Zero Motorcycles 2014 ZERO S Owner'S Manual Download Page 103

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Troubleshooting

6.5

General Troubleshooting

SYMPTOM

POTENTIAL CAUSE

POTENTIAL SOLUTION

Motorcycle does not turn on

Power Pack not charged. Key not properly engaged.
Motor stop switch turned OFF. Fault code set.

Charge Power Pack. Recheck key in ignition, turn OFF/ON
again. Press the motor stop Switch ON button. See Charge
Fault Code chart on

page 6.7

or see Understanding BMS

Flash Code Patterns starting on

page 6.7

Charger not working

A/C power missing fault code set

Check A/C outlet for power, A/C source check fuse/voltage.
See Charge Fault Code chart on

page 6.8

or see

Understanding BMS Flash Code Patterns on

page 6.8

Handlebars wobbly (shimmy)

Incorrect tire pressure

Inflate to correct tire pressure. See

page 5.13

Deformed front tire

Replace/balance front tire with the same tire supplied from the
factory.

Bald tire (excess wear)

Replace/balance tire with the same tire supplied from the
factory.

Loose headset bearings

Inspect the headset for wear or damage, replace any worn or
damaged parts. Tighten the headset pre-load.

Summary of Contents for 2014 ZERO S

Page 1: ...ZERO S ZERO SR ZERO DS 2014 OWNER S MANUAL ...

Page 2: ......

Page 3: ...g 1 17 Safety Information 2 1 General Safety Precautions 2 1 General Safety Precautions 2 1 Important Operating Information 2 2 Location of Important Labels 2 3 Location of Important Labels 2 3 Controls and Components 3 1 Controls and Components 3 1 Motorcycle Controls 3 2 Left Side View 3 4 Right Side View 3 6 Dash Overview 3 8 Warning Indicator Lights 3 10 Dash Settings 3 12 Smartphone Applicati...

Page 4: ...oting 6 1 Electric Motorcycle Precautions 6 1 Troubleshooting Your Motorcycle 6 1 System Warning Indicator 6 2 General Troubleshooting 6 5 Battery Management System 6 6 Cold and Hot Weather Considerations 6 12 Safety Interlocks 6 14 Warranty and Customer Information 7 1 Limited Warranty Information 7 1 What Does This Limited Warranty Cover 7 1 What Is The Coverage Period Of This Limited Warranty 7...

Page 5: ... it is by law an important part of the vehicle If you have any questions concerning the operation or maintenance of your motorcycle please contact Zero at support zeromotorcycles com For 24 hour updates and additional information about your motorcycle visit the Owner Resources section of the Zero Motorcycles website http www zeromotorcycles com owner resources About This Manual This manual covers ...

Page 6: ...ycle should be serviced by technicians with special training High voltage cable or wiring has an orange covering Do not probe tamper with cut or modify high voltage cable or wiring Plug in Your Z Force Power Pack WARNING Proper care of the motorcycle s power pack is essential When not in use the power pack should be left on the charger even if fully charged Failure to do so could damage the power ...

Page 7: ...Identification Numbers 1 3 Identification Numbers Owner Information Record information pertaining to your motorcycle here When contacting your dealer you may need to provide this information ...

Page 8: ...a 5 digit number used to create duplicate keys This number is located on a tag that accompanies the original keys Vehicle Identification Number VIN The VIN is a 17 digit number stamped on the head tube of the frame Do not alter or remove this number as it is the legal identifier for your motorcycle See the location of all important labels on page 2 3 Chassis Number The motorcycle chassis number in...

Page 9: ...cation Numbers 1 5 VIN Break Down The following breakdown of the VIN will help you understand the significance of each digit or character in case you need to reference it when contacting Zero or ordering parts ...

Page 10: ...ndard ZF8 5 6 0 hours 100 charged 5 5 hours 95 charged ZF11 4 7 9 hours 100 charged 7 4 hours 95 charged Supplemental Charger Quick Charge Time accessory ZF8 5 3 6 hours 100 charged 3 1 hours 95 charged ZF11 4 4 6 hours 100 charged 4 1 hours 95 charged CHAdeMO Recharge Time 0 to 95 1 0 hour CHAdeMO Recharge Time 0 to 100 1 5 hours Input Standard 110 V AC or 220 V AC Charger Type 1 3kW Integrated E...

Page 11: ...ion 43 mm inverted aluminum slider forks with adjustable compression and rebound damping Rear Suspension Piggy back reservoir shock with adjustable spring preload compression and rebound damping DIMENSION Wheel Base 55 5 in 1 410 mm Seat Height 31 8 in 807 mm Rake 24 0 degrees Trail 3 2 in 80 mm WEIGHT Frame 22 lbs 10 kg Curb Weight ZF8 5 367 lbs 166 kg ZF11 4 399 lbs 181 kg Carrying capacity ZF8 ...

Page 12: ...100 charged 9 3 hours 95 charged Supplemental Charger Quick Charge Time accessory ZF11 4 4 6 hours 100 charged 4 1 hours 95 charged ZF14 2 5 8 hours 100 charged 5 1 hours 95 charged CHAdeMO Recharge Time 0 to 95 1 0 hour CHAdeMO Recharge Time 0 to 100 1 5 hours Input Standard 110 V AC or 220 V AC Charger Type 1 3kW Integrated Estimated Power Pack Life to 80 city ZF11 4 308 000 miles 496 000 km ZF1...

Page 13: ...ont Suspension 43 mm inverted aluminum slider forks with adjustable compression and rebound damping Rear Suspension Piggy back reservoir shock with adjustable spring preload compression and rebound damping DIMENSION Wheel Base 55 4 in 1 410 mm Seat Height 31 8 in 807 mm Rake 24 0 degrees Trail 3 2 in 80 mm WEIGHT Frame 22 lbs 10 kg Curb Weight ZF11 4 407 lbs 185 kg ZF14 2 452 lbs 205 kg Carrying c...

Page 14: ...r Quick Charge Time accessory ZF8 5 3 6 hours 100 charged 3 1 hours 95 charged ZF11 4 4 6 hours 100 charged 4 1 hours 95 charged CHAdeMO Recharge Time 0 to 95 1 0 hour CHAdeMO Recharge Time 0 to 100 1 5 hours Input Standard 110 V AC or 220 V AC Charger Type 1 3 kW Integrated Estimated Power Pack Life to 80 city ZF8 5 213 000 miles 343 000 km ZF11 4 284 000 miles 457 000 km RANGE City EPA UDDS ZF8 ...

Page 15: ...compression and rebound damping Rear Suspension Piggy back reservoir shock with adjustable spring preload compression and rebound damping DIMENSION Wheel Base 56 2 in 1 427 mm Seat Height 33 2 in 843 mm Rake 26 5 degrees Trail 4 6 in 117 mm WEIGHT Frame 22 lbs 10 kg Curb Weight ZF8 5 372 lbs 169 kg ZF11 4 404 lbs 183 kg Carrying Capacity ZF8 5 393 lbs 178 kg ZF11 4 361 lbs 164 kg ECONOMY Typical C...

Page 16: ...e versus performance of your motorcycle then you can adjust your riding characteristics if you so desire This applies mainly to riders with trip profiles which are at the edge of the performance envelope Those individuals with relatively short commutes can expect to ride quite aggressively and reach their destination with energy to spare Reported motorcycle range values are measured using two diff...

Page 17: ...out one hour For additional information contact your Zero Motorcycles dealer Maximizing Your Range Range varies in electric motorcycles similarly to how it varies in gas motorcycles However the big difference between electric and gas is that energy consumption is averaged over a shorter distance on an electric motorcycle Electric motorcycles are designed for convenient daily recharges versus less ...

Page 18: ...General Information 1 14 ...

Page 19: ...General Information 1 15 ...

Page 20: ...t is the only kind of vehicle which actually gets cleaner in terms of air pollution each year as the electricity grid gets cleaner and more renewable Zero Emissions Vehicles ZEV s offer greater efficiency and can help solve the serious air pollution global warming and energy security problems facing the country and the world WARNING Please use only Zero approved parts and accessories for your Zero...

Page 21: ...rew The fork must be fully extended most likely on a stand or balanced on the kickstand with the front tire in the air then the air can be bled and capped Ensure that the screw is tightened before riding It is recommended that the motorcycle be tied down using ratchet straps Place the ratchet straps around a frame contact point Soft straps must be used to prevent scratches or other damage Use two ...

Page 22: ...Notes 1 18 ...

Page 23: ...g drugs before operating your electric motorcycle Persons unwilling or unable to take responsibility for their actions should not use this motorcycle You assume all responsibility while operating your motorcycle The seller assumes no liability for misuse or operator negligence Prior to each use the rider must check everything in the every ride column of the maintenance schedule on page 5 2 and the...

Page 24: ...ll be sitting unused for more than 30 days The power pack must be charged within 24 hours if fully discharged and must be charged within 90 days if stored fully charged Zero recommends you plug in your power pack after 90 days even if it is fully charged Please leave your power pack plugged in whenever possible You should also use the supplied cable as it is designed for use with your motorcycle s...

Page 25: ...ion of Important Labels The vehicle could contain the following information for both North American and European models A VECI Vehicle Emission Control Information label B VIN label European Union certification label C VIN label North America certification label shown ...

Page 26: ...Location of Important Labels 2 4 Anti Tamper Control Label Europe only The anti tamper control label shown below is located on the left side of the frame ...

Page 27: ...Location of Important Labels 2 5 High Voltage Warning Label Affixed to battery ...

Page 28: ...Notes 2 6 ...

Page 29: ...Controls and Components 3 1 Controls and Components Controls and Components THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 30: ...Controls and Components 3 2 Motorcycle Controls ...

Page 31: ...w For description and operation see Dash Overview on page 3 8 D Cavity for Accessory 12 Volt Socket Location for Zero dealer installed 12 volt accessory socket E Front Brake Fluid Reservoir For description and operation see Brakes on page 5 9 F Right Handlebar Control For description and operation see Handlebar Controls on page 3 16 G Front Brake Lever For description and operation see Handlebar C...

Page 32: ...Controls and Components 3 4 Left Side View ...

Page 33: ...l light bulb replacement see Brake Tail LED Replacement on page 5 19 E Rear Turn Signal For turn signal operation see Handlebar Controls on page 3 16 F Kickstand The kickstand swings out from the side and supports the motorcycle when parked The key switch should be in the OFF position when parked G Kickstand Switch This switch is a safety feature that prevents motor operation when the kickstand is...

Page 34: ...Controls and Components 3 6 Right Side View ...

Page 35: ... see Power Pack on page 4 5 D Rear Brake Pedal The rear brake pedal controls the rear brake when the pedal is pressed When braking the throttle should be in the closed position The brake light illuminates when the rear brake pedal is applied E Brushless Motor Controller Precisely meters the flow of electricity from the power pack to the motor according to the action of the throttle and surrounding...

Page 36: ...Controls and Components 3 8 Dash Overview ...

Page 37: ...ea displays which performance riding mode ECO SPORT and CUSTOM has been selected by the rider using the performance level mode button located on the right handlebar control assembly See Performance Level Mode Button on page 3 19 I Output Meter The OUTPUT meter indicates the amount of Torque applied to the rear wheel and the Power energy being used while riding J Regen Meter The regenerative REGEN ...

Page 38: ...Controls and Components 3 10 Warning Indicator Lights ...

Page 39: ...ry over under temperature See Temperature Indicator on page 4 13 for more information D Armed Indicator Indicates the motorcycle is live or ready to move if the throttle is actuated For troubleshooting see Troubleshooting Your Motorcycle on page 6 1 E Charging Indicator Flashes slowly when the motorcycle is accepting a charge The indicator flashes rapidly when a charging error is detected The indi...

Page 40: ...s Note Once a feature is selected it will stop flashing after 15 seconds if no further button press is detected and the dash will return to its normal operating mode Displays A B Display A To select Display A with the dash in its normal operating mode momentarily press the SEL button once Press the ADJ button to toggle through the following fields Trip 1 Odometer Displays individual trip mileage a...

Page 41: ...perature may not read accurately during the first 5 miles of a ride while the application is calibrating itself Life AV Displays the average energy usage over the life of the motorcycle in watt hours Wh per mile mi or kilometer km depending on the currently selected display unit Setting the Clock To set the clock with the dash in its normal operating mode press and hold the SEL button for 5 second...

Page 42: ...arily press the SEL button to return to normal operating mode Unit Display Temperature To change the units that the temperature display is shown 1 With the dash in its normal operating mode press and hold the SEL button for 5 seconds 2 Momentarily press the SEL button 4 times the Temp icon on the lower dash will start to flash 3 Press the ADJ button to toggle between F or C on the display 4 Moment...

Page 43: ...ycle 1 Ensure that the motorcycle is not Armed The motorcycle must be keyed ON the kickstand must be in the down position and the run switch must be in the Stop position 2 Press and hold the Mode button on the right handlebar for a minimum of 5 seconds until the Bluetooth symbol on the dash begins to blink then you may release the Mode button 3 Your motorcycle will be discoverable with the Bluetoo...

Page 44: ...Controls and Components 3 16 Handlebar Controls ...

Page 45: ...aking the throttle should be in the closed position The brake light also illuminates D Throttle Control Twist the throttle in a counter clockwise rotation A to energize the motor and start the motorcycle in a forward direction Release the throttle and it snaps back to the closed position B de energizing the motor and regenerative braking begins When the motorcycle is moving and the throttle contro...

Page 46: ...19 G Turn Signal Switch When the turn signal switch is pushed in the left or right position the corresponding front and rear turn signals flash When the turn signal switch is ON the corresponding turn signal indicator on the lower dash illuminates Always signal your turns and other maneuvers as required by law Unlike an automobile the turn signals must always be canceled manually on the motorcycle...

Page 47: ... motorcycle It is an ideal mode for when you want softer acceleration This position is also good for newer riders and for extending range The SPORT selection causes the motorcycle to accelerate at a significantly faster rate This position is recommended for advanced riders The CUSTOM selection has customizable performance settings by using the smartphone application refer to Smartphone Application...

Page 48: ...cle makes use of a tank bag for additional storage You can remove the tank bag by pulling upwards on its sides Note Before riding your Zero motorcycle secure the tank bag with the lock above the tank bag At high speeds the bag could eject if is not secured ...

Page 49: ...f equipped If your Zero S SR DS motorcycle is equipped with a dealer installed optional equipment Power Tank in place of the tank bag the power pack size will be increased from a ZF11 4 to a ZF14 2 which increases charge time and riding range ...

Page 50: ...Notes 3 22 ...

Page 51: ...proper specifications See Tire Inflation on page 5 13 5 Inspect the hydraulic brake system Follow the hydraulic line from the reservoirs to the calipers and verify that there are no leaks or damage to the brake lines Verify that the brakes function properly 6 Make sure the motorcycle key switch is OFF then twist the throttle to make sure its rotation is smooth and it returns correctly 7 Inspect bo...

Page 52: ...orcycle Inner Assembly Carefully remove plastic cover from motorcycle Locate small parts box below motorcycle and put to the side This box contains important documentation owner s manual keys etc Remove the tie down straps from crate base Carefully lift rear portion of the motorcycle over the swingarm standoff and off crate base Carefully lift front wheel out of crate base Deploy kickstand lean mo...

Page 53: ...plying the brakes Throttle With the key switch in the OFF position apply the throttle and release to verify that the throttle is smooth and returns correctly Tires Check both tires for condition and tread depth Check cold tire pressure frequently Check for damage and alignment Maintain correct tire pressure as specified on page 5 13 Replace the tires when the tread height is 0 08 in 2 mm or less C...

Page 54: ...ed to prevent theft The key can be removed in either the OFF or steering lock position Steering Lock Using the steering lock when parked prevents unauthorized use and helps prevent theft To operate the steering lock 1 Turn the handlebar all the way to the left 2 Push the key down from the OFF position and turn the key counter clockwise while still pushing it in 3 Remove the key To unlock the steer...

Page 55: ...le The integrated onboard charger minimizes charge time and can work in parallel with Zero s quick charge accessories to cut charge times by as much as 70 The charging time will remain the same if the onboard charger is connected to a 120 V AC or a 240 V AC supply The normal recharging time of the power pack to a 100 charge is usually less than 6 hours for the ZF8 5 and 7 9 hours for ZF11 4 in mil...

Page 56: ...and Cold and Hot Weather Considerations on page 6 12 for further information The BMS is sealed inside the power pack As a rider you don t need to think much about the BMS it just silently does its job as you charge ride and store your motorcycle Add On Electrical Equipment WARNING Do not add electrical components to your motorcycle unless approved by an authorized Zero Motorcycles dealer Some add ...

Page 57: ...nsure that the power pack is charged check the charge indicator on the dash display prior to riding If the power pack terminates the charge before the charger reaches the state previously mentioned then the charger continues to cycle and tops off the power pack until the power pack is removed from the charger or the charger reaches the complete state previously noted The onboard charger LED indica...

Page 58: ...uld ensure the internal temperature is below 131 F 55 C If the power pack was recently run and it will not take a charge the power pack should cool and begin taking a charge in around 30 minutes or less The maximum charging temperature cutoff is a power pack longevity feature Charging at higher temperatures can shorten the life of the power pack Note Frequent top off charging is good for the power...

Page 59: ...rs draw as much as 12 amps from the 120 V AC circuit when charging 3 The charging icon A flashes as the battery is being charged Once charging is complete the icon stays illuminated 4 Charging a fully discharged power pack to 100 takes about ZF8 5 6 hours ZF11 4 7 9 hours Note The charging icon is solid green when fully charged and plugged into the charger ...

Page 60: ...ental accessory chargers can reduce the charging time by up to 70 Note The time for charging the motorcycle using quick charging will vary with the number of chargers used The accessory charging connector is located above the motor For more information on how to connect additional chargers refer to the quick charger s owner s manual A AC Power Cord B AC Power Cord Connection C Power Pack Charger D...

Page 61: ...er to a GROUNDED outlet When using an extension cord avoid excessive 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 120 V AC or 240 V AC current The voltage does not change the amount of time that the motorcycle takes to charge 5 Connect the off board accessory charger See Quick Charging Off Board Accessory Charger on page 4 10 6 When the...

Page 62: ...s on solid the charging is complete and the charger will enter maintenance mode If it is flashing the absorption phase is complete and the charger is in finish phase D AC ON The AC ON LED is an amber indicator If it is on solid the AC power is good If it is flashing the AC voltage is low Check for proper voltage and if an extension cord is being used verify that it is the correct length Maximum le...

Page 63: ...es should bring the Zero motorcycle to a complete stop without locking the wheels Your Zero motorcycle is a light weight performance product and therefore practice is strongly recommended to perfect safe emergency stops Stopping Your Motorcycle To stop your motorcycle 1 With the throttle in the closed position press the motor stop switch to the OFF position This switch can also be used in an emerg...

Page 64: ...ect of the strategy will be that your motorcycle will be gradually slowed down to the point that the top speed of the bike is sustainable from a thermal standpoint If you encounter the strategy due to a different sustained high power event such as continued powering through a low traction surface power will simply be reduced to ensure the continued safe operation of your powertrain Please note tha...

Page 65: ... Transporting on page 1 17 2 Bleeding the fork Bleed the fork regularly let any excess air out after each ride Rebound Damping The rebound damping is adjusted by turning the slotted brass adjuster screw B on the top of both fork legs Next to the screw are the letters S F meaning Slow and Fast The adjuster has 18 stages of adjustment This determines how quickly the fork returns to its extended posi...

Page 66: ...is set too fast will cause the fork to bottom out harshly If the fork is bottoming out turn the adjuster one click at a time until the bottom out stops Adjust each fork leg evenly Replace the rubber dust cover after the adjustment Note Adjusters should never be forced completely Fast or Slow always leave one click of adjustment in either direction Factory Supplied Front Suspension Settings The fol...

Page 67: ...r weight This adjustment is a recommended guideline personal riding preference may vary from the specifications given To Check the Sag value 1 Support your motorcycle on a stand with the rear wheel off the ground 2 Measure vertically from the rear axle to the rear fender Mark this spot as it is used for other measurements 3 Record this measurement this is the measurement referred to as M1 4 Remove...

Page 68: ...ment M1 Example Measurement Operator Value M1 23 62 in 600 mm M2 21 65 in 550 mm Sag 1 97 in 50 mm The total sag is 1 97 in 50 mm Refer to the chart below for the correct sag If the sag is not correct the spring pre load should be adjusted MODEL SAG S SR 1 77 in 45 mm DS 2 36 in 60 mm ...

Page 69: ... specified value increase the pre load on the spring by turning the spring nut B clockwise on the shock Rebound Adjustment The rebound adjuster knob A is at the bottom of the shock It has 8 stages of adjustment Printed on the knob is S F meaning Slow and Fast The rebound adjuster knob controls how slow or fast the shock returns to its extended position after being compressed Turning the knob clock...

Page 70: ...ith a middle setting and fine tune the compression from there Proper compression allows the tire to track the ground over consecutive bumps Compression that is set too slow will pack up feel harsh over consecutive bumps while compression that is set too fast causes the shock to bottom out harshly If the shock is bottoming out turn the adjuster one click at a time until the bottom out stops Note Ad...

Page 71: ...motorcycle was originally supplied with S SR Models ADJUSTMENT SETTING Rear Shock Compression 16 clicks out from fully closed Rear Shock Rebound 2 clicks out from fully closed Rear Shock Spring Preload 7 mm DS Model ADJUSTMENT SETTING Rear Shock Compression 14 clicks out from fully closed Rear Shock Rebound 4 clicks out from fully closed Rear Shock Spring Preload 7 mm ...

Page 72: ...Notes 4 22 ...

Page 73: ...proved parts and Zero Motorcycles accessories The operator is responsible for learning and obeying all country federal state and local laws governing the operations of an electric motorcycle Always wear a regionally approved helmet goggles appropriate boots and all other appropriate safety equipment when operating an electric motorcycle Parts Maintenance Items The proper replacement parts fluids a...

Page 74: ...hs 8K mi 13K km or 12 months 12K mi 19K km or 18 months 16K mi 25K km or 24 months 20K mi 31K km or 30 months 1 Brake Fluid front and rear Check brake fluid level Add brake fluid as necessary Replace brake fluid every 12 months 2 Front Brake Check operation and for fluid leakage Replace brake pads if necessary 3 Rear Brake Check operation and for fluid leakage Replace brake pads if necessary 4 Whe...

Page 75: ...ck operation and for oil leakage Service rebuild if necessary 11 Front Fork Check operation and for oil leakage Service rebuild if necessary 12 Rear Shock Absorber Assembly Check operation and for oil leakage Replace if necessary 13 Throttle Grip Check operation and free play 14 Kickstand Pivots Check operation Apply silicon grease lightly ITEM ROUTINE EVERY RIDE INITIAL INITIAL ODOMETER MILEAGE R...

Page 76: ...g from 8 000 mi 13 000 or 12 months 15 Kickstand Switch Check operation and replace if necessary ITEM ROUTINE EVERY RIDE INITIAL INITIAL ODOMETER MILEAGE READING 600 mi 1K km or 1 month 4K mi 7K km or 6 months 8K mi 13K km or 12 months 12K mi 19K km or 18 months 16K mi 25K km or 24 months 20K mi 31K km or 30 months ...

Page 77: ...nk to frame front 19 lb ft 26 Nm I Main pivot bolt nut swingarm 75 lb ft 102 Nm J Upper Lower triple clamps pinch bolts 15 lb ft 20 Nm upper 17 lb ft 23 Nm lower Use LOCTITE 242 or equivalent K Front axle pinch bolts 9 lb ft 12 Nm Use LOCTITE 242 or equivalent L Rear brake pedal pivot bolt 34 lb ft 46 Nm Use LOCTITE 242 or equivalent M Rear brake master cylinder to frame bolts 9 lb ft 12 Nm Use LO...

Page 78: ...Maintaining Your Motorcycle 5 6 Left Side of Motorcycle Refer to Torque table on page 5 5 ...

Page 79: ...Maintaining Your Motorcycle 5 7 Right Side of Motorcycle Refer to Torque table on page 5 5 ...

Page 80: ... The power pack is a lithium ion power system While it does require charging it does not require maintenance 2 The power pack should be kept away from excessive heat The lithium ion cells should not get above 160 F 71 C Do not store in a hot trailer or leave the power pack in direct sunlight 3 Only an authorized service agent is qualified to have access to the power pack 4 Dispose of the power pac...

Page 81: ...id level for both the front and rear brakes Your motorcycle uses specific brake pads for stopping power Both front and rear pad examples are shown in the following sections Front Brake Pads An example of the front brake pads is shown below Rear Brake Pads An example of the rear brake pads is shown below ...

Page 82: ...d or the hydraulic system for leaks Use only new DOT 4 brake fluid from a sealed container Front Brake Inspect the level of the front brake fluid through the sight glass C If the fluid level is visibly below the low level indicator B brake fluid must be added Clean any dirt or debris from the cover A before opening the reservoir Note The motorcycle should be in an upright position prior to checkin...

Page 83: ... brake fluid through the reservoir housing If the fluid level is visibly below the low minimum MIN indicator C brake fluid must be added until level reaches the upper MAX indicator B Do not overfill Clean any dirt or debris from the cap and reservoir opening A before opening the reservoir Unscrew the cap and add new DOT 4 brake fluid Inspect the cap seal ensuring that it is free of any wear or dam...

Page 84: ...ly The brake rotor should also be checked for thickness The minimum thickness is 0 15 in 3 85 mm Suspension Front For maintenance see Maintenance Schedule on page 5 2 To adjust the fork see Suspension Adjustment on page 4 15 Rear CAUTION The shock absorber assembly contains highly pressurized gas Do not attempt to tamper with or open the cylinder or shock Do not subject the shock to high temperatu...

Page 85: ...tires are found to have any of the above conditions replace the wheel and tire immediately Tire Inflation CAUTION Under inflation is a common cause of tire failure and may result in severe tire cracking tread separation blowout or unexpected loss of motorcycle control causing serious injury or death Tire pressure should be checked and adjusted to the proper inflation levels before each ride Tire p...

Page 86: ...at the base of the belt teeth If any of the above conditions are found the belt should be replaced Checking Drive Belt Tension Proper belt tension is essential for optimum operation of the drive system Lack of belt tension can lead to ratcheting The teeth of the belt slide over the teeth of the rear sprocket This causes an unpleasant sound the ratcheting can also cause damage to the carbon tensile...

Page 87: ...of the measurement The measurement should be in the range of 20 30 kg Drive Belt Adjustment Procedure Note Adjust both sides equally 1 Remove key from the key switch 2 Loosen the rear axle nut A 3 Loosen the left and right 13 mm jam nuts C 4 Turn the left and right 13 mm adjustment bolts B 1 4 turn at a time until the belt adjustment is within specification Note Belt tension will increase slightly...

Page 88: ...light can be adjusted vertically If the vertical adjustment is off it causes the beam to point too close to or too far ahead of the motorcycle With the headlight on the low beam position the motorcycle perpendicular to the ground and the operator sitting on the motorcycle verify the beam alignment The motorcycle is shipped with the headlight at a 0 5 2 5 dip The adjustment screw A is located on th...

Page 89: ...ch could result in serious injury To help avoid injury Turn the key switch OFF and allow the bulb to cool before changing the bulb Leave the key switch OFF until the bulb change is complete Always wear eye protection when changing a halogen bulb Avoid touching the glass To replace the bulb 1 Working from behind the headlight disconnect the headlight bulb connector A and rubber cover B ...

Page 90: ...adlight bulb free of contaminants Oil from your fingers or contaminants will shorten the life of the bulb Thoroughly clean any fingerprints or contaminants from the bulb using a clean cloth moistened with alcohol 4 Install the headlight bulb into the lens 5 Install the headlight bulb retainer and turn it clockwise until it locks into position 6 Install the headlight bulb rubber cover 7 Connect the...

Page 91: ... turn the bulb counterclockwise and then pull the bulb out 3 Insert the new bulb into the socket push in and turn clockwise until it stops 4 Install the lens and screw tighten the screw Do not over tighten the screw Brake Tail LED Replacement The brake tail LED A is not serviceable Please contact your Zero Motorcycle dealer for replacement ...

Page 92: ... Replacement 1 Working from behind the headlight remove the bulb socket A from the headlight by squeezing the metal clip 2 Pull the old bulb straight out from the socket 3 Push the new bulb into the socket and push the socket into the headlight ...

Page 93: ...e Note We recommend the use of a garden hose to wash your motorcycle High pressure washers like those at coin operated car washes can damage certain parts 1 Gently wash your motorcycle with a sponge or a clean soft cloth mild detergent and plenty of water 2 Use care when cleaning the plastic parts dash fenders and side panels which can scratch easier than the other parts of your motorcycle 3 After...

Page 94: ...er pack and the electrical system see page 4 13 WARNING Opening of the power pack is for trained Zero Motorcycles technicians Please be aware that incorrect handling of a Zero power pack can be dangerous DO NOT OPEN Zero Motorcycles Accessories Zero motorcycle accessories are designed to complement and function with other systems on your motorcycle Your dealer can accessorize the motorcycle using ...

Page 95: ...he cover To access the 12 volt fuse center 1 Remove two bolts securing the seat to the motorcycle frame Refer to Component Fasteners page 5 5 2 Pull the seat rearward to gain access to the fuse center 3 Squeeze the tabs A on the fuse center to remove the cover 4 Replace the fuse s The 12 volt fuse values are listed below FUSE RATING CIRCUITS CONTROLLED 1 10A Headlight 2 10A Accessory Port 3 10A Fl...

Page 96: ...gh voltage fuse center 1 Remove the two bolts securing the seat to the motorcycle frame 2 Pull the seat rearward to gain access to the fuse center 3 Unscrew the fuse s cover 4 Replace the fuse The high voltage fuse values are listed below FUSE RATING CIRCUITS CONTROLLED 1 ABC20A Charger 2 ABC4A Main Bike Board Controller 3 ABC4A DC DC Converter 4 ATM30 Quick Charger ...

Page 97: ...ice Record 5 25 Service Record Follow the maintenance schedules on page 5 2 After a scheduled service or routine is performed record the information on the chart below DATE ITEM SERVICE ROUTINE DESCRIPTION ...

Page 98: ...Notes 5 26 ...

Page 99: ...igh voltage System components can be hot to touch during and after starting and when the motorcycle is shut off Be careful of both the high voltage and the high temperature Obey all labels that are attached to the motorcycle CAUTION The motorcycles high voltage system has no user serviceable parts Disassembling removing or replacing high voltage components cables or connectors can cause severe bur...

Page 100: ...ing 6 2 System Warning Indicator If a fault has been detected count the number of times the red indicator light A flashes Refer to the table starting on the next page for possible causes and solutions to the issue ...

Page 101: ... action and or check connection 5 High Throttle Disable Could not pre charge motor controller Contact your dealer 6 Low Power Pack Disable Charge Power Pack Before Riding 7 Contactor Error Contact Zero or your dealer 8 Controller Area Network CAN Error Contact Zero or your dealer 9 Battery Management System BMS Throttle Disable Contact Zero or your dealer 10 Throttle Out of Range Bad throttle or c...

Page 102: ... Turn the ignition OFF and ON If problem persists contact Zero or your dealer 17 Temperature Protection Error Turn the ignition OFF and allow to cool off and then restart If problem persists contact Zero or your dealer 18 Throttle Output Error Turn the ignition OFF and ON If problem persists contact Zero or your dealer 19 Kickstand Error Bad kickstand switch or connection Replace kickstand switch ...

Page 103: ... 7 Charger not working A C power missing fault code set Check A C outlet for power A C source check fuse voltage See Charge Fault Code chart on page 6 8 or see Understanding BMS Flash Code Patterns on page 6 8 Handlebars wobbly shimmy Incorrect tire pressure Inflate to correct tire pressure See page 5 13 Deformed front tire Replace balance front tire with the same tire supplied from the factory Ba...

Page 104: ...ower pack and is fitted with a window A to provide visual notification about the status of the power pack There are four LED lamps that will flash one red and three green lamps The window is located on the front of the power pack behind the front wheel See the next page for the meanings of these patterns ...

Page 105: ...2 GREEN 3 GREEN 4 GREEN ON OFF MEANING SOLUTION 50 ms 5 sec Healthy BMS OK 50 ms 5 ms Isolation Fault Contact Zero or the Dealer 50 ms 60 sec Pack Low Charge power pack 50 ms 1 sec Number of Cell Packs Not Set Contact Zero or the Dealer 50 ms 1 sec Self Test Failed Contact Zero or the Dealer 50 ms 250 ms Waiting for UART Input Contact Zero or the Dealer sec seconds ms milliseconds ...

Page 106: ...ll flash depending on the power pack s state of charge 1 RED 2 GREEN 3 GREEN 4 GREEN ON OFF MEANING SOLUTION 1 sec 5 sec Charge Complete Unplug Charger Charging 250 ms 25 Continue Charging 250 ms 50 Continue Charging 250 ms 75 Continue Charging 250 ms 100 Continue Charging Balancing 500 ms Power Pack Unbalanced Let the Power Pack Cool Down 500 ms Temperature Disable 100 ms 500 ms Too Hot Let the P...

Page 107: ... key is in the ON position 1 RED 2 GREEN 3 GREEN 4 GREEN ON OFF MEANING SOLUTION 5 sec 1 sec 25 of Power Remaining Charge Soon 5 sec 1 sec 50 of Power Remaining Charge Soon 5 sec 1 sec 75 of Power Remaining Charge Soon 5 sec 1 sec 100 of Power Remaining OK sec seconds ms milliseconds ...

Page 108: ... itself to prevent damage Power Pack Too Hot The power pack contains internal temperature sensors If the BMS measures excessive internal temperatures it flashes an error code and disables the throttle You cannot ride the motorcycle until the power pack cools down Place the motorcycle in a cool well ventilated location and wait a few minutes before riding again If the Too Hot error code still flash...

Page 109: ...atterns If the BMS in your power pack produces an error code which is not described in Understanding BMS Flash Code Patterns then the power pack has encountered a serious internal hardware problem and must be repaired or replaced by a dealer ...

Page 110: ...t allow the battery to be discharged below 22 F 30 C which is the absolute lowest discharge temperature prescribed by the cell manufacturer Storage of the motorcycle for the winter in a non heated garage is acceptable as long as 1 the coldest temperature in the garage does not fall below 31 F 35 C 2 the battery is left on the charger continuously 3 the battery is initially topped off at a temperat...

Page 111: ...ttery In hot temperatures greater than 110 F 43 C the charger reduces its charge current to the battery increasing charge time accordingly the hotter the ambient temperature the greater the effect Above a battery temperature of 131 F 55 C the BMS will no longer allow charging Note Storing the motorcycle or its battery in direct sunlight in ambient temperatures above 105 F 41 C may result in accele...

Page 112: ...er requesting that the throttle control on the motorcycle be disabled When the throttle control is disabled the motor will not deliver power to the rear wheel and the motorcycle cannot be ridden If the throttle is disabled while riding the motorcycle will cease to provide power and the operator must pull over to a safe location All conditions which would cause the BMS to disable the throttle are a...

Page 113: ... charger requesting that charging terminates immediately When the charger is disabled the indicator lights on the charger displays that charging has stopped There are two conditions that cause the BMS to disable charging 1 Too hot The BMS detects an internal power pack temperature above 131 F 55 C 2 Too cold The BMS detects an internal power pack temperature below 32 F 0 C ...

Page 114: ...Notes 6 16 ...

Page 115: ...art of the Z Force Power Pack or Power Tank including the battery integrated battery management system internal wiring and internal structures What Is The Coverage Period Of This Limited Warranty The duration of this Limited Warranty for 2014 Zero S DS SR motorcycles not including the Power Packs is a period of 2 years from the original in service date Note The in service date is the date that the...

Page 116: ...ction is within expected norms Further this Limited Warranty only covers 2014 Zero S DS SR motorcycles or Power Packs Power Tanks that are operated according to proper use and under normal operating conditions For purposes of this exclusion the following definitions apply Normal operating conditions require routine care and maintenance of the 2014 Zero S DS SR motorcycle and Power Packs as describ...

Page 117: ...d by the improper repair of the motorcycle installation of any parts or accessories not sold or approved by Zero the installation and use of any parties or accessories that alter the motorcycle s specifications from those set by Zero or the use of new or used parts not approved by Zero Damage malfunctions or performance problems caused by fire collision accident or improper storage Damage malfunct...

Page 118: ...k to its owner mechanic s travel time or communication charges loss or damage to personal property loss or time or inconvenience Some states do not allow the exclusion or limitation of incidental or consequential damages so this limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state Zero Motorcycl...

Page 119: ...proper use of your Zero motorcycle and Power Pack as detailed in this Owner s Manual Learn and obey all federal state and local laws governing the operations of a motorcycle generally and an electric motorcycle specifically At all times when operating a Zero motorcycle wear proper safety equipment and clothing including but not limited to helmet goggles and appropriate boots What Will Zero Do Unde...

Page 120: ...d Canada Zero Motorcycles Inc 380 El Pueblo Road Scotts Valley CA 95066 USA Europe Zero Motorcycles BV Fluorietweg 12D Alkmaar 1812 RR NL U S and International Patents and Trademarks Pending Transfer Of Ownership And Warranty When it comes time to sell your Zero Motorcycle please visit the Zero Motorcycles website and access the Owner Resources section to fill out the on line transfer of ownership...

Page 121: ...ources section of the Zero Motorcycles website www zeromotorcycles com owner resources Reporting Safety Defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death you should immediately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying Zero Motorcycles Inc If NHTSA receives similar complaints it may open an ...

Page 122: ...Notes 7 8 ...

Page 123: ... Motorcycle 5 21 Contact information NHTSA 7 7 D Dash Settings 3 12 Drive Belt 5 14 Checking Drive Belt Tension 5 14 E Emissions Information 1 16 F First Time Set Up 4 1 Fuses 5 22 High Voltage Fuse Center 5 24 G General Operation 4 3 Key Switch Steering Lock Positions 4 4 Pre Ride Inspection 4 3 General Safety Precautions 2 1 General Troubleshooting 6 5 H Headlight Alignment 5 16 Bulb Replacement...

Page 124: ...rmance Level Mode Button 3 19 ECO Position 3 19 SPORT Position 3 19 Power Pack 5 8 Plug in Your Z Force Power Pack 1 2 Serial Number 1 4 Pre Ride Inspection 4 3 Public Charging Stations 1 13 Q Quick Charging 4 10 R Reporting safety defects 7 7 S Safe Riding Information 1 2 Safety Interlocks 6 14 Serial Number Motor 1 4 Power Pack 1 4 Smartphone Application 3 15 State of Charge SOC 3 15 Storage Lon...

Page 125: ...ting 1 17 Troubleshooting Battery Management System BMS 6 6 Charge Mode 6 8 Run Mode 6 9 Turn Signal Light Bulb Replacement 5 19 U Unpacking Your Zero Motorcycle 4 2 Recycling 4 2 V Vehicle Identification Number VIN Location 1 4 Understanding Your VIN Number 1 5 Vehicle Range 1 12 W Warning Lights 3 8 3 10 Warranty Coverage 7 1 Exclusions 7 2 Transfer Of Ownership And Warranty 7 6 Wheels And Tires...

Page 126: ...Notes INDEX 4 ...

Page 127: ...First Responder Information High Voltage Components Locations ...

Page 128: ...TAKE CHARGE WWW ZEROMOTORCYCLES COM ...

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