Zero Motorcycles 2016 ZERO DS Owner'S Manual Download Page 100

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Troubleshooting

7.2

System Warning Indicator

If a fault has been detected, count the number of times the
red indicator light (A) flashes (flashing sequence does
repeat).

Refer to the table starting on the next page for possible
causes and solutions to the issue.

Zero Owner's Manual (S and DS).book Page 2 Friday, October 30, 2015 11:13 AM

Summary of Contents for 2016 ZERO DS

Page 1: ...ZERO S ZERO SR ZERO DS ZERO DSR Zero Owner s Manual S and DS book Page 1 Friday October 30 2015 11 13 AM ...

Page 2: ...Zero Owner s Manual S and DS book Page 2 Friday October 30 2015 11 13 AM ...

Page 3: ...izing Your Range 1 7 Transporting 1 10 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 Se...

Page 4: ... Your Motorcycle 6 1 Maintaining Your Motorcycle 6 1 Owner s Responsibilities 6 1 Parts Maintenance Items 6 2 General Maintenance 6 10 Brakes 6 10 Suspension 6 13 Wheels And Tires 6 14 Tire Inflation 6 14 Drive Belt 6 15 Headlight Alignment 6 17 Turn Signal Light Bulb Replacement 6 20 Brake Tail LED Replacement 6 20 Running Light Bulb Replacement 6 21 Cleaning 6 22 Parking and Long Term Storage 6 ...

Page 5: ... 9 2 What Is Not Covered By This Limited Warranty 9 3 What Other Limitations Or Disclaimers Apply To This Limited Warranty 9 5 What Are Your Responsibilities As A Customer 9 6 What Will Zero Motorcycles Do Under This Limited Warranty 9 7 How Does This Limited Warranty Relate To State Law 9 7 How Do You Obtain Service Under This Limited Maintenance Record 10 1 Maintenance Record 10 1 Service Histor...

Page 6: ...Zero Owner s Manual S and DS book Page 4 Friday October 30 2015 11 13 AM ...

Page 7: ...re that this manual stays with the motorcycle 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 About This Manual This manual covers the following motorc...

Page 8: ...urns and even death The high voltage components on the motorcycle should be serviced only by technicians with special training Plug in Your Z Force Power Pack CAUTION 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 pack and therefore void your power pack warranty See p...

Page 9: ...fication Numbers Owner Information Record information pertaining to your motorcycle here When contacting your dealer you may need to provide this information Zero Owner s Manual S and DS book Page 3 Friday October 30 2015 11 13 AM ...

Page 10: ...ey code is 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 Zero Owner s Manual S...

Page 11: ...ng 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 Motorcycles or ordering parts Zero Owner s Manual S and DS book Page 5 Friday October 30 2015 11 13 AM ...

Page 12: ...ver for parts and accessories which have not been approved Vehicle Range The range of an electric vehicle is defined as the distance the vehicle travels on a single full charge of the power pack Just like EPA mileage estimates on an automobile your mileage may vary Your range results are a direct reflection of your riding habits The more conservative you ride the better range you can expect from y...

Page 13: ...Combined are based on a calculation that assumes a duty cycle comprised of 50 City 50 Highway See technical specification charts on page 8 1 through page 8 7 for these ranges 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...

Page 14: ...General Information Zero Owner s Manual S and DS book Page 8 Friday October 30 2015 11 13 AM ...

Page 15: ...General Information Zero Owner s Manual S and DS book Page 9 Friday October 30 2015 11 13 AM ...

Page 16: ... around a frame contact point Soft straps must be used to prevent scratches or other damage Use two ratchet straps in the front and two in the rear The tie down straps should be at a 45 angle from the motorcycle Follow the manufacturer s instructions for the ratchet straps you are using Zero Owner s Manual S and DS book Page 10 Friday October 30 2015 11 13 AM ...

Page 17: ...ver use alcohol or mind altering drugs before operating your electric motorcycle Persons unwilling or unable to take responsibility for their actions should not use this motorcycle You Prior to each use the rider must check everything in the every ride column of the maintenance schedule on page 6 2 and the charge level of the power pack as indicated on the dash display charge indicator Your safety...

Page 18: ...otorcycle is sitting in storage or if it will 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 CAUTION Charge the Zero power pack with the motorcycle s on board charger or the approved Zero accesso...

Page 19: ...s Location of Important Labels Location of Important Labels The vehicle could contain the following information for both North American and European models Zero Owner s Manual S and DS book Page 3 Friday October 30 2015 11 13 AM ...

Page 20: ...Location of Important Labels High Voltage Warning Label Affixed to battery Zero Owner s Manual S and DS book Page 4 Friday October 30 2015 11 13 AM ...

Page 21: ...Controls and Components Controls and Components Controls and Components THIS PAGE INTENTIONALLY LEFT BLANK Zero Owner s Manual S and DS book Page 1 Friday October 30 2015 11 13 AM ...

Page 22: ...Controls and Components Motorcycle Controls Zero Owner s Manual S and DS book Page 2 Friday October 30 2015 11 13 AM ...

Page 23: ...ee 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 6 10 G Front Brake Lever For description and operation see Handlebar Controls on page 3 16 H Throttle Control For description and operation see Handlebar Controls on page 3 16 I Motor Stop Switc...

Page 24: ...Controls and Components Left Side View Zero Owner s Manual S and DS book Page 4 Friday October 30 2015 11 13 AM ...

Page 25: ...bulb replacement see Brake Tail LED Replacement on page 6 20 E Rear Turn Signal 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 down If the kickstand were down when riding it could contact the grou...

Page 26: ...Controls and Components Right Side View Zero Owner s Manual S and DS book Page 6 Friday October 30 2015 11 13 AM ...

Page 27: ...age 5 1 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 conditions F Drive ...

Page 28: ...Controls and Components Dash Overview Zero Owner s Manual S and DS book Page 8 Friday October 30 2015 11 13 AM ...

Page 29: ...r using the performance level mode button located on the right handlebar control assembly See Performance Level Mode Button on page 3 20 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 energy REGEN meter indicates the amount of TORQUE on the rear wheel and the POWER energy feeding b...

Page 30: ...Controls and Components Warning Indicator Lights Zero Owner s Manual S and DS book Page 10 Friday October 30 2015 11 13 AM ...

Page 31: ...to move if the throttle is actuated For E ABS Anti Lock Brake System Indicator The indicator illuminates when the key is in the ON position The light will extinguish when the motorcycle exceeds 3 mph 5 km h Unless there is a fault the indicator will stay off until the key is cycled off and back to the ON position again See ABS Anti lock Brake System on page 4 6 for more information F Charging Indi...

Page 32: ... Select Button SEL By momentarily pressing or holding the SEL button 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 and is reset by pressing and holding the ADJ button for 2 seconds Note Trip 1 is reset each time t...

Page 33: ...ture of the motor in Fahrenheit F or Celsius C Note The temperature 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 Setting the Clock To set the clock with the dash in its normal operating mode press and hold the SEL button for 5 seconds then...

Page 34: ... 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 Momentarily press the SEL button to return to...

Page 35: ...hone with your motorcycle 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 discover...

Page 36: ...Controls and Components Handlebar Controls Zero Owner s Manual S and DS book Page 16 Friday October 30 2015 11 13 AM ...

Page 37: ...ever is squeezed When braking the throttle should be in the closed position The brake light also illuminates E 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...

Page 38: ... situations which include needing to stop or park under emergency conditions When the bottom of the switch is pressed the hazard warning circuit will turn off I 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 illumina...

Page 39: ...ey is in the ON position the horn A sounds when the button is pressed Electric vehicles run quietly the horn can be used to warn pedestrians or other motorists of your presence Zero Owner s Manual S and DS book Page 19 Friday October 30 2015 11 13 AM ...

Page 40: ...e acceleration and top 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 on page 3 15 Those who take advantage of the ECO position are likely to see a slight increase in range and experie...

Page 41: ...lever can be adjusted by turning the adjustment knob A located on the master cylinder assembly Turning the knob clockwise or counter clockwise will adjust the distance between the lever and the throttle control Zero Owner s Manual S and DS book Page 21 Friday October 30 2015 11 13 AM ...

Page 42: ...he tank bag with the lock in front of the tank bag At high speeds the bag could eject if it is not secured Power Tank if equipped Your Zero motorcycle may be equipped with a dealer installed optional equipment Power Tank in place of the tank bag The Power Tank s power pack increases the battery capacity of the motorcycle which increases the riding range and charge time Zero Owner s Manual S and DS...

Page 43: ...1772 charge connector which is concealed by a hinged protective rubber cover Compared to Level 1 charging on board charge times are effectively tripled with this Level 2 charge accessory The battery can be charged at public charging stations using the popular J1772 standard For use and more information see Charge Tank if equipped on page 5 8 Zero Owner s Manual S and DS book Page 23 Friday October...

Page 44: ...Notes Zero Owner s Manual S and DS book Page 24 Friday October 30 2015 11 13 AM ...

Page 45: ...ith 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 6 14 Replace the tires when the tread height is 0 08 in 2 mm or less WARNING Under inflation is a ...

Page 46: ...teering Lock A OFF B ON C 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 With the key in the OFF position push the key down and turn the key counter clockwise 3 Remove the key Zero Owner s Manual S and DS book Page 2 Friday October 30 2015 11 13 AM ...

Page 47: ...motorcycle OFF disabling the electrical system ON Position This position is used for operating the motorcycle In this position the following sequence occurs Lights turn ON Dash display turns ON Zero Owner s Manual S and DS book Page 3 Friday October 30 2015 11 13 AM ...

Page 48: ...ot operated brake pedal This pedal controls the rear brake When braking the throttle should be in the closed position WARNING If you apply the front or rear brake hard 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 throttl...

Page 49: ...orcycle s power will be reduced accordingly If you encounter the strategy while trying to maintain a high vehicle speed the effect 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 throug...

Page 50: ...vironments may reduce the effectiveness of the ABS and require stopping distances equivalent to those of a motorcycle without ABS When the motorcycle is stationary and the key is turned to the ON position it is normal for the ABS warning indicator A on the dash to illuminate The indicator will remain on until the system detects the motorcycle s speed exceeds 3 mph 5 km h after which will stay off ...

Page 51: ...ABS starting with the motorcycle at rest 4 Resume normal operation ABS Warning Indicator When the motorcycle is stationary and the key turned to the ON position it is normal for the ABS warning indicator on the dash to illuminate The indicator will remain on until the system detects the motorcycle s speed exceeds 3 mph 5 km h after which it will stay off until the key is cycled off and back to the...

Page 52: ...e will operate as a non ABS equipped motorcycle with increased stopping distance and unpredictable brake control WARNING If the front and rear wheel speeds vary in speed significantly such as during a burnout wheelie or off road riding the ABS indicator will illuminate and disable ABS Note To reactivate the ABS bring the motorcycle to a complete stop then turn the key to the OFF position wait for ...

Page 53: ...puts the front tire 1 3 of the way through its vertical travel Heavier riders require stiffer spring rates A good approximation of your front springs requirements can be found by measuring the front suspension s sag This measurement quickly determines if your front springs are approximately correct for your weight This adjustment is a recommended guideline personal riding preference may vary from ...

Page 54: ...1 Example The total sag is 1 77 in 45 mm Refer to the chart below for the correct sag If the sag is not correct the spring preload should be adjusted Measurement Operator Value M1 4 13 in 105 mm M2 2 36 in 60 mm Sag 1 77 in 45 mm MODEL SAG S SR 1 77 in 45 mm DS DSR 2 32 in 59 mm Zero Owner s Manual S and DS book Page 10 Friday October 30 2015 11 13 AM ...

Page 55: ...r screw A on the top of both fork legs Next to the screw are the letters H meaning Hard slower rebound and S meaning Soft faster rebound The adjuster has 9 stages of adjustment This determines how quick the fork returns to its extended position after being compressed Turning the rebound adjuster screw clockwise slows the rebound speed down making it better for larger rolling terrain or bumps Turni...

Page 56: ...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 Soft or Hard always leave one click of adjustment in either direction Factory Supplied Front Suspension Settings The following information will allow you to adjust the front suspension back to ...

Page 57: ...ct for your 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 M...

Page 58: ...50 mm Refer to the chart below for the correct sag If the sag is not correct the spring preload should be adjusted Measurement Operator Value M1 23 62 in 600 mm M2 21 65 in 550 mm Sag 1 97 in 50 mm MODEL SAG S SR 1 77 in 45 mm DS DSR 2 36 in 60 mm Zero Owner s Manual S and DS book Page 14 Friday October 30 2015 11 13 AM ...

Page 59: ...ebound Adjustment The rebound adjuster knob A is at the bottom of the shock It has 8 stages of adjustment Printed on the knob is H meaning Hard slower rebound and S meaning Soft faster rebound The ride quality adjustment knob controls the hardness or softness the ride quality of your motorcycle Turning the knob clockwise or H direction is good for big impacts Turning the knob counter clockwise or ...

Page 60: ...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 hard will pack up feel harsh over consecutive bumps while compression that is set too soft 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 Adjuster...

Page 61: ...s DS DSR Models ADJUSTMENT SETTING Rear Shock Compression 12 clicks out from fully closed Rear Shock Rebound 8 clicks out from fully closed Rear Shock Spring Preload 2nd position ADJUSTMENT SETTING Rear Shock Compression 9 clicks out from fully closed Rear Shock Rebound 12 clicks out from fully closed Rear Shock Spring Preload 5th position Zero Owner s Manual S and DS book Page 17 Friday October 3...

Page 62: ...Notes Zero Owner s Manual S and DS book Page 18 Friday October 30 2015 11 13 AM ...

Page 63: ...ide of the range of 23 F to 140 F 5 C to 60 C the Battery Management System BMS turns off the power controller The power pack must be charged within 24 hours if fully discharged and charged within 90 days if stored fully charged Zero recommends you plug in your Zero motorcycle after 90 days even if fully charged Please leave your Zero motorcycle plugged in whenever possible Battery Management Syst...

Page 64: ...e are two possible cases that can occur When connected to the charger the power pack will receive a full charge Once fully charged the charger will check the status of the power pack once every 72 hours to ensure that it maintains a full charge When fully charged a green light illuminates on the charger Should the charger not read that the power pack is full If the power pack terminates the charge...

Page 65: ...Charge the Zero power pack in a location that is well ventilated and away from combustible materials If charging your Zero motorcycle outdoors avoid charging in the rain The maximum power pack internal charging temperature is 122 F 50 C If the power pack s internal temperature is over that it will not accept a charge until it is cooled below 122 F 50 C Also if the power pack has just been run hard...

Page 66: ...cting the Zero charger and another device to a single 120 V AC 15A 20A circuit as it may become overloaded Zero chargers 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 For charging times refer to the Technical Specifications section for charging times specific to th...

Page 67: ...the charging time by up to 75 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 Charger LED Indicators E Connector ...

Page 68: ...nded 3 wire 12 AWG cord no longer than 25 ft 7 6 m 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 7 Connect the AC Power Cord to the AC Power Cord Connection on the off board accessory charger See Quick Charging Off Board Accessory Charger on page 5 5 8 The green charge LED on the dash will begin blinking s...

Page 69: ...ete 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 length is 25 ft 7 6 m 12 AWG E Fau...

Page 70: ...e Tank option can be installed by an authorized Zero dealer in place of the tank bag Using the Charge Tank 1 Ensure that the key switch is in the ON position 3 Plug the J1772 charging connector into the Charge Tank charging receptacle B Once connected charging automatically starts 4 The charging icon on the dash flashes as the battery is being charged Once charging is complete the icon stays illum...

Page 71: ...for locations in your area For example search for charging stations Note Use of a Level 2 charging adapter accessory cord Zero PN 10 03267 doesn t improve charge times unless a supplemental accessory charger is also used Note If your Zero motorcycle is equipped with a dealer installed Charge Tank use of a Level 2 charger would greatly improve charge times Add On Electrical Equipment WARNING Do not...

Page 72: ...Notes Zero Owner s Manual S and DS book Page 10 Friday October 30 2015 11 13 AM ...

Page 73: ...rm routine care and maintenance of your electric motorcycle as detailed in this owner s manual Use only Zero approved 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 safet...

Page 74: ...riding conditions Some items will need more frequent service if you ride in unusually wet or dusty areas Consult your dealer for recommendations applicable to your individual needs and use It is recommended that you have your Zero motorcycle serviced every 12 months by a Zero Dealer regardless of the distance ridden Maintenance Schedule The scheduled maintenance must be performed in accordance wit...

Page 75: ...ary 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 Wheels Check run out and for damage Replace if necessary 5 Tires Check tread depth and for damage Replace if necessary Check air pressure See page 6 14 Correct if necessary 6 Wheel Bearings C...

Page 76: ...ont Brake Lever Pivot Shaft Apply silicon grease lightly Check operation Service rebuild if necessary 11 Front Fork Check operation and for oil leakage Service rebuild if necessary 12 Rear Shock Absorber Check operation and for oil leakage 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 ...

Page 77: ...ase lightly 15 Kickstand Switch Check operation and replace if necessary 16 Drive Motor Commissioning and timing 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 Zero Owner s Manual S and DS book Page 5 Friday October 30 2015 11 ...

Page 78: ...lb ft 46 Nm Use LOCTITE 242 or equivalent G Controller heat sink to frame bolts rear 19 lb ft 26 Nm H Controller heat sink to frame front 19 lb ft 26 Nm I Main pivot bolt 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 pivo...

Page 79: ...Maintaining Your Motorcycle Left Side of Motorcycle Zero Owner s Manual S and DS book Page 7 Friday October 30 2015 11 13 AM ...

Page 80: ...Maintaining Your Motorcycle Right Side of Motorcycle Zero Owner s Manual S and DS book Page 8 Friday October 30 2015 11 13 AM ...

Page 81: ...le 1 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 s interior 4 Dispose o...

Page 82: ... will cause them to crack Always place a shop towel under the master cylinder reservoir prior to removing cover cap Low fluid levels may indicate worn brake pads or a leak in Front Brake Fluid Reservoir Inspect the level of the front brake fluid visible through the reservoir C If the fluid level is visibly below the MIN level mark B brake fluid must be added Clean any dirt or debris from the cover...

Page 83: ...n upright position prior to checking fluid level 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 damage then reinstall the cap Zero Owner s Manual S and DS book Page 11 Friday October 30 2015 11 13 AM ...

Page 84: ... mm or less If the brake pads A are worn replace both brake pads immediately Brake Pad Replacement Bedding in new brake pads and or new brake discs is recommended to ensure proper brake performance and maximize brake life Proper bedding improves brake pedal lever feel and reduces or eliminates brake squeal Bedding in the brakes is a process of depositing an even layer of pad material on the surfac...

Page 85: ...just the fork see Suspension Adjustment on page 4 9 Rear WARNING 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 temperature or open flame WARNING Doing either of the above actions can cause the cylinder or shock to explode causing personal injury or death For maintenance see Maintenance Schedu...

Page 86: ...the wheel and tire immediately Tire Inflation WARNING 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 pressure should be checked using an accurate gauge when the t...

Page 87: ...e base of the belt teeth 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 cords If ratcheting has occurred you should replace the belt before the n...

Page 88: ...4 Remove the tester carefully from the belt Avoid rough movements of the tester as this would change the results of the measurement The measurement should Drive Belt Adjustment Procedure Note Adjust both sides left and right 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 ...

Page 89: ... 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 the back upper right corner of the headla...

Page 90: ...ow 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 CAUTION Using higher wattage bulbs that specified can will cause the headlight lens to melt To replace the bulb 1 Working from behind the headlight disconnect the headlight bulb connector A and rubber cover B Zero O...

Page 91: ... glass portion of the headlight bulb Keep the headlight bulb free of contaminants Oil 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 headlight bulb connector Zero Owner s Manual S and DS book Page 19 Friday October 30 2015 11 13 AM ...

Page 92: ... 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 Zero Owner s Manual S and DS book Page 20 Friday October 30 2015 11 13 AM ...

Page 93: ...hind 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 Zero Owner s Manual S and DS book Page 21 Friday October 30 2015 11 13 AM ...

Page 94: ...een in contact with strong abrasive cleaning 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 washing rinse your motorcycle thoroughly with plenty of clean water to remove any detergent residue 4 Dry you...

Page 95: ... see page 5 1 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 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 genuine Zero accessories A full line of par...

Page 96: ... the fuses To remove the cover squeeze the tabs together and pull off the cover To access the 12 volt 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 5A ABS 4 Key 2 10A ABS 9 Valve 3 10A Headlight Zero Owner s Manual S and DS book Page 24 Friday October 30 2015 11 13 AM ...

Page 97: ...er from the red cap gently pull the tab away from the cap and lift fuse holder To access the 12 volt ABS fuse 3 Gently pull the tab A away from the red cap to release the fuse holder and pull upwards 4 Replace the fuse The 12 volt fuse value is listed below FUSE RATING CIRCUITS CONTROLLED 0 25A ABS 18 Motor Zero Owner s Manual S and DS book Page 25 Friday October 30 2015 11 13 AM ...

Page 98: ... 2 Pull the seat rearward to gain access to the fuses The high voltage fuse values are listed below Note If the charge fuse 4 needs replacement contact your Zero Motorcycles dealer FUSE RATING CIRCUITS CONTROLLED 1 SPT3 15A Low Power B 2 ABC4A Main Bike Board Controller 3 ABC4A DC DC Converter 4 100A Charge Fuse inline Zero Owner s Manual S and DS book Page 26 Friday October 30 2015 11 13 AM ...

Page 99: ...ished douse with a water based fire extinguisher WARNING Your motorcycle uses high voltage System components can be too 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 WARNING The motorcycle s high voltage system has no user identification see First Responder ...

Page 100: ...detected count the number of times the red indicator light A flashes flashing sequence does repeat Refer to the table starting on the next page for possible causes and solutions to the issue Zero Owner s Manual S and DS book Page 2 Friday October 30 2015 11 13 AM ...

Page 101: ...rottle connection is bad Verify throttle action and or check connection 4 Precharge Fail Could not pre charge motor controller Contact Zero or your dealer 5 Low Power Pack Disable Charge Power Pack Before Riding 6 Contactor Error Contact Zero or your dealer 7 Charger Problem Contact Zero or your dealer 8 Controller Area Network CAN Error Contact Zero or your dealer 9 Battery Management System BMS ...

Page 102: ...Zero or your dealer 16 Battery Management System BMS Internal Disable Cycle Ignition Key OFF and then ON again or reset BMS with button If problem persists contact Zero or your dealer 17 Battery Management System BMS Internal Fault Cycle Ignition Key OFF and then ON again or reset BMS with button If problem persists contact Zero or your dealer 18 Miscellaneous Error Contact Zero or your dealer NUM...

Page 103: ...rieved from the dash Display A To retrieve the error code see Display A on the Displays A B on page 3 12 Refer to the table starting on the next page to identify the error associated with the Error Code number Zero Owner s Manual S and DS book Page 5 Friday October 30 2015 11 13 AM ...

Page 104: ... Warning 13 Reserve Switch Warning 14 Safety Override Active 15 Charger Attached But Not Charging 16 CIB Contactor Compromised 17 Charger Error 23 Post Error 24 Startup Error 25 Contactor Open Warning 26 Contactor Welded Error 27 Precharge Error 28 BMS Isolation Fault 29 BMS Isolation Danger 30 BMS Can Error 31 SEVCON CAN Error 32 Module Variance Too High 33 SEVCON Error Turn Off 34 Charge Error T...

Page 105: ...sable 49 Contactor Open Disable 50 BMS Self Test Error 51 BMS Self Test Warning 52 Reserve Partition Disable 53 BMS Internal Disable 54 Internal Disable Error 55 Internal Fault Error 56 Monolith Not Connected CODE ERROR DESCRIPTION Zero Owner s Manual S and DS book Page 7 Friday October 30 2015 11 13 AM ...

Page 106: ...g Fault code set Check A C outlet for power A C source check fuse voltage See Charge Fault Code chart on page 7 11 or see Understanding BMS Flash Code Patterns on page 7 11 Handlebars wobbly shimmy Incorrect tire pressure Inflate to correct tire pressure See page 6 14 Deformed front tire Replace balance front tire with the same tire supplied from the factory Bald tire excess wear Replace balance t...

Page 107: ... 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 Zero Owner s Manual S and DS book Page 9 Friday October 30 2015 11 13 AM ...

Page 108: ...ealthy BMS OK 50 ms 2 sec Isolation Fault Contact Zero or the dealer 50 ms 60 sec Pack Low Charge power pack 50 ms 2 sec BMS Internal Error Reset BMS with button If problem persists contact Zero Motorcycles or your dealer 50 ms 1 sec BMS Self Test Failure Reset BMS with button If problem persists contact Zero Motorcycles or your dealer sec seconds ms milliseconds Zero Owner s Manual S and DS book ...

Page 109: ... will flash depending on the power pack s state of charge 1 RED 2 GREEN 3 GREEN 4 GREEN ON OFF MEANING SOLUTION 100 ms 5 sec Charge Complete Leave Charger Plugged in Until Ready to Ride Charging 2 sec 25 Continue Charging 2 sec 50 Continue Charging 2 sec 75 Continue Charging 2 sec 100 Continue Charging Balancing 500 ms Power Pack Unbalanced Continue Charging 500 ms Zero Owner s Manual S and DS boo...

Page 110: ...N 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 Zero Owner s Manual S and DS book Page 12 Friday October 30 2015 11 13 AM ...

Page 111: ...l the BMS will terminate charging 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 High Battery Temperatu...

Page 112: ...roduces 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 Zero Owner s Manual S and DS book Page 14 Friday October 30 2015 11 13 AM ...

Page 113: ...w 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 temperature above 32 F 0 C Storage temperatures b...

Page 114: ...in direct sunlight in ambient temperatures above 105 F 41 C may result in accelerated permanent decay of battery performance and hence it is not recommended Safety Interlocks If the BMS detects a serious internal fault it can take either or both of two actions to prevent damage to the power pack Throttle Disable The BMS disables the throttle if the power pack is empty or if the BMS detects certain...

Page 115: ...s and back ON again to enter self test mode The flash code pattern from the BMS reports any of the error conditions which would cause the BMS to disable the throttle Each of these conditions the associated self test flash code pattern and the suggested remedies are discussed in Understanding BMS Flash Code Patterns on page 7 11 Charger Disable Interlock When the charger is attached and plugged in ...

Page 116: ...Notes Zero Owner s Manual S and DS book Page 18 Friday October 30 2015 11 13 AM ...

Page 117: ...8 9 hours 100 charged Supplemental Charger Quick Charge Time with max accessory chargers ZF9 8 2 0 hours 100 charged 1 5 hours 95 charged ZF13 0 2 6 hours 100 charged 2 1 hours 95 charged Input Universal 100 240 V AC Charger Type 1 3 kW Integrated Estimated Power Pack Life to 80 city ZF9 8 272 000 miles 438 000 km ZF13 0 362 000 miles 583 000 km RANGE City EPA UDDS ZF9 8 121 miles 195 km ZF13 0 16...

Page 118: ... mm inverted cartridge forks with adjustable spring preload compression and rebound damping Rear Suspension Showa 40 mm piston 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 23 lb 10 4 kg Curb Weight ZF9 8 376 lb 171 kg ZF13 0 408 lb 185 kg C...

Page 119: ...ZF13 0 8 9 hours 100 charged 8 4 hours 95 charged Supplemental Charger Quick Charge Time with one accessory charger ZF13 0 5 2 hours 100 charged 4 7 hours 95 charged Supplemental Charger Quick Charge Time with ZF13 0 2 6 hours 100 charged 2 1 hours 95 charged RANGE City EPA UDDS ZF13 0 161 miles 259 km Highway 55 mph 88 km h ZF13 0 98 miles 158 km Combined City 55 mph ZF13 0 122 miles 196 km Highw...

Page 120: ... 70 R17 M C 66H Front Wheel 3 00 x17 Rear Wheel 3 50 x17 Front Suspension Showa 41 mm inverted cartridge forks with adjustable spring preload compression and rebound damping Rear Suspension Showa 40 mm piston 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...

Page 121: ...r Quick Charge Time with max accessory chargers ZF9 8 2 0 hours 100 charged 1 5 hours 95 charged ZF13 0 2 6 hours 100 charged 2 1 hours 95 charged Input Universal 100 240 V AC Charger Type 1 3 kW Integrated Estimated Power Pack Life to 80 city ZF9 8 272 000 miles 438 000 km ZF13 0 331 000 miles 533 000 km Type Z Force Li Ion Intelligent Power Pack RANGE City EPA UDDS ZF9 8 110 miles 177 km ZF13 0 ...

Page 122: ...ted cartridge forks with adjustable spring preload compression and rebound damping Rear Suspension Showa 40 mm piston 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 23 lbs 10 4 kg Curb Weight ZF9 8 381 lb 173 kg ZF13 0 413 lb 187 kg Carrying...

Page 123: ... ZF13 0 8 9 hours 100 charged 8 4 hours 95 charged Supplemental Charger Quick Charge Time with one accessory charger ZF13 0 5 2 hours 100 charged 4 7 hours 95 charged Supplemental Charger Quick Charge Time with ZF13 0 2 6 hours 100 charged 2 1 hours 95 charged RANGE City EPA UDDS ZF13 0 147 miles 237 km Highway 55 mph 88 km h ZF13 0 88 miles 142 km Combined City 55 mph ZF13 0 110 miles 177 km High...

Page 124: ...ont Wheel 2 50 x 19 Rear Wheel 3 50 x 17 Front Suspension Showa 41 mm inverted cartridge forks with adjustable spring preload compression and rebound damping Rear Suspension Showa 40 mm piston piggy back reservoir shock with adjustable spring preload compression and rebound damping DIMENSION Wheel Base 56 8 in 1 443 mm Seat Height 33 2 in 843 mm Rake 26 5 degrees Trail 4 6 in 117 mm WEIGHT Frame 2...

Page 125: ...Zero Motorcycles Inc Zero warrants that all factory manufactured 2016 Zero motorcycles are free from defects in material and workmanship during the period of this Limited Warranty This Limited Warranty covers parts including the motor motor controller frame swing arm fork rear shock brake assemblies wheels and electrical sub assemblies and approved Zero accessories installed at the time of purchas...

Page 126: ...these events occur on different dates the later date shall be the Up to five 5 years or 100 000 miles 160 000 km whichever occurs first from the in service date of the host 2016 Zero S SR DS DSR motorcycle for the Z Force Power Tank accessory If purchased after the host Power Pack warranty has expired the Power Tank will receive the standard warranty of one 1 year from date of purchase Five 5 year...

Page 127: ...there is a normal expected reduction in range capacity that Power Packs can yield over time and usage Depending on use and storage conditions Power Packs will degrade during the duration of this Limited Warranty period Zero will only repair or replace pursuant to this Limited Warranty a Power Pack that exhibits a nominal storage capacity reduction of greater than 20 of the published nominal capaci...

Page 128: ...idden Any cosmetic concerns that arise as a result of environmental conditions owner abuse misuse lack of Zero motorcycles and Power Packs used for racing or other competitive events Zero motorcycles and Power Packs misused or improperly operated Damage malfunctions or performance problems caused by modifications or alterations to 2016 Zero motorcycles and or Power Packs including modifications or...

Page 129: ...rranty The following additional limitations and disclaimers apply to this Limited Warranty This Limited Warranty is the only express warranty made in connection with the sale of this Zero Motorcycle model Any implied warranty including any warranty of merchantability or warranty of fitness for a particular purpose is limited in duration to the stated period of this written warranty Some states do ...

Page 130: ...d all safety warnings instructions and Limited Warranty if the unit is sold loaned or otherwise transferred to another person What Are Your Responsibilities As A Customer As the owner of a product covered by this Limited Warranty it is your responsibility to read and understand the Owner s Manual this Limited Warranty and all product warnings before operating your Zero motorcycle Serious injury or...

Page 131: ...y 2016 Zero motorcycle Power Packs or parts that are covered by this Limited Warranty and found by Zero or an authorized Zero dealer to be defective in factory materials or workmanship How Does This Limited Warranty Relate To State Law This warranty gives you specific legal rights and you may also have other rights which vary from State to State Zero Owner s Manual S and DS book Page 7 Friday Octo...

Page 132: ...erica Monday Friday 8am to 5pm Pacific Time or 31 0 72 5112014 UK Europe and global markets or via e mail at support zeromotorcycles com In any written or telephonic communication please state the specific nature of any circumstances leading to the problem and include the VIN and odometer reading North America Zero Motorcycles Inc 380 El Pueblo Road Scotts Valley CA 95066 USA UK Europe and global ...

Page 133: ...ero Motorcycles the ability to contact the new owner in the unlikely event of a safety related issue Use the email address below or feel free to contact the Zero Motorcycles Customer Service department for assistance North America Phone 1 888 786 9376 Monday Friday 8am to 5pm Pacific Time E mail support zeromotorcycles com UK Europe and global markets Phone 31 0 72 5112014 E mail support zeromotor...

Page 134: ...telephone number Vehicle identification number VIN Date of purchase Motor serial number if visible An owner information chart is provided on page 1 3 to record this information Zero Motorcycles Inc can be contacted as follows Zero Motorcycles Inc 380 El Pueblo Road Scotts Valley CA 95066 USA Phone 1 888 786 9376 Monday Friday 8am to 5pm Pacific Time E mail support zeromotorcycles com 24 hours Zero...

Page 135: ...153 go to http www safercar gov or write to Administrator National Highway Traffic Safety 1200 New Jersey Avenue SE Canada If you believe that your vehicle has a defect which could cause a crash or could cause injury or death you should immediately inform Transport Canada in addition to notifying Zero Motorcycles Inc To contact Transport Canada call their toll free number 1 800 333 0510 United Kin...

Page 136: ...Notes Zero Owner s Manual S and DS book Page 12 Friday October 30 2015 11 13 AM ...

Page 137: ...urself about or mention at the next service 600 miles 1000 km or 1 month Odometer reading Date Notes Performed by 4 000 miles 7 000 km or 6 months Odometer reading Date Notes 8 000 miles 13 000 km or 12 months Odometer reading Date Notes Performed by 12 000 miles 19 000 km or 18 months Odometer reading Date Notes Performed by 16 000 miles 25 000 km or 24 months Odometer reading Date Notes Zero Own...

Page 138: ...eter reading Date Notes Performed by 28 000 miles 43 000 km Odometer reading Date Notes 32 000 miles 49 000km Odometer reading Date Notes Performed by 36 000 miles 55 000 km Odometer reading Date Notes Performed by 40 000 miles 61 000 km Odometer reading Date Notes Zero Owner s Manual S and DS book Page 2 Friday October 30 2015 11 13 AM ...

Page 139: ...ate Notes Performed by 52 000 miles 79 000 km Odometer reading Date Notes 56 000 miles 85 000 km Odometer reading Date Notes Performed by 60 000 miles 91 000 km Odometer reading Date Notes Performed by 64 000 miles 97 000 km Odometer reading Date Notes Zero Owner s Manual S and DS book Page 3 Friday October 30 2015 11 13 AM ...

Page 140: ...te Notes Performed by 76 000 miles 115 000 km Odometer reading Date Notes 80 000 miles 121 000 km Odometer reading Date Notes Performed by 84 000 miles 127 000 km Odometer reading Date Notes Performed by 88 000 miles 133 000 km Odometer reading Date Notes Zero Owner s Manual S and DS book Page 4 Friday October 30 2015 11 13 AM ...

Page 141: ...eaning Your Motorcycle 6 22 Contact information NHTSA 9 11 Zero Motorcycles 9 10 E Emissions Information 1 6 F Fuses 6 23 12 Volt Fuse Center 6 24 High Voltage Fuse Center 6 26 G General Operation 4 1 Key Switch Steering Lock Positions 4 2 Pre Ride Inspection 4 1 General Safety Precautions 2 1 General Troubleshooting 7 8 H Headlight Alignment 6 17 Bulb Replacement 6 18 I Important Operating Inform...

Page 142: ...d 1 3 Owner s Responsibilities 6 1 P SPORT Position 3 20 Power Pack 6 9 Plug in Your Z Force Power Pack 1 2 Serial Number 1 4 Pre Ride Inspection 4 1 Public Charging Stations 5 9 Q Quick Charging 5 5 R Reporting safety defects 9 11 S Safe Riding Information 1 2 Safety Interlocks 7 16 Serial Number Motor 1 4 Power Pack 1 4 Smartphone Application 3 15 State of Charge SOC 3 15 Storage Long Term 6 23 ...

Page 143: ...Technical Specifications 8 1 Zero SR Technical Specifications 8 3 Tire Inflation 6 14 Transporting 1 10 Troubleshooting Battery Management System BMS 7 9 Charge Mode 7 11 Run Mode 7 12 Turn Signal Light Bulb Replacement 6 20 V Vehicle Identification Number VIN W Warning Lights 3 8 3 10 Warranty Coverage 9 1 Exclusions 9 3 Transfer Of Ownership And Warranty 9 9 Wheels And Tires 6 14 Zero Owner s Ma...

Page 144: ...Notes Zero Owner s Manual S and DS book Page 4 Friday October 30 2015 11 13 AM ...

Page 145: ...First Responder Information High Voltage Components Locations First Responder Information High Voltage Components Locations Zero Owner s Manual S and DS book Page 1 Friday October 30 2015 11 13 AM ...

Page 146: ...Zero Owner s Manual S and DS book Page 1 Friday October 30 2015 11 13 AM ...

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