannot ride the motorcycleuntil the problem is resolved.
The solution to the problem is to plug-in the chargerand allow the power pack to charge for 72 hours.This will allow the BMS to re-balance the cells in thepower pack. If the Power Pack Unbalanced error-beepstill sounds after the power pack has spent morethan 72 hours charging, contact your CSC. Yourpower pack may need to be repaired or replaced.
Low-Power Pack Warning
The BMS provides a low-power pack warning tellingthe operator that the remaining range is limited, andthe power pack should be recharged soon. This isequivalent to a “low fuel” warning-light on a gasoline-powered vehicle. This beep-warning is different fromthe others because it can sound at any time whenthe motorcycle is on (the other warnings only soundwhen the key-switch is first turned ON).
6-5
The Low-Power Pack warning beep will soundcontinuously until either (1) the motorcycle is turnedOFF, or (2) the throttle control is disabled for anyreason, which includes the power pack beingcompletely empty. The Low-Power Pack warning-beepwill sound when you can still ride the motorcycle, butthe remaining range is limited. It means: “Stop at adestination and charge-up.”
The solution is to recharge the power pack. If theLow-Power Pack warning-beep still sounds after thepower pack has charged for two hours, contact CSC.Your power pack may need to be repaired orreplaced.
Other Error-Beep Patterns
If the BMS in your power pack produces an error-beep which is not described in the Beep PatternsTable, then the power pack has encountered aserious internal hardware problem and must berepaired or replaced by a CSC.
BMS Appendix
There are other beeps which may occur under twocircumstances that operators will normally never see.Unlike many electronic systems, the BMS essentiallynever “power cycles.” A typical BMS is powered-ononly once, in the factory, when it is connected to thewiring-harness inside the power pack. It may quitepossibly operate continuously for years without everbeing powered-down.
But on that one occasion when it is first powered-on,the BMS will perform a simple sanity check andreport the result with a beep pattern. Note that thissanity check (and the resulting beep patterns) isdifferent from the key on self-test. The sanity test (andthe beeps) happens immediately when the board isfirst powered-up (connected to a power pack).
During service or maintenance, the BMS-board maybe disconnected from and then reconnected to thepower pack wiring harness. In those cases, the BMSwill perform the sanity check (and result-beeps) everytime it is plugged-in.
6-6
PATTERN WHEN MEANING
2 ShortPwr-onM-cmd
PassSanity/Mfg.test
3 LongPwr-onM-cmd
FailSanity/Mfg.test
It is possible to encounter the sanity check result error-beeps from a badly-malfunctioning or damaged powerpack. If so, the user should return the power pack toZero for repair or replacement.
Beep Patterns
Safety Interlocks
If the BMS detects a serious internal fault, it can takeeither or both of two actions to prevent damage to thepower pack:
1 Throttle-Disable The BMS will disable the throttleif the power pack is empty, or if the BMS detectscertain serious internal problems. You cannot ridethe motorcycle until the problem is resolved.
2 Charger-Disable The BMS will prevent charging ifit detects certain serious internal problems - evenif the power pack is connected to a charger andplugged-in to AC power. The power pack cannotbe charged until the problem is resolved.
The Throttle-Disable Interlock
The BMS communicates with the main motorcycle-control module. The BMS can send a signal to themain motorcycle controller requesting that the throttle-control on the motorcycle be disabled. When thethrottle-control is disabled, the motor will not deliverpower to the rear wheel, and the motorcycle cannotbe ridden.
6-7
If the throttle is disabled while riding, the motorcyclewill cease to provide power, and the operator mustpull over to a safe location.
All conditions which would cause the BMS to disablethe throttle are also signaled by an error beep patternat self-test. If you suspect that the BMS has disabledthe throttle control on your motorcycle, turn the keyswitch OFF and back ON again to enter self testmode. The beep-pattern from the BMS will report anyof the error-conditions which would cause the BMS todisable the throttle.
Each of these conditions, the associated self-testbeep pattern, and the suggested remedies arediscussed in Understanding Beep Sequences onpage 6-3.
• Charger Still Plugged-In
• Power Pack Empty
• Too Hot
• Power Pack Unbalanced
The Charger-Disable Interlock
When the charger is attached and plugged-in to ACpower, the BMS communicates with the charger. TheBMS can send a signal to the charger requesting thatcharging terminates immediately. When the charger isdisabled, the indicator-lights on the charger will showthat charging has stopped.
There are two conditions that will cause the BMS todisable charging. One of these conditions is alsoreported by a self-test-result beep-pattern, the other isnot.
Too Hot
If the BMS detects high internal power pack-temperatures, it will both disable the throttle andprevent charging. This condition is also reported byan error-beep pattern after BMS self-test when themotorcycle is turned-on. See Understanding BeepSequences on page 6-3 for a description of the TooHot error-beep and the solutions.
6-8
Power Pack Full (High Power Pack-Voltage)
If the BMS detects that the power pack is already full,it will disable further charging to prevent damage tothe power pack.
This is not an error-condition; it is the result of asuccessful charging-cycle. There is no self-test error-beep which reports this condition.
During an ordinary charging cycle, when the cells arebalanced, the charger (not the BMS) will sense thatthe power pack is full and terminate the charging-cycle with a “green light.” The BMS does have aredundant back-up mechanism to preventovercharging of the power pack. If the charger fails toterminate a charging-cycle when the power pack isfull, the BMS will terminate charging itself to preventdamage.
Instrument Panel
Main Power Indicator
If a fault has been detected, count the number oftimes the green LED flashes. Refer to the tables onpages 6-9 and 6-10 for possible cause and solutionto the issue.
6-9
NEERGFOREBMUNSEHSALF
ESUAC NOITULOS
1hctiwsllikoteuddelbasidelcycrotoM
hctiwsdnatskcikro
ehtsserP.noitisopFFOehtnisihctiwslliK.nwodsidnatskcik,rO.nottubNOhctiwsllik
.dnatskcikesiaR
2 eruliafputratsmetsySrewopyrT.tsetflesno-rewopstideliafdraoB
.hctiwsyekehtgnilcyc
3 elbasidelttorhthgiH.dabsinoitcennoc/elttorhtroNOsielttorhT
.noitcennockcehcro/dnanoitcaelttorhtyfireV
4 egnarfotuoelttorhTelttorhtyfireV.snoitcennocroelttorhtdaB
.noitcennockcehcro/dnanoitca
5tonrosneserutarepmetrotoM
detceted
rorosneserutarepmetrotomdaBrosneserutarepmetecalpeR.snoitcennoc
.snoitcennockcehcro/dna
6 detcetedegatlovwoL.snoitcennocroegatlovkcaprewopwoL
kcehcro/dnakcaprewopegrahC.snoitcennoc
7 erutarepmet-revosidraoBehtteL.detaehrevoevahyamdraoB
.nwodloocelcycrotom
8 evitcanisiSMBmorfelbaneelttorhT
dab,detcennocregrahc,kcaprewopwoLniamdnaSMBneewtebnoitcennoc
ro/dnakcaprewopegrahC.draobelcycrotom.snoitcennockcehc
6-10
NUMBER OF GREENFLASHES
CAUSE SOLUTION
9 Precharge failureCould not pre-charge motor controller.Contact CSC.
10 Current sensor errorProblem with current sensor or connection.Contact CSC.
11 Board temperature sensor errorProblem sensing temperature of board.Contact CSC.
12 Unknown system error Contact Zero or CSC.
6-11
General Troubleshooting
SYMPTOM POTENTIAL CAUSE POTENTIAL SOLUTION
Motorcycle does not turnon
Power Pack not chargedKey not properly engagedMain power cut-off not engagedKill Switch turned off
Charge Power Pack.Recheck key in ignition, turn OFF/ON again.Move the main power cut-off to the UP/ON position.Press the Kill Switch "ON" button.
Charger not workingA/C power missingMain power cut-off engaged
Check A/C outlet for power, A/C source checkfuse/voltage.Move the main power cut-off to the UP/ON position.
Handlebars wobbly(shimmy)
Incorrect tire pressure Inflate to correct tire pressure. See page 5-9.
Deformed front tireReplace/balance front tire with the same tire suppliedfrom the factory.
Bald tire (excess wear)Replace/balance tire with the same tire supplied fromthe factory.
6-12
NOTES
7-1
Warranty/Customer Assistance
Customer Assistance
Zero Motorcycles Inc. can be contacted via the contactmethods listed below. Please have available thefollowing, as it is essential to effectively and efficientlyanswer your questions or resolve your concerns.
• Owner’s name and address
• Owner’s telephone number
• Vehicle identification number (VIN)
• Date of purchase
• Battery serial number
An owner information chart is provided on page 1-3 torecord this information.
Zero Motorcycles1 Victor SquareScotts Valley, California 95066USA
Phone:(888) 786-9376Monday-Friday8am to 5pm Pacific Time
E-mail:[email protected] hours
7-2
* No warranty on dirt bike wheels once ridden.
Warranty Information
LIMITED WARRANTY COVERAGE
MOTORCYCLEPARTS COVERED
STANDARD EXTENDED(Replaces 2nd Year
of the StandardWarranty)
NO FAULT(Replacement Partsare 50% of Retail
Cost Unless Noted)First YearSecond Year
(Excluding Shippingand Labor)
Motor (35% Discount)
Controller
Power Pack (20% Discount)
Fork
Rear Shock
Frame
Swingarm
Brake Assemblies
Electrical
Wheels * * * *
7-3
Zero Motorcycles LimitedWarranties
Zero Motorcycles Inc. expressly warrants all Zeromanufactured products from defects in material andworkmanship to the original owner under normaloperating conditions and according to proper use for2 years from the date of delivery.
These warranties are transferrable subject to a $50processing fee and a new registration card tosubsequent owners.
Standard Warranty:
The first year of this standard limited warranty coversparts, standard shipping and labor for all majorcomponents, defined herein as including the motor,motor controller, power pack, frame, swing arm, fork,rear shock, brake assemblies, wheels, and electricalsub-assemblies.
This warranty covers Zero manufactured accessoriesinstalled at the time of purchase.
The second year of this standard limited warrantycovers parts only for these same major components.
Standard Warranty Exclusions:
This warranty does not apply to tire wear, chain orsprocket condition, brake pads or rotors, fork seals,grips, foot pegs, the seat, or any other parts subjectto normal wear and tear. Wheels are excluded fromthis standard warranty on off-road bikes once theyhave been ridden.
This standard warranty excludes aftermarketaccessory kits which may be subject to their ownwarranties.
This standard warranty excludes parts andcomponents damaged by use or operation underabnormal circumstances or contrary to therequirements described in the owner’s manual, ordamaged by improper use or accidents.
Racing or competitive use voids this warranty.
Modifications or alterations to major components ofthe manufacturer’s original product or its sub-components void all warranties. Zero Motorcycles Inc.assumes no liability for any misuse or improperoperation of Zero motorcycles.
7-4
Under this limited warranty and liability agreement,Zero Motorcycles Inc. shall have no obligation and thepurchaser shall have no remedy against ZeroMotorcycles Inc. and its officers and/or agents for anydamages, including but not limited to incidental,consequential, special, punitive damages arising fromdirect or indirect injury to person or property, or anyother loss, whether or not occasioned by negligenceor otherwise on the part of Zero Motorcycles Inc.
Extended Warranty:
The extended warranty is available for purchase bythe original owner within 90 days of the date ofdelivery of the covered product. This adds to thestandard warranty by covering shipping and labor forthe 2nd year of ownership.
Extended Warranty Exclusions:
This warranty does not apply to tire wear, chain orsprocket condition, brake pads or rotors, fork seals,grips, foot pegs, the seat, or any other parts subjectto normal wear and tear. Wheels are excluded fromthis extended warranty on off-road bikes once theyhave been ridden.
This extended warranty excludes aftermarketaccessory kits which may be subject to their ownwarranties.
This extended warranty excludes parts andcomponents damaged by use or operation underabnormal circumstances or contrary to therequirements described in the owner’s manual ordamaged by improper use or accidents.
Racing or competitive use voids this warranty.
Modifications or alterations to major components ofthe manufacturer’s original product or its sub-components void all warranties. Zero Motorcycles Inc.assumes no liability for any misuse or improperoperation of Zero motorcycles.
Under this limited warranty and liability agreement,Zero Motorcycles Inc. shall have no obligation and thepurchaser shall have no remedy against ZeroMotorcycles Inc. and its officers and/or agents for anydamages, including but not limited to incidental,consequential, special, punitive damages arising fromdirect or indirect injury to person or property, or anyother loss, whether or not occasioned by negligenceor otherwise on the part of Zero Motorcycles Inc.
7-5
No Fault Warranty:
The “No Fault” warranty option is available within thefirst 90 days from date of delivery of the coveredproduct. It applies to the same two year period asthe standard warranty but adds additional coverageallowing for the replacement of any parts that need tobe replaced for any reason at a 35% discount fromretail cost for motors, a 20% discount from retail costfor Power Packs and a 50% discount from retail costfor all other parts.
For the purposes of this No Fault warranty, “No Fault”means that regardless of how the part or componentmay have been damaged or rendered unusable (fullyor partially) by the owner or authorized user of theproduct, Zero will provide replacement parts at theappropriate discount without questions being asked.
This warranty also covers Zero manufacturedaccessories installed at the time of purchase.
No Fault Warranty Exclusions:
Accessory kits include their own warranties and arenot included in this no fault coverage.
Modifications or alterations to major components ofthe manufacturer’s original product or its sub-components void all warranties including this no faultcoverage. Zero Motorcycles Inc. assumes no liabilityfor any misuse or improper operation of Zeromotorcycles.
Under this limited warranty and liability agreement,Zero Motorcycles Inc. shall have no obligation and thepurchaser shall have no remedy against ZeroMotorcycles Inc. and its officers and/or agents for anydamages, including but not limited to incidental,consequential, special, punitive damages arising fromdirect or indirect injury to person or property, or anyother loss, whether or not occasioned by negligenceor otherwise on the part of Zero Motorcycles Inc.
Disclaimers Applicable to StandardWarranty, Extended Warranty and NoFault Warranty:
The purchaser acknowledges that there is an inherentrisk in the operation of Zero motorcycles and all otherZero Motorcycles Inc. products, and herewithassumes liability for any injury arising from alloperation of any Zero Motorcycles Inc. product.
7-6
The original registered owner or subsequentregistered transferee as documented on the ZeroMotorcycle warranty registration form will indemnifyand hold Zero Motorcycles Inc. harmless and take fullresponsibility for conveying all safety warnings,instructions and limited warranty if the unit is sold,loaned or otherwise transferred to other persons, andwill indemnify Zero Motorcycles Inc. from any claimsagainst it for original owner’s failure to do so.
Zero Motorcycles Inc. does not assume or authorizeanyone to assume for them any other obligation.Some states do not allow limitations on how long animplied warranty lasts, so the above limitation maynot apply to you.
Zero Motorcycles Inc. assumes no responsibility forincidental, consequential or other damages includingbut not limited to: expense of returning the Zeroproduct to a certified service center, expense ofdelivering it back to the owner, mechanic’s travel,time, communication charges, rental of a like productduring the time the warranty service is beingpreformed, travel, loss or damage to personalproperty, loss of revenue, loss of use of the product,loss of time, or inconvenience. Some states do notallow the exclusion or limitation of incidental or
consequential damages, so the above limitation orexclusion may not apply to you.
Zero Motorcycles Inc. reserves the right to change orimprove the design of any electric motorcycle productwithout assuming any obligation to modify any productpreviously manufactured.
These warranties give you specific legal rights, andyou also have other rights, which vary from state tostate and country to country. These warranties applyto all Zero Products manufactured by Zero MotorcyclesInc.
Normal operating conditions require routine care andmaintenance by the purchaser of the ZeroMotorcycles Inc. electric motorcycle and power pack.
Proper Use:
For the purposes of these warranties, ‘proper use’means only the use of a motorcycle in the mannerintended for a single rider with proper safetyequipment as described in the Owner’s Manual onsafe and dry surfaces in accordance with localregulations. “Proper use” also means charging the
7-7
Power Pack after each use and storing it in a fullycharged state, or recharging it every 7 days, orkeeping it on the charger when in storage or out ofregular use.
Purchaser’s Responsibilities:
Read and understand the Owner’s Manual and allproduct warnings before operating your ZeroMotorcycles Inc. electric motorcycle. Serious injury ordeath may result from improper operation or failure toobserve warnings and safety instructions on anymotorized motorcycle or vehicle.
Submit the warranty registration card for your ZeroMotorcycle within the required time period as printedon the registration card.Perform routine care and maintenance of your ZeroMotorcycles Inc. electric motorcycle and power packas detailed in the Owner’s Manual.
The rider is responsible for learning and obeying allfederal, state, and local laws governing the operationsof an electric motorcycle.
Always wear a helmet, knee and elbow guards,goggles, appropriate boots and all other appropriatesafety equipment when operating a motorcycle.
Warranty Procedures:
Warranty services may be obtained by contacting ZeroMotorcycles Inc. at (888) 786-9376 or via e-mail [email protected].
Service may also be available from a local ZeroMotorcycles Certified Service Center please see thelocator on www.zeromotorcycles.com for the nearestlocation.
In any written or telephonic communication, pleasestate the specific nature of and any circumstancesleading to the problem. A service technician willcontact you with specific instructions to ensure thatyou receive the best service for your motorcycle.
Zero Motorcycles1 Victor SquareScotts Valley, CA 95066USA88-01902-00
(U.S. and International Patents and TrademarksPending)
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Transfer Of Ownership And Warranty
When it comes time to sell your Zero motorcycle,please visit the Zero Motorcycles website and accessthe Owner Resources section to fill out the on-linetransfer of ownership and warranty form. This mustbe performed to allow Zero Motorcycles the ability tocontact the new owner in the unlikely event of a safetyrelated issue. Use the URL address below or feelfree to contact the Zero Motorcycles Customer Servicedepartment for assistance.
Phone:(888) 786-9376Monday-Friday8am to 5pm Pacific Time
E-mail:[email protected] hours
http://www.zeromotorcycles.com/owner-resources/
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NOTES
7-10
NOTES
INDEX-1
INDEX
AAccessories ............................................................... 5-23Add On Electrical Equipment .................................... 4-7An Important Message To You From Zero ............... 1-1
BBattery Charger ........................................................... 4-9Battery Management System (BMS) .......................... 4-8
Beep-Signals ........................................................ 4-8Dangerously Low Voltage .................................... 4-8High or Low Temperature ................................... 4-8High Voltage ......................................................... 4-8Low Voltage .......................................................... 4-8Safety Interlocks ................................................... 4-9
Beep Patterns ............................................................. 6-6Beep-Signals ............................................................... 4-8Beeps .......................................................................... 4-9BMS Appendix ............................................................. 6-5Bolt Torque Table ....................................................... 5-2Brake Fluid Level Inspection ..................................... 5-6
Brake Pad Inspection ................................................. 5-7Brakes ................................................................ 4-4, 5-6
Brake Fluid Level Inspection ............................... 5-6Brake Pad Inspection .......................................... 5-7Front Brake ........................................................... 5-6Rear Brake ............................................................ 5-7
Braking ...................................................................... 4-14
CChain ......................................................................... 5-10
Checking The Drive Chain ................................ 5-11Cleaning The Drive Chain ................................. 5-10Drive Chain Adjustment Procedure ................... 5-12Lubricating The Drive Chain ............................. 5-11
Charger LED Indicators ........................................... 4-11Charger-Disable ......................................................... 6-6Charging The Power Pack ...................................... 4-12Checking The Drive Chain ...................................... 5-11Cleaning .................................................................... 5-18Cleaning The Drive Chain ....................................... 5-10
INDEX-2
Controls And Components ........................................ 3-1Customer Assistance ................................................. 7-1
DDangerously Low Voltage .......................................... 4-8Disclaimers Applicable to StandardWarranty, Extended Warranty andNo Fault Warranty ....................................................... 7-5Drive Chain ................................................................. 4-4Drive Chain Adjustment Procedure ......................... 5-12
EElectrical System ........................................................ 4-4Emissions Information ..................................................1-10Extended Warranty ...................................................... 7-4
FFirst Time Set-Up ....................................................... 4-1Fork Lock ..................................................................... 4-5Front Brake .................................................................. 5-6Front Fork Adjustment .............................................. 4-15
Fuse Center Location .............................................. 5-24Fuses ......................................................................... 5-23
GGeneral Information .................................................... 1-6General Maintenance ................................................. 5-6
Brakes ................................................................... 5-6Chain ................................................................... 5-10Headlamp Alignment .......................................... 5-13Headlamp Bulb Replacement ........................... 5-14Maintenance Schedule ....................................... 5-20Motor ...................................................................... 5-6Parking And Long Term Storage ....................... 5-19Running Lamp Bulb Replacement ................... 5-17Stop/Tail Lamp Bulb Replacement ................... 5-16Suspension ........................................................... 5-8Tire Inflation .......................................................... 5-9Turn Signal Bulb Replacement ......................... 5-16Wheels And Tires ................................................. 5-8
General Operation ...................................................... 4-4
INDEX-3
Brakes ................................................................... 4-4Drive Chain ........................................................... 4-4Electrical System .................................................. 4-4Power Pack ........................................................... 4-4Throttle .................................................................. 4-4Tires ...................................................................... 4-4
General Safety Precautions ....................................... 2-1General Troubleshooting ..............................................6-11
HHandlebar Controls .................................................... 3-9Headlamp Alignment ................................................ 5-13Headlamp Bulb Replacement ................................. 5-14
IIndicators ..................................................................... 2-8Instrument Panel ........................................................ 3-7Introduction .................................................................. 1-1
KKey Switch Positions .................................................. 4-5
LLeft Side View ............................................................. 3-3Limited Warranties ..................................................... 7-3Location Of Important Labels .................................... 2-3
Main Power Cut-Off Label ................................... 2-6Power Pack (Battery) Fuse Label ....................... 2-6Power Pack Information Label ............................ 2-4Power Pack Labels .............................................. 2-5Throttle And Speed Control Label ....................... 2-5
Low-Power Pack Warning .......................................... 6-4Lubricating The Drive Chain .................................... 5-11
MMain Power Cut-Off .................................................... 4-6Main Power Cut-Off Label .......................................... 2-6Maintaining Your Motorcycle ....................................... 5-1Maintenance Schedule ............................................. 5-20Motor ............................................................................ 5-6Motorcycle Controls .................................................... 3-1
NNo Fault Warranty ....................................................... 7-5
INDEX-4
OOperating Information ................................................. 2-2Operating Your Motorcycle ........................................ 4-14
Braking ................................................................ 4-14Starting ................................................................ 4-14Stopping .............................................................. 4-14
Optimizing Your Range By Adapting YourRiding Style ................................................................. 1-9Owner Information ...................................................... 1-3Owner’s Responsibilities ........................................... 5-1
PParking And Long Term Storage ............................. 5-19Parts/Maintenance Items .......................................... 5-23Performance Envelope ............................................... 2-7Performance Specifications/Operation Guidelines 2-7Power Pack ................................................. 4-4, 4-7, 5-5Power Pack (Battery) Fuse Label ............................. 2-6Power Pack And Charger .......................................... 6-1
Low-Power Pack Warning ................................... 6-4Other Error-Beep Patterns ................................... 6-5Power Pack Empty ............................................... 6-4Power Pack Unbalanced ..................................... 6-4
Too Hot .................................................................. 6-4Power Pack Empty ..................................................... 6-4Power Pack Full (High Power Pack-Voltage) ........... 6-8Power Pack Information Label .................................. 2-4Pre-Ride Inspection .................................................... 4-4
Power Pack ........................................................... 4-4Proper Use .................................................................. 7-6Public Charging Stations ..............................................1-10Purchaser’s Responsibilities .................................... 7-7
RRear Brake .................................................................. 5-7Rear Shock Adjustment .......................................... 4-17Right Side View .......................................................... 3-5Running Lamp Bulb Replacement ......................... 5-17
SSafety Information ....................................................... 2-1Safety Interlocks ................................................. 4-9, 6-6Standard Warranty ...................................................... 7-3Starting ....................................................................... 4-14
INDEX-5
Starting And Operating ................................................ 4-1Stop/Tail Lamp Bulb Replacement ......................... 5-16Stopping ..................................................................... 4-14Suspension ................................................................. 5-8
Front ...................................................................... 5-8Rear ....................................................................... 5-8
Suspension Adjustment ........................................... 4-15Front Fork Adjustment ........................................ 4-15Rear Shock Adjustment ..................................... 4-17
System Error Indicator ................................................ 2-8
TTechnical Specifications ............................................. 1-6
Zero DS Technical Specifications ....................... 1-7Zero S Technical Specifications .......................... 1-6
Throttle And Speed Control Label ............................. 2-5Throttle-Disable ........................................................... 6-6Tire Inflation ................................................................ 5-9Tires ............................................................................. 4-4Transfer Of Ownership And Warranty ..........................7-8Transporting .............................................................. 1-11Troubleshooting .......................................................... 6-1Turn Signal Bulb Replacement ............................... 5-16
UUncrating Your Motorcycle .......................................... 4-2Understanding Beep Sequences .............................. 6-3
VVehicle Identification Number(VIN) ............................ 1-4
VIN Break Down ................................................... 1-4VIN Location ......................................................... 1-4
Vehicle Range ............................................................. 1-9
WWarranty ....................................................................... 7-3
Disclaimers ........................................................... 7-5No Fault Warranty ................................................ 7-5Standard Warranty ................................................ 7-3Transfer Of Ownership And Warranty ................. 7-8
Warranty Information ................................................... 7-2Warranty Procedures .................................................. 7-7Warranty/Customer Assistance .................................. 7-1Wheels And Tires ....................................................... 5-8
INDEX-6
ZZ-Force Air Induction System ..................................... 2-7Z-Force Power Pack Battery Fuses ........................ 5-24Zero Motorcycles Limited Warranties ........................ 7-3
