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2009 ZERO S / DS OWNER'S MANUAL

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CONSUMER INFORMATION 

WARRANTY INFORMATION

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WARRANTY COVERAGE CHART

Motorcycle Parts Covered

STANDARD:

Includes Shipping and Labor Coverage.

STANDARD 2ND YEAR:

Parts Only, Excludes Shipping and Labor Coverage.

EXTENDED:

Includes Shipping and Labor Coverage.

NO FAULT:

Includes Shipping and Labor Coverage, and 

any Non-covered Parts at 50% Retail Cost.

Motor

1 Year

1 Year

2 Years

2 Years

Controller

1 Year

1 Year

2 Years

2 Years

Power Pack

1 Year

1 Year

2 Years

2 Years

Fork

1 Year

1 Year

2 Years

2 Years

Rear Shock

1 Year

1 Year

2 Years

2 Years

Frame

1 Year

1 Year

2 Years

2 Years

Swingarm

1 Year

1 Year

2 Years

2 Years

Brake Assemblies

(Excludes Pads and Rotors)

1 Year

1 Year

2 Years

2 Years

Electrical Sub-Assemblies (Kill 

Switch, Throttle, Dash Assembly, 

Etc)

1 Year

1 Year

2 Years 

2 Years

Wheels

Initial quality only, no warranty once 

ridden.

N/A

Initial quality only, no warranty once 

ridden.

2 Years @ 50% of retail cost.

Zero Motorcycles Inc. expressly warrants all Zero manufactured products from defects in material and workmanship 
under normal operating conditions and according to proper use for 2 years from the date of delivery. The first year of 
this limited warranty covers parts, standard shipping and labor for all major components, defined herein as including 
the motor, motor controller, power pack, fork, rear shock and frame, swingarm, brake assemblies, and electrical  
sub-assemblies. The second year of this limited warranty covers parts only for these same major components. 

Should the EXTENDED WARRANTY be purchased, the coverage level from the first year of the warranty is 
extended unchanged through the second year including parts, standard shipping and labor coverage. 

The NO FAULT option applies to the same two year period but adds additional coverage allowing for the  
replacement of any parts that need to be replaced for any reason at 50% of retail cost. This warranty does not 
apply to tire wear, chain or sprocket condition, brake pads or rotors, fork seals, grips, foot pegs, the seat, or  
any other parts subject to normal wear and tear. It does not cover use or operation under abnormal circumstances 
nor contrary to the requirements described in the owner’s manual or damage to the vehicle brought on by  
improper use or accidents. Racing or competitive use voids this warranty.

Modifications or alterations to the manufacturer’s original product or its components void all warranties. 
Zero Motorcycles Inc. assumes no liability for any misuse or improper operation of Zero Motorcycles.

Under this limited warranty and liability agreement, Zero Motorcycles Inc. shall have no obligation and the  
purchaser shall have no remedy against Zero Motorcycles Inc. and its officers and/or agents for any damages,  
including but not limited to incidental, consequential, special, punitive damages arising from direct or indirect 
injury to person or property, or any other loss, whether or not occasioned by negligence or otherwise on the  
part of Zero Motorcycles Inc.

Summary of Contents for S 2009

Page 1: ...ZERO MOTORCYCLES 2009 S DS OWNER S MANUAL...

Page 2: ......

Page 3: ...re while this manual contains the most current product information available at the time of printing there may be minor discrepancies between your motorcycle and this manual If you have any questions...

Page 4: ...2009 ZERO S DS OWNER S MANUAL 2...

Page 5: ...harger Led Indicators 21 Maintenance and Repair 21 Power Pack Care and Technical Information 22 Bolt Torque Table 23 Maintenance Schedule 24 General Maintenance 24 Motor Maintenance 24 Suspension 24 W...

Page 6: ...2009 ZERO S DS OWNER S MANUAL 4...

Page 7: ...that allows for using freeways or highways for a few miles when necessary You can expect to achieve 40 miles of average range under normal use stop and go city traffic with a maximum range of 60 miles...

Page 8: ...ck warning to the rider in the form of a rapid acceleration deceleration pulsing of the motorcycle At this point it is strongly recommended that you reduce your speed and consider finding a safe area...

Page 9: ...unable to take responsibility for their actions should not use this motorcycle You assume all responsibility while operating your motorcycle The seller will assume no liability for misuse or operator...

Page 10: ...S DS connected to the charger when your motorcycle is sitting in storage or if it will be sitting unused for more than 7 days 6 Always firmly apply the rear brake while turning the master switch on o...

Page 11: ...2009 ZERO S DS OWNER S MANUAL 9 1 EPA Label Shown Actual Size LOCATION OF IMPORTANT LABELS 1 SAFETY INFORMATION...

Page 12: ...2009 ZERO S DS OWNER S MANUAL 10...

Page 13: ...l Module 3 Front Brake Lever 4 Key Switch 5 Right Handlebar Control Module 6 Front Brake Fluid Reservoir and Master Cylinder 7 Mirrors 8 Warning Indicator CONTROLS AND COMPONENTS MOTORCYCLE CONTROLS 2...

Page 14: ...Headlight 2 Tail Light Brake Light License Plate Light 3 On Board Power Connection 4 Kickstand Sidestand 5 Main Power Coupling 6 Sidestand Switch 7 Onboard Charger CONTROLS AND COMPONENTS LEFT VIEW 4...

Page 15: ...ERO S DS OWNER S MANUAL 13 1 Drive Chain 2 Rear Brake Fluid Reservoir 3 Rear Brake Master Cylinder 4 Chain Tensioner 5 Rear Brake Pedal 6 Zero S DS Power Pack RIGHT VIEW 4 1 3 2 5 6 CONTROLS AND COMPO...

Page 16: ...10 1 2 4 5 6 3 7 8 9 8 Shown Actual Size 1 Main Power Indicator 2 Energy Gauge 3 Speedometer 4 Odometer 5 Trip Odometer 6 Warning Indicator 7 High Beam Indicator 8 Turn Signal Indicator 9 Select Adju...

Page 17: ...ZERO S DS OWNER S MANUAL 15 20 30 40 50 60 70 80 90 100 1 10 120 10 1 Headlight Hi Low Beam Selector 2 Turn Signal Switch 3 Horn 4 High Beam Flasher LEFT HANDLEBAR CONTROLS 1 4 2 3 CONTROLS AND COMPON...

Page 18: ...009 ZERO S DS OWNER S MANUAL 16 20 30 0 90 100 1 10 120 10 1 Motor Stop Switch Kill Switch 2 Front Brake Lever 3 Throttle CONTROLS AND COMPONENTS RIGHT HANDLEBAR CONTROLS CONTROLS AND COMPONENTS 1 2 3...

Page 19: ...raulic 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 7 Make sure the motorcycle is off then twist th...

Page 20: ...riding in dusty or wet areas BRAKE Squeeze the brake lever and push the motorcycle to see if it rolls You should be able to lock up the wheels up completely using the brakes Check for sufficient brake...

Page 21: ...AWG cord no longer than 25ft 7 5 m 5 AVOID connecting the Zero S DS motorcycle charger and another device to a single 15A 20A circuit or the circuit may become overloaded 6 Charging a fully discharged...

Page 22: ...6 for 11 seconds if no battery is connected 80 Charge Amber Solid Flashing Bulk charge phase complete 80 charged In Absorption phase With no battery connected indicates algorithm selected by number o...

Page 23: ...nced and complete charge at all times without wasting any electricity 2 Over extended periods of time the power pack is checked every 72 hours to ensure that the cells are balanced and that the power...

Page 24: ...threadlocker D Shock mount bolts 13 15 N m Use grease E Rear axle bolts 18 20 N m Use grease F Motor mount bolt 30 N m Use anti sieze paste G Rear Caliper mount bolts 11 13 N m Use grease H Triple cla...

Page 25: ...eel Bearings Check bearings for smooth operation Replace if necessary 7 Swingarm Pivot Bearings Check bearing assemblies for looseness Moderately repack with lithium grease Ensure main pivot bolt is p...

Page 26: ...s preload and rebound damping adjustments Preload is altered by loosening the lock ring on the spring and turning the adjuster to either compress or decompress the spring Rebound damping is adjusted u...

Page 27: ...or mounting bolts Do not over tighten the motor mounting bolts since the motor adapter plate is aluminum A worn chain will damage the sprockets so it is advisable to replace the chain before it is too...

Page 28: ...2009 ZERO S DS OWNER S MANUAL 26...

Page 29: ...pounds 36 3 kg Total weight 270 pounds 122 5 kg ECONOMY Typical cost to recharge Less than 01 per mile or kilometer MOTOR Type Brushed permanent magnetic electric Top Speed 55 mph 90 kph POWER SYSTEM...

Page 30: ...patterns and their meanings SAFETY INTERLOCKS The BMS can disable the bike s throttle control if the pack is fully discharged or in case of other errors The BMS can also disable charging under certain...

Page 31: ...ycle and your commute Once you become familiar with the range versus performance of your motorcycle then you can adjust your driving characteristics if you so desire This applies mainly to drivers wit...

Page 32: ...l warming and energy security problems facing the country and the world EMISSIONS The Zero S and DS do not require any gasoline and as a result do not get miles per gallon For the sake of emissions co...

Page 33: ...d be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold 2 Read and understand the owner s manual and all product warnings before opera...

Page 34: ...2009 ZERO S DS OWNER S MANUAL 32...

Page 35: ...power for 15 seconds 3 Charge Timeout caused by battery pack not reaching required voltage Charger output was reduced due to high temperatures Check connections Operate charger at a lower ambient temp...

Page 36: ...tle You cannot ride the bike until the pack cools down Place the bike in a cool well ventilated location and wait a few minutes before riding again If the Too Hot error beep still sounds after the pac...

Page 37: ...ed off or b The throttle control is disabled for any reason which includes the pack being completely empty The Low Pack warning beep will sound when you can still ride the bike but the remaining range...

Page 38: ...BMS can send a signal to the main bike controller requesting that the throttle control on the bike be disabled When the throttle control is disabled the drivetrain will not deliver power to the rear...

Page 39: ...is also reported by an error beep pattern after BMS self test when the bike is turned on See Understanding Beep Sequences page 34 for a description of the Too Hot error beep and the remedies PACK FULL...

Page 40: ...result with a beep pattern Note that this sanity check and the resulting beep patterns is different from the key on self test The sanity test and the beeps happen immediately when the board is first...

Page 41: ...up ON position page 12 item 5 Flip Kill Switch to the ON position page 16 item 1 Charger not working A C power missing Main power coupling not engaged Check A C outlet for power A C source check fuse...

Page 42: ...2009 ZERO S DS OWNER S MANUAL 40...

Page 43: ...s and electrical sub assemblies The second year of this limited warranty covers parts only for these same major components Should the EXTENDED WARRANTY be purchased the coverage level from the first y...

Page 44: ...the above limitation or exclusion may not apply to you Zero Motorcycles Inc reserves the right to change or improve the design of any electric motorcycle product without assuming any obligation to mo...

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Page 47: ...TES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU This warranty gives you specific legal rights and you also...

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