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Zero Motorcycles MX, Owner'S Manual, Page: 31 / 100

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Zero Motorcycles MX Owner'S Manual Download Page 31

4-2

Uncrating Your Motorcycle

The X/MX motorcycle arrives almost entirely
assembled. It is recommended that you have an
assistant to help with the uncrating procedure. We
advise wearing protective gloves and protective
eyewear when uncrating the Zero motorcycle. It is
possible during shipping that sharp edges or points
may occur. Please use caution. Retain the crate and
all other shipping items for future shipping of the
motorcycle.

Note: The shipping crate may differ slightly than
shown, below are general guidelines for uncrating the
motorcycle.

1. Remove the crate clamps (A) and remove the

crate end panel (B).

2. With the aid of an assistant, lift and move (C) the

crate off of the base.

A

C

B

Summary of Contents for MX

Page 1: ......

Page 2: ...Range By Adapting Your Riding Style 1 9 Public Charging Stations 1 9 Emissions Information 1 10 Transporting 1 10 Safety Information 2 1 General Safety Precautions 2 1 Important Operating Information...

Page 3: ...ed Warranty and No Fault Warranty 7 5 Proper Use 7 6 Purchaser s Responsibilities 7 7 Warranty Procedures 7 7 Transfer Of Ownership And Warranty 7 8 Starting And Operating 4 1 First Time Set Up 4 1 Un...

Page 4: ...enance requirements of this motorcycle Zero continually seeks advancements in product design and quality Therefore this manual contains the most current product information available at the time of pr...

Page 5: ...rating features and until you have been trained in safe and proper riding techniques Regular inspections and careful maintenance along with good riding skills will help you to safely enjoy the capabil...

Page 6: ...ress Model Date of Purchase PIN Telephone No E mail Battery Serial Number Owner Information Record important information here pertaining to your motorcycle When contacting your Certified Service Cente...

Page 7: ...N Label Canadian version only PIN Break Down PIN Location The PIN is a 17 digit number stamped on the head tube of the frame Do not alter or remove this as it is the legal identifier for your motorcyc...

Page 8: ...68 Cell 3 2nd Generation 4 336 Cell M Mars P Perm Z Z Motor Force A Agni 05 0 50 HP 51 50 100 HP 10 100 HP 9 2009 A 2010 B 2011 Production Number S 3 9 1 M 9 05 123456 Model Line Motor Type Model Year...

Page 9: ...Range Up to 2 hours or 64 km 40 miles Recharge Time Less than 2 hours Input Standard 110 V AC or 220 V AC DRIVETRAIN Transmission Clutchless one speed Drive System Sport 12T 71T 420 Chain Extreme 15T...

Page 10: ...Pack 52 2 kg 115 pounds ECONOMY Typical Cost to Recharge Less than 01 per mile or kilometer MOTOR Type Brushed permanent magnetic electric Motor Sport Mars Extreme Perm Torque 67 7 N m 50 lb ft Peak H...

Page 11: ...echarge Less than 01 per mile or kilometer DRIVETRAIN Transmission Clutchless one speed Drive System Sport 12T 71T 420 Chain Extreme 15T 71T 420 Chain CHASSIS SUSPENSION BRAKES Front Suspension Travel...

Page 12: ...motorcycle then you can adjust your riding characteristics if you so desire Public Charging Stations There are more public charging stations coming on line every day and there may be some in your are...

Page 13: ...in front of the rebound adjuster on each fork leg This bleed screw A is used to release the built up pressure Loosen the screw slowly but do not remove Once all the air is out tighten the bleed screw...

Page 14: ...lace the ratchet straps around the frame or a solidly mounted part 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 st...

Page 15: ...1 12 NOTES...

Page 16: ...E RIDER ONLY 5 Never permit a guest to ride your electric motorcycle without proper instruction These are performance motorcycles and should be treated with extreme caution 6 Never use alcohol or mind...

Page 17: ...the motorcycle using partial throttle or damage to the motor may occur 4 The Zero X MX power pack should be plugged in when storing the motorcycle for extended periods of time 5 Keep your Zero X MX co...

Page 18: ...Certification Label contains the following information Gross Vehicle Weight Rating GVWR Gross Axle Weight Rating GAWR Front and Rear Production Identification Number PIN Rim Size Tire Pressures Manuf...

Page 19: ...2 4 7 Power Pack Information Label...

Page 20: ...2 5 There is no engine braking Throttle And Speed Control Label...

Page 21: ...2 6 NOTES...

Page 22: ...3 1 SPEED 0 50 MP H 80 KM H 0 25 MP H 40 KM H A C E D B F Controls And Components Motorcycle Controls A Kill Switch B Rear Brake C Instrument Panel D Key Switch E Front Brake F Throttle...

Page 23: ...3 2 A B C E D A Drive Chain B Frame Rail Knob C Power Pack D Frame Rail E Chain Adjuster Right Side View...

Page 24: ...0 25 position reduces the top speed of the motorcycle to below 25 mph Using this setting typically results in greater range because the motorcycle is moving at a lower average speed Due to the Zero mo...

Page 25: ...to red The energy gauge is segmented into 3 colors the colors indicate the following Torque Control Switch The torque control is a two position switch that toggles between high and low To select eithe...

Page 26: ...3 5 A D B C B A A Brake Lever Master Cylinder B Brake Lever Reach Adjustment C Kill Switch D Throttle Handlebar Controls...

Page 27: ...tral returned position The brake lever is adjustable To adjust see Brake Adjustment on page 4 16 Left Handlebar Control Rear Brake Lever The rear brake lever engages the rear brake when the lever is s...

Page 28: ...3 7 NOTES...

Page 29: ...3 8 NOTES...

Page 30: ...ressure and adjust to proper specifications See Tire Inflation on page 5 8 6 Inspect the hydraulic brake system Follow the hydraulic lines from the reservoirs to the calipers and verify that there are...

Page 31: ...e Zero motorcycle It is possible during shipping that sharp edges or points may occur Please use caution Retain the crate and all other shipping items for future shipping of the motorcycle Note The sh...

Page 32: ...motorcycle upright remove the ratchet straps B 4 Fold down the ramp A and lower the protective plastic B B A 5 Remove the fork support A located between the wheel and front fender A 6 Carefully roll...

Page 33: ...areas See Chain on page 5 8 Brakes Squeeze each brake lever individually and push the motorcycle to see if it rolls You should be able to lock up the wheels completely by applying the brakes Throttle...

Page 34: ...ime of the power pack is usually less than 2 hours in ambient temperatures Out of the normal temperature range charging and run time times will vary The batteries should not be used outside of the ran...

Page 35: ...uick change power pack This allows the rider to charge one power pack while using another To change the power pack perform the following Removal 1 Remove the key from the key switch and safely support...

Page 36: ...for a host of predefined conditions and then takes actions according to these conditions Some of these conditions are listed below Also see Understanding Beep Sequences on page 6 3 Low Voltage Action...

Page 37: ...e will not run until the temperature returns to an acceptable level The charger will also be disabled in this condition High Voltage Action If the BMS detects a voltage that is too high it shuts down...

Page 38: ...p pattern reports the self test result Whenever the key switch is ON and the power pack is nearly empty The BMS will continuously sound a warning when the power pack is low The warning will stop when...

Page 39: ...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 will il...

Page 40: ...complete 80 charged In Absorption phase With no power pack connected indicates algorithm selected by number of flashes Flashing Also displays algorithm 1 6 for 11 seconds if no power pack is connecte...

Page 41: ...heat and burst It is recommended to charge in a location that is away from combustible materials and in a well ventilated area Avoid outdoor charging of your power pack in the rain 4 Connect the batte...

Page 42: ...a few miles of range left This beep tells you your power pack is dangerously low on energy and needs to be recharged immediately Your power pack will continue to beep even when it s charging until it...

Page 43: ...NDED 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 110 V AC or 220 V AC current The vol...

Page 44: ...d be applied together with a slight amount more of braking on the front CAUTION If you apply the front or rear brake hard enough it is possible to lock the wheels This could cause you to lose control...

Page 45: ...h by turning the reach adjustment knob A Turning the knob counter clockwise will adjust the lever closer to the handlebar Turning the knob clockwise will adjust the lever further from the handlebar Do...

Page 46: ...he slotted brass adjuster screw B on the top of both fork legs Next to it will be the writing S F meaning Slow and Fast The adjuster has 18 stages of adjustment This determines how quickly the fork re...

Page 47: ...adjuster counter clockwise Start with a middle setting and fine tune the compression from there Proper compression will allow the tire to track the ground over consecutive bumps Compression that is s...

Page 48: ...e fork is designed to use zero pressure and should never exceed 275 kpa 40 psi The fork holds a small amount of air avoid large volume air compressors as this will damage the fork 3 Damping Tuning Reb...

Page 49: ...g serious injury or death S L O W FAST A B set too fast will cause the fork to top out harshly If the fork is topping out and you have the correct spring for your weight turn the adjuster one turn at...

Page 50: ...al riding preference may vary from the specifications given Checking Sag 1 Support your motorcycle on a stand with the rear wheel off the ground 2 Measure vertically from the rear axle to the rear fen...

Page 51: ...easurement M2 10 Subtract the second measurement M2 from the first measurement M1 M2 Example If the total is between 90 to 100 mm 3 5 to 4 0 in the sag is correct If it is not within 90 to 100 mm 3 5...

Page 52: ...spring nut B clockwise on the shock 4 Recheck the sag If the sag is correct tighten the lock nut A Rebound Adjustment The rebound adjuster knob C is at the bottom of the shock It has 8 stages of adjus...

Page 53: ...4 24 NOTES...

Page 54: ...re and maintenance on your electric motorcycle as detailed in this owner s manual 3 Use only genuine Zero approved parts and accessories 4 The operator is responsible for learning and obeying all coun...

Page 55: ...nut swingarm 105 110 N m 77 81 lb ft Use LOCTITE 270TM E Shock mount bolts 13 15 N m 10 11 lb ft Use anti sieze lubricant F Rear caliper mount bolts 11 13 N m 8 10 lb ft Use LOCTITE 242 G Rear axle pi...

Page 56: ...5 3 D A B E H G C F See Bolt Torque Table on page 5 2...

Page 57: ...5 4 A C I D G H See Bolt Torque Table on page 5 2...

Page 58: ...uld not get above 71 C 160 F Do not store in a hot car or trailer or leave the power pack in direct sunlight 3 Only an authorized service agent is qualified to have access to and troubleshoot the powe...

Page 59: ...d The brakes are a sealed system and should require no additional brake fluid unless a leak is detected Brake Pad Inspection The brake pads must be inspected when specified in the maintenance schedule...

Page 60: ...n Adjustment on page 4 16 Wheels And Tires Inspect both wheels for the following Bent loose or missing spokes Bent or cracked wheels Impact marks on the wheels Inspect both tires for the following Cut...

Page 61: ...cle s ability to stop This could result in serious personal injury Follow the manufacturer s instructions for the chain cleaner you are using see general guidelines on page 5 9 Tire Inflation CAUTION...

Page 62: ...d Failure to do so could result in serious personal injury Never place your hand between the chain and sprockets Work with the chain only in the middle between the two sprockets Failure to do so could...

Page 63: ...e Chain Adjustment Procedure 1 Remove the key from the key switch 2 Loosen both front motor mount Allen bolts B 3 Loosen both rear motor mount Allen bolts A 4 Loosen the 10 mm jam nut C on the chain t...

Page 64: ...leaners they can cause water intrusion of bearing seals and electrical components When using pressure washers avoid spraying water of great force around the instrument panel or controller Avoid using...

Page 65: ...ger stops charging and continues to monitor the power pack This ensures that electricity is not wasted in maintaining an optimized power pack 3 To prolong the life of your power pack you should store...

Page 66: ...onths 18 months 24 months 30 months 1 Front Brake Check operation and for fluid leakage Replace brake pads if necessary 9 9 9 9 9 9 9 2 Rear Brake Check operation and for fluid leakage Replace brake p...

Page 67: ...nsure main pivot bolt is properly torqued See Bolt TorqueTable on page 5 2 9 8 Drive Chain Check chain slack alignment and condition Adjust and lubricate chain with chain lubricant thoroughly Replace...

Page 68: ...onths 11 Front Fork Check operation and for oil leakage Service Rebuild if necessary Refer to the service manual for more information 9 9 9 9 9 9 12 Rear Shock Absorber Assembly Check operation and fo...

Page 69: ...a circuit the fusible element will melt and create an open or incomplete circuit Fuses are a onetime protection device and must be replaced each time the circuit is overloaded Replace the fuse with o...

Page 70: ...5 17 Follow the maintenance schedules on pages 5 13 through 5 15 After a scheduled service or routine is performed record the information on the chart below DATE ITEM SERVICE ROUTINE DESCRIPTION...

Page 71: ...5 18 NOTES...

Page 72: ...are unable to solve an issue with your Zero X MX electric motorcycle take it to an authorized Certified Service Center CSC at your convenience If there is no CSC in your area call Zero Motorcycles cu...

Page 73: ...output was reduced due to high temperatures Check connections Operate charger at a lower ambient temperature 4 Check power pack power pack could not be trickle charged up to minimum voltage Contact C...

Page 74: ...on on the meaning of the beep sequences PATTERN WHEN MEANING SOLUTION 1 Short Key on Self Test Pass BMS OK Ready to ride 1 Trill 2 Long Key on Charger Still Plugged In Unplug charger try again 2 Long...

Page 75: ...ividual cells The BMS continuously monitors the cells and tries to keep them all in balance at the same level of charge If any of the cells are grossly out of balance the BMS will sound a Power Pack U...

Page 76: ...repaired or replaced by a CSC BMS Appendix There are other beeps that may occur under two circumstances that operators will normally never see Unlike many electronic systems the BMS essentially never...

Page 77: ...he power pack is empty or if the BMS detects certain serious internal problems You cannot ride the motorcycle until the problem is resolved 2 Charger Disable The BMS will prevent charging if it detect...

Page 78: ...age 6 3 Power Pack Empty Too Hot Power Pack Unbalanced The Charger Disable Interlock When the charger is attached and plugged in to AC power the BMS communicates with the charger The BMS can send a si...

Page 79: ...e balanced the charger not the BMS will sense that the power pack is full and terminate the charging cycle with a green light The BMS does have a redundant back up mechanism to prevent overcharging of...

Page 80: ...of range Bad throttle or connections Verify throttle action and or check connection 5 Motor temperature sensor not detected Bad motor temperature sensor or connections Replace temperature sensor and...

Page 81: ...lure Could not pre charge motor controller Contact CSC 10 Current sensor error Problem with current sensor or connection Contact CSC 11 Board temperature sensor error Problem sensing temperature of bo...

Page 82: ...r e w o p C A k c e h c e c r u o s C A r e w o p r o f t e l t u o C A k c e h C e g a t l o v e s u f y l b b o w s r a b e l d n a H y m m i h s e r u s s e r p e r i t t c e r r o c n I 8 5 e g a...

Page 83: ...6 12 NOTES...

Page 84: ...wer your questions or resolve your concerns Owner s name and address Owner s telephone number Production Identification Number PIN Date of purchase Battery serial number An owner information chart is...

Page 85: ...PARTS COVERED STANDARD EXTENDED Replaces 2nd Year of the Standard Warranty NO FAULT Replacement Parts are 50 of Retail Cost Unless Noted First Year Second Year Excluding Shipping and Labor Motor 35 Di...

Page 86: ...f this standard limited warranty covers parts only for these same major components Standard Warranty Exclusions This warranty does not apply to tire wear chain or sprocket condition brake pads or roto...

Page 87: ...luded from this extended warranty on off road bikes once they have been ridden This extended warranty excludes aftermarket accessory kits which may be subject to their own warranties This extended war...

Page 88: ...warranties and are not included in this no fault coverage Modifications or alterations to major components of the manufacturer s original product or its sub components void all warranties including t...

Page 89: ...product during the time the warranty service is being preformed travel loss or damage to personal property loss of revenue loss of use of the product loss of time or inconvenience Some states do not a...

Page 90: ...esponsible for learning and obeying all country federal state and local laws governing the operations of an electric motorcycle Always wear a helmet knee and elbow guards goggles appropriate boots and...

Page 91: ...and warranty form This must be performed to allow Zero Motorcycles the ability to contact the new owner in the unlikely event of a safety related issue Use the URL address below or feel free to conta...

Page 92: ...7 9 NOTES...

Page 93: ...7 10 NOTES...

Page 94: ...5 6 Brake Lever 3 6 Brake Pad Inspection 5 6 Braking 4 15 C Chain 5 8 Checking The Drive Chain 5 10 Cleaning The Drive Chain 5 8 Drive Chain Adjustment Procedure 5 10 Lubricating The Drive Chain 5 9...

Page 95: ...5 16 G General Information 1 6 Zero MX Technical Specifications 1 7 Zero X Technical Specifications 1 6 General Maintenance 5 6 Brakes 5 6 Chain 5 8 Cleaning 5 11 Motor 5 6 Suspension 5 6 Tire Inflat...

Page 96: ...The Drive Chain 5 9 M Main Power Indicator 3 4 Maintaining Your Motorcycle 5 1 Accessories 5 16 Bolt Torque Table 5 2 Fuses 5 16 General Maintenance 5 6 Owner s Responsibilities 5 1 Power Pack 5 5 Ma...

Page 97: ...Information Label 2 4 Power Pack Swapping 4 6 Pre Ride Inspection 4 4 Production Identification Number PIN 1 4 PIN Break Down 1 4 PIN Location 1 4 Public Charging Stations 1 9 Purchaser s Responsibil...

Page 98: ...ck Adjustment 4 21 T Throttle And Speed Control Label 2 5 Throttle Control 3 6 Tire Inflation 5 8 Torque Control Switch 3 4 Torque Table 5 2 Transfer Of Ownership And Warranty 7 8 Transporting 1 10 Tr...

Page 99: ...INDEX 6 NOTES...

Page 100: ......

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