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Zero Motorcycles XU 2012, Owner'S Manual

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Zero Motorcycles XU 2012 Owner'S Manual Download Page 112

6-3

Battery Management System

The Battery Management System (BMS) is located
inside the power pack and is fitted with a window (A)
to provide visual notification about the status of the
power pack. There are four LED lamps, one red and
three green, that will blink. The window is located on
the end of the power pack, below the charger
connector. See Understanding BMS Light Patterns for
the meanings of these patterns.

A

Summary of Contents for XU 2012

Page 1: ...ZERO X ZERO MX ZERO XU 2012 Owner s Manual ...

Page 2: ...ifications 1 9 Zero XU Street Legal Technical Specifications 1 11 Vehicle Range 1 13 Optimizing Your Range By Adapting Your Riding Style 1 14 Public Charging Stations 1 14 Emissions Information 1 14 Transporting 1 15 Safety Information 2 1 General Safety Precautions 2 1 Important Operating Information 2 2 Location Of Important Labels 2 3 Throttle And Speed Control Label 2 4 Anti Tamper Control Lab...

Page 3: ... 5 29 Accessories 5 29 Fuses 5 29 Instrument Panel MX Dirt 3 11 Performance Level Switch MX Dirt 3 12 Instrument Panel X XU Street Legal 3 13 Indicators 3 14 Performance Level Switch 3 15 XU Street Legal 3 15 X Street Legal 3 16 Handlebar Controls MX Dirt 3 17 Handlebar Controls X XU Street Legal 3 19 Starting And Operating 4 1 First Time Set Up 4 1 Unpacking Your Zero Motorcycle 4 2 General Opera...

Page 4: ...Temperature Indicator 6 14 General Troubleshooting 6 17 Warranty Customer Assistance 7 1 Customer Assistance 7 1 Warranty Information 7 2 Zero Motorcycles Warranties 7 2 Standard Warranty 7 2 Disclaimers Applicable to Standard Warranty 7 4 Proper Use 7 5 Purchaser s Responsibilities 7 5 Warranty Procedures 7 5 Transfer Of Ownership And Warranty 7 6 ...

Page 5: ...TOC 4 NOTES ...

Page 6: ...nually seeks advancements in product design and quality Therefore this manual contains the most current product information available at the time of printing Because of this your motorcycle may differ from the information supplied in this owner s manual No legal claims can be made on the basis of data in this manual When it comes time to sell your Zero please remember to hand over this manual it i...

Page 7: ... inspections and careful maintenance along with good riding skills will help you to safely enjoy the capabilities and the reliability of this motorcycle Disregarding the above may render the warranty invalid 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 ...

Page 8: ... pertaining to your motorcycle here When contacting your dealer you may need to provide this information Dealer Information Motorcycle Information Power Pack Serial Number Address PIN MX Key Code Date of Purchase VIN X XU Telephone No E mail Name Model ...

Page 9: ...used to create duplicate keys This number is located on a tag that accompanies the original keys Motor Serial Number The motor serial number is stamped on the silver metal cooling cover that wraps around the Agni motor or on the casting band for the Motenergy brushless motor Motor Identification A Motenergy Brushless Motor XU Street Legal B Agni MX Dirt X Street Legal B A ...

Page 10: ...Vehicle Identification Number VIN is found on the X XU Street Legal The Production Identification Number PIN is found on the MX Dirt This is a 17 digit number A stamped on the head tube of the frame Do not alter or remove this as it is the legal identifier for your motorcycle A ...

Page 11: ... 11 12 MY XU LSM X U2 X C A1 12345 538 On Road L2 12 MY XU M U2 12 MY XU C2 12 MY XU LSM X2 12 MY MX A1 Type A 9kW 12 1 HP X M0 Type M 4 1 kW 5 5 HP XU LSM M2 Type M 5 2 kW 7 0 HP XU World Manufacturer Identifier C California Model Line Model Year Plant Location Model Net Brake Horsepower C C Europe Only Canada Only ...

Page 12: ...e standard 3 1 hours 100 charged 2 7 hours 95 charged Quick Recharge Time optional 2 0 hours 100 charged 1 3 hours 95 charged POWER SYSTEM Input Standard 120 V AC or 240 V AC Charger Type 1 kW Stand alone Estimated Pack Life to 80 City 165 000 Km 103 000 miles Estimated Pack Life to 80 Trail 4 000 hours DRIVETRAIN Transmission Clutchless one speed Drive System 13T 61T Sprockets 420 Chain CHASSIS S...

Page 13: ...ear Suspension Direct Link shock with adjustable spring preload compression and rebound damping DIMENSIONS Wheel Base 141 cm 55 5 in Seat Height standard 87 cm 34 3 in Rake 26 4 degrees Trail 89 mm 3 5 in RANGE Trail 60 120 minutes City EPA UDDS 61 km 38 miles WEIGHT Frame 6 6 kg 14 5 pounds GVWR 211 kg 465 pounds Curb Weight 98 kg 215 pounds Carrying Capacity 113 kg 250 pounds ECONOMY Typical Cos...

Page 14: ... Maximum Capacity 3 kWh Nominal Capacity 2 6 kWh RANGE MX Track 40 90 minutes Trail 60 120 minutes DRIVETRAIN Transmission Clutchless one speed Drive System 13T 71T Sprockets 420 Chain POWER SYSTEM Recharge Time standard 3 1 hours 100 charged 2 7 hours 95 charged Quick Recharge Time optional 2 hours 100 charged 1 3 hours 95 charged Input Standard 120 V AC or 240 V AC Charger Type 1 kW Stand alone ...

Page 15: ...m 8 7 in Front Suspension 38 mm inverted fork with adjustable compression and rebound damping Rear Suspension Direct Link shock with adjustable spring preload compression and rebound damping Front Brakes 2 Piston Hydraulic 220 x 4 mm Rotor Foot Actuated Rear Brakes 1 Piston Hydraulic 220 x 4 mm Rotor Foot Actuated Brake Rotor Minimum Thickness 3 85 mm 0 15 in Front Tire 100 70 19 in Rear Tire 100 ...

Page 16: ...ours 100 charged 2 7 hours 95 charged Quick Recharge Time optional 2 hours 100 charged 1 3 hours 95 charged Charger Type 1 kW Integrated Estimated Pack Life to 80 182 000 Km 113 000 miles Input Standard 120 V AC or 240 V AC MOTOR Type High Efficiency Axial Flux Permanent Magnet Brushless Motor with Integrated Forced Air Cooling Controller High Efficiency 220 amps 3 phase Brushless Controller with ...

Page 17: ...onomy Highway 359 MPGe 0 66 liters 100 km 0 17 gallons 62 miles CHASSIS SUSPENSION BRAKES Front Suspension Travel 135 mm 5 3 in Rear Suspension Travel 141 mm 5 5 in Front Suspension 38 mm 1 5 in inverted fork with adjustable compression and rebound damping Rear Suspension Direct Link shock with adjustable spring preload and rebound damping Front Brakes 2 Piston Hydraulic 220 x 4 mm Rotor Hand Actu...

Page 18: ... is calculated using industry standardized formulas These ranges are separated into four categories City Highway Trail and Track City EPA UDDS Environmental Protection Agency EPA Universal Dynamometer Driving Schedule UDDS The City EPA UDDS range is a U S federal test procedure to give an estimate on how many miles an electric vehicle will go on a single charge X XU Highway range is to provide the...

Page 19: ...nal J1772 Zero motorcycle accessory These stations are often available at a variety of locations including shopping centers city parking lots airports hotels government offices and other businesses We recommend that you search the internet for locations in your area For example search for charging stations Optimizing Your Range By Adapting Your Riding Style Apply the throttle slowly and try to mat...

Page 20: ...ht on the front tire the screw must be opened again to allow for stabilization Ensure that the screw is tightened before riding Transporting Zero Emissions Vehicles ZEVs 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 motorcycl...

Page 21: ...t straps 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 ...

Page 22: ...his motorcycle is designed for a SINGLE RIDER ONLY 5 Never permit a guest to ride your electric motorcycle without proper instruction 6 Never use alcohol or mind altering drugs before operating your electric motorcycle 7 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 will a...

Page 23: ... Use the rear brake when you are stopped on an incline Do not hold the motorcycle using partial throttle or damage to the motor may occur 4 The power pack should be plugged in when storing the motorcycle for extended periods of time 5 Keep your Zero connected to the charger when your motorcycle is sitting in storage or if it will be sitting unused for more than 7 days The power pack must be charge...

Page 24: ...n the following information Gross Vehicle Weight Rating GVWR Gross Axle Weight Rating GAWR Front and Rear Production Identification Number PIN Rim Size Tire Pressure Date of Manufacture 7 Failure to follow power pack storage and charging instructions as described in this Zero Motorcycles Owner s Manual may void the warranty of your Zero motorcycle These guidelines have been rigorously tested to en...

Page 25: ...2 4 A Throttle And Speed Control Label A Anti Tamper Control Label Europe Only Located on the left side of the frame ...

Page 26: ...CATEGORY B BO5 BATTERY MODEL X 1 1 2 3 4 5 MO2 MOTOR 2 CO6 CONTROLLER 3 41BS13 13T FR SPROCKET 4 RS61T 61T RR SPROCKET 5 TRADE NAME ZERO MOTORCYCLES VEHICLE CATEGORY B BO5 BATTERY MODEL XU 1 1 2 4 5 MO5 MOTOR 2 CO5 CONTROLLER 3 RS132T 132T RR SPROCKET 5 FS 25T 25T FR SPROCKET 4 3 ...

Page 27: ...2 6 NOTES ...

Page 28: ... I 09 33 PU SH P A B E F D C Controls And Components Motorcycle Controls MX Dirt A Motor Stop Switch B Instrument Panel C Key Switch Steering Lock D Performance Level Switch E Front Brake Brake Fluid Reservoir F Throttle Control ...

Page 29: ...ion see pages 3 11 and 3 12 C Key Switch Steering Lock For description and operation see page 4 5 D Performance Level Switch For description and operation see page 3 12 E Front Brake Fluid Reservoir For description and operation see Brakes on page 5 6 F Throttle Control For description and operation see page 3 18 ...

Page 30: ...le Controls X XU Street Legal A Mirrors B Left Handlebar Control C Key Switch Steering Lock D Instrument Panel E Performance Level Switch F Front Brake Brake Fluid Reservoir G Motor Stop Switch H Throttle Control XU Shown X Similar ...

Page 31: ...rrors B Left Handlebar Control For description and operation see pages 3 19 through 3 21 C Key Switch Steering Lock For description and operation see page 4 5 D Instrument Panel For description and operation see pages 3 13 and 3 14 E Performance Level Switch For description and operation see pages 3 15 and 3 16 F Front Brake Fluid Reservoir Cylinder For description and operation see Brakes on page...

Page 32: ...Chain B Power Pack Rail Knob C Power Pack D Power Pack Rail Right Side View MX Dirt E Fuse Center Behind Trim Panel F Rear Brake Fluid Reservoir Behind Trim Panel G Rear Brake Pedal H Drive Chain Tension Adjuster I Cooling Fan Fuse ...

Page 33: ...b secures the power pack in place Do not operate the motorcycle without this rail in place E Fuse Center For description and operation see Fuses on page 5 29 F Rear Brake Fluid Reservoir See Rear Brake on page 5 7 G 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 H Drive Chain Tension Adjuster See Dr...

Page 34: ... A Drive Chain B Power Pack Rail Security Bolt C Power Pack Rail D Power Pack Right Side View X Street Legal E Fuse Center and I P Inline Fuse F Rear Brake Fluid Reservoir G Rear Brake Pedal H Drive Chain Tension Adjuster ...

Page 35: ...curity bolt secures the power pack in place Do not operate the motorcycle without this rail in place E Fuse Center For description and operation see Fuses on page 5 29 F Rear Brake Fluid Reservoir See Rear Brake on page 5 7 G 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 will illumi...

Page 36: ... Belt B Power Pack Rail Security Bolt C Power Pack Rail D Power Pack E Fuse Center Behind Trim Panel Right Side View XU Street Legal F Rear Brake Fluid Reservoir G Rear Brake Pedal H Drive Belt Tension Adjuster I Power Pack Charger ...

Page 37: ... place D Power Pack For description and operation see page 4 6 E Fuse Center For description and operation see Fuses on page 5 29 F Rear Brake Fluid Reservoir See Rear Brake on page 5 7 G 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 will illuminate when the rear brake pedal is appl...

Page 38: ...ator will flash and gently oscillate the motor output to notify the rider Back off of the throttle to reduce heat and eliminate the oscillation Doing so will also eliminate the indicator flashing If the red LED is flashing the system has detected a fault For troubleshooting see section 6 C Temperature Lamp This will flash in the event that you exceed the motorcycle s performance capabilities The t...

Page 39: ...te This position is recommended for advanced riders Those who take advantage of the I position are likely to see a slight increase in range A Performance Level Switch IGN I T I O N OFF ON A D Charge Indicator The charge indicator on the motorcycle is used to inform you of the amount of remaining energy in the power pack The charge indicator is segmented into 3 colors the colors indicate the follow...

Page 40: ... A Left Turn Signal Indicator B High Beam Indicator C Main Power Indicator D System Warning Indicator E Temperature Indicator F Right Turn Signal Indicator G Select Button H Adjust Button I Display Area J Charge Indicator A B C D E I J F G H ...

Page 41: ... on page 6 14 for more information G Select Button By pressing the select button you can toggle between Ride Time and Total Hours displayed H Adjust Button By pressing the adjust button you can toggle between the odometer trip odometer setting A trip odometer setting B RPM and Max Holding it down will clear the trip odometer resetting it back to zero I Display Area The backlit digital display disp...

Page 42: ...osition The Eco position reduces the acceleration and top speed of the motorcycle It is an ideal position to use for times when you want softer acceleration This position is also good for newer riders and for extending range The Sport position causes the motorcycle to accelerate at a significantly faster rate This position is recommended for advanced riders Those who take advantage of the Eco posi...

Page 43: ...on reduces the acceleration and top speed of the motorcycle It is an ideal position to use for times when you want softer acceleration This position is also good for newer riders and for extending range The II position causes the motorcycle to accelerate at a significantly faster rate This position is recommended for advanced riders Those who take advantage of the I position are likely to see a sl...

Page 44: ...3 17 A B C A Motor Stop Switch B Front Brake Lever C Throttle Control Handlebar Controls MX Dirt ...

Page 45: ...ting the motor When the button A is pressed it will stop power to the motor controller The motor controller will remain in this state until the ON B button is pressed The switch does not turn off all electrical circuits just the operation of the motor A B A Motor Stop Switch B Front Brake Lever The front brake lever engages the front brake when the lever is squeezed When braking the throttle shoul...

Page 46: ...9 A B C E D G F A High Beam Flash to Pass B Headlight High Low Beam Switch C Front Brake Lever D Throttle Control Handlebar Controls X XU Street Legal E Motor Stop Switch F Turn Signal Switch G Horn Button ...

Page 47: ...ased this switch will default back to the low beam position The high beam indicator will also illuminate 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 will snap back to the closed position B de energizing the motor XU Only When the motorcycle is moving and the throttle contro...

Page 48: ...oller will remain in this state until the ON B button is pressed The switch does not turn off all electrical circuits just the operation of the motor Always signal your turns and other maneuvers as required by law Unlike an automobile the turn signals must always be cancelled manually on the motorcycle Push in on the switch and it will return to the center or OFF position G Horn Button When the ke...

Page 49: ...3 22 NOTES ...

Page 50: ...to proper specifications See Tire Inflation on page 5 9 6 Inspect the hydraulic brake system Follow the hydraulic lines 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 key switch is OFF then twist the throttle to make sure it s rotation is smooth and returns correctly 8 Inspect b...

Page 51: ...only Unscrew lower crate cover retaining screws and washers Lift or cut outer box away from motorcycle 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 Cut cable ties holding handlebar to motorcycle MX only Position and center handlebar in riser and mount using...

Page 52: ...d inspect in accordance with delivery inspection sheet Recycling Your Zero Motorcycle s shipping crate and packaging materials were designed to be completely recycled Please cut down and recycle all cardboard plastic and metal materials in appropriate receptacles The tie down straps that accompanied your motorcycle can be reused as regular tie down straps for transporting your motorcycle ...

Page 53: ... Belt on page 5 9 Brakes Squeeze the brake lever and press the brake pedal individually and push the motorcycle to see if it rolls You should be able to completely lock up the wheels by applying the brakes Throttle With the key switch in the OFF position twist the throttle and release to verify that the throttle is smooth and returns correctly Tires Check both tires for condition and tread depth C...

Page 54: ...e key should be removed from the motorcycle when parked to prevent theft The key can be removed in either the OFF or Steering Lock Position A Steering Lock Using the steering lock when parked will prevent unauthorized use and help prevent theft To 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 do...

Page 55: ... V AC or 240 V AC The charger output will be the same The normal recharging time of the power pack to 100 is usually less than 3 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 range of 7 C 71 C 20 F 160 F the Battery Management System BMS will turn off the motor controller outside of this range...

Page 56: ... 7 days even if fully charged Please leave your Zero motorcycle plugged in whenever possible The power pack should maintain up to 80 of its capacity for approximately 3 000 hours MX Track 4 000 hours MX Trail 182 000 km 113 000 miles XU 165 000 km 103 000 miles X City 4 000 hours X Trail Track range represents the riding time that most riders can expect to achieve while riding on tracks The track ...

Page 57: ...om the key switch and safely support the motorcycle 2 Disconnect the power pack charging connector A XU only 3 Locate the thumb screw B MX Dirt or T 40 security bolt C X XU Street Legal The security bolt requires the supplied tool located under the seat to remove and install The security bolt can be replaced with the thumb screw available from Zero Motorcycles Accessories See image on page 4 9 4 P...

Page 58: ...k weighs 24 kg 53 pounds 7 Using a firm grip slide the power pack out of the frame DO NOT lift the power pack by the plastic connector housing D E Installation 1 Slide the power pack into the frame 2 Connect the power pack connectors 3 Install the power pack rail into the front slot first then push the rear side into the frame 4 Install and securely tighten the thumb screw security bolt ...

Page 59: ...ery Management System BMS which monitors the condition of the cells and optimizes the charging process to provide the highest performance longest range and longest life for the power pack The BMS safeguards the power back by means of safety interlocks These interlocks turn off or control certain operations that could damage the power pack See Safety Interlocks on page 6 10 for more information The...

Page 60: ...harge 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 illuminate on the charger Should the charger not read that the power pack is full it will continue to attempt to fully charge the power pack In this event the green light may not illuminate however the power pack may be ful...

Page 61: ...ne or more cells have reached maximum voltage C 100 Charge The 100 Charge LED is a green indicator If it is 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...

Page 62: ...pack in the rain The minimum charge temperature is 0 C 32 F The maximum power pack internal charging temperature is 65 C 149 F If the power pack is kept in an environment over 65 C 149 F it will not accept a charge until it is moved to a cooler location Also if the pack has just been run hard it may internally be above 65 C 149 F even if the ambient temperature is lower If you experience a pack th...

Page 63: ...ltage 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 Note AVOID connecting 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 10 amps from the 120 V AC circ...

Page 64: ... on 120 V AC or 240 V AC current The voltage does not change the amount of time that the motorcycle takes to charge Note AVOID connecting 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 10 amps from the 120 V AC circuit when charging 4 Charging a fully discharged Zero power pack to 100 takes about 3 1 hours When the...

Page 65: ...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 Note AVOID connecting 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 10 amps from the 120 V AC circuit when charging 4 Charging a fully discharged power pack to 100 takes about ...

Page 66: ...ens the charging time to about 2 hours for a 100 charge Not Installed in Motorcycle 1 Remove the power pack from the motorcycle See Power Pack Swapping on page 4 8 2 Connect the quick charger harness and both chargers to the power pack 3 Always connect the chargers 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 ...

Page 67: ...0A circuit as it may become overloaded Zero chargers draw as much as 10 amps from the 120 V AC circuit when charging 4 Quick charging to 100 from a fully discharged power pack takes about 2 hours of quick charging 5 When the power pack is fully charged disconnect the chargers 6 Install the power pack into the motorcycle See Power Pack Swapping on page 4 8 3 Connect the stand alone charger to this ...

Page 68: ...e Note AVOID connecting 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 10 amps from the 120 V AC circuit when charging 6 Quick charging to 100 from a fully discharged power pack takes about 2 hours When the power pack is fully charged disconnect the power cord from the chargers Disconnect the stand alone charger co...

Page 69: ...brakes should be applied together with a slight amount more braking on the front CAUTION If you apply the front or rear brakes hard enough it is possible to lock the wheels This could cause you to lose control of the motorcycle We suggest progressive use of the brakes to bring the Zero motorcycle to a complete stop without locking the wheels Your Zero motorcycle is a light weight performance produ...

Page 70: ...arly let any excess air out after each ride 2 Rebound Damping The rebound damping is adjusted by turning the 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 S U S P E N S I O N F A S T A C E C O M F S S U S P E N S I O N FAS T A C E C O M F S IGN I T I O N OFF ON A B B A The adjuster has 18 stages of adjustment This determines ho...

Page 71: ...d fine tune the compression from there Proper compression will allow 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 will cause the fork to bottom out harshly If the fork is bottoming out turn the adjuster one click at a time until the bottoming out stops Adjust each fork leg ...

Page 72: ...rear spring is approximately correct for your weight This adjustment is a recommended guideline personal 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 fender mark this spot as it will be used for other measurements 3 Record this measurement this will b...

Page 73: ...nd measurement M2 from the first measurement M1 Example The total sag is 100 mm 4 0 in Refer to the chart below for the correct sag If the sag is not correct the spring pre load should be adjusted See Spring Pre load Adjustment M1 600 mm 24 in M2 500 mm 28 in Sag 100 mm 4 in MODEL SAG X Street Legal 74 mm 2 91 in MX Dirt 74 mm 2 91 in XU Street Legal 46 mm 1 81 in ...

Page 74: ...g by turning the 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 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 th...

Page 75: ... and fine tune the compression from there Proper compression will allow 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 will cause 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 X Street Legal and ...

Page 76: ... maintenance on your electric motorcycle as detailed in this owner s manual 3 Use only Zero approved parts and Zero Motorcycle Accessories 4 The operator is responsible for learning and obeying all country federal state and local laws governing the operation of an electric motorcycle 5 Always wear a regionally approved helmet goggles appropriate boots and all other appropriate safety equipment whe...

Page 77: ...Shock mount bolts 52 N m 38 lb ft E Rear caliper mount bolts 20 N m 15 lb ft Use LOCTITE 242 F Rear axle end bolt 26 N m 19 lb ft Use LOCTITE 242 G Rear axle pinch bolts 26 N m 19 lb ft Use LOCTITE 242 H Motor mount bolts rear 24 N m 18 lb ft I Motor mount bolts front 30 N m 22 lb ft J Triple tree pinch bolts 15 N m 11 lb ft Use LOCTITE 242 K Front axle pinch bolts 18 N m 13 lb ft Use LOCTITE 244 ...

Page 78: ...5 3 ZERO A C D E F B See Bolt Torque Table on page 5 2 ...

Page 79: ...5 4 G H J I K See Bolt Torque Table on page 5 2 ...

Page 80: ...ls should 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 power pack 4 Dispose of the power pack according to your state and local laws It is encouraged that the power pack be recycled rather than disposed of in landfills Please contact Zero at support zer...

Page 81: ...ly Always place a shop towel under the master cylinder reservoir prior to removing the cap cover Low fluid levels may indicate worn brake pads or a leak in the hydraulic system Inspect the brake pads for wear and 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 B If the fluid leve...

Page 82: ...l ensuring that it is free of any wear or damage then reinstall the cap A Brake Pad Inspection The brake pads must be inspected when specified in the maintenance schedule See Maintenance Schedule on pages 5 23 through 5 28 Visually inspect the brakes by looking at the remaining brake pad material through the sides of the brake caliper Replace the brake pads if either pad s thickness is 1 35 mm 0 0...

Page 83: ...ntenance Schedule on pages 5 23 through 5 28 To adjust the shock see Suspension Adjustment on page 4 23 Wheels And Tires Inspect both wheels for the following Bent loose or missing spokes Bent or cracked rims Impact marks on the rims Inspect both tires for the following Cuts cracks splits or missing tread lugs in the tread or sidewall area Bumps or bulges within the tire body Uneven tire tread wea...

Page 84: ... maintenance and quiet operation with minimal stretch Keep dirt grease oil and debris off the belt and sprockets The drive belt tension should be checked and adjusted at the intervals specified in the Maintenance Schedule See Maintenance Schedule on pages 5 26 through 5 28 Clean the belt with mild soap and water when washing you motorcycle Towel dry and inspect for the following Cuts or unusual we...

Page 85: ... 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 next time you ride Too much tension can increase the wear of your drive system and the system can drag The tension is checked by using a Tension Tester The Tension Tester has a plastic measurement arm located in a slot Along this slot there is a me...

Page 86: ...refully from the belt Avoid rough movements of the tester as this would change the results of the measurement The measurement should be in the range of 20 30 kg A 3 Loosen both front motor mount bolts B using a 6 mm Allen Hex wrench Loosen the 13 mm jam nut C on the belt tensioner see image on next page Note Belt tension will increase slightly when motor mounts bolts are fully torqued Drive Belt A...

Page 87: ... the cleaner to get on the brake rotors or brake pads If the brake rotors or brake pads are contaminated with cleaner it will impair the motorcycle s ability to stop This could result in serious personal injury Follow the manufacturer s instructions for the chain cleaner you are using page 5 13 contains general guidelines C B D 5 Tighten all motor mount Allen bolts See Bolt Torque Table on page 5 ...

Page 88: ...lure 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 result in serious personal injury Do not allow any of the lubricant to get on the brake rotors or brake pads If the brake rotors or brake pads are contaminated with lubricant it will impair the motorcycle...

Page 89: ...he key from the key switch 2 Loosen both front motor mount 5 16 hex bolts D See image on next page 3 Loosen both rear motor mount 7 32 hex bolts A 4 Loosen the 10 mm jam nut B on the chain tensioner Note Chain tension will increase slightly when motor mount bolts are fully torqued 5 Turn the tensioner bolt C a 1 4 turn at a time until the chain adjustment is within specification 6 Tighten all moto...

Page 90: ...adjustment is off the beam will point too far off to one side If the vertical adjustment is off it will cause the beam to point too closely 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 headlight is adjusted at the factory with a 0 5 2 5 dip To adj...

Page 91: ...atter into flying glass fragments To help avoid personal 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 1 Remove the three screws A from the headlight trim ring ...

Page 92: ...ontaminants will shorten the life of the bulb Thoroughly clean any fingerprints or contaminants from the bulb using a clean cloth moistened with alcohol 4 Lift up on the spring clip and remove the headlight bulb B 2 Disconnect the headlight bulb connector B 3 Unhook the headlight bulb spring clip C by 1 pushing down then 2 pushing to the side ...

Page 93: ...im ring with gasket and install the trim ring screws Turn Signal Light Bulb Replacement 1 Remove the turn signal lens screw A and remove the lens 2 Push in on the bulb turn the bulb counter clockwise and then pull the bulb out 3 Insert the new bulb into the socket push in and turn clockwise until it stops 4 Install the lens and screw tighten the screw Do not over tighten the screw A X XU ...

Page 94: ...ws A and remove the lens 2 Push in on the bulb and turn the bulb counter clockwise then pull the bulb out 3 Insert the new bulb into the socket push in and turn clockwise until it stops 4 Install the brake tail light lens and screws tighten the screws Do not over tighten the screws ...

Page 95: ...lb 4 Install the headlight into the housing install the trim ring with gasket and install the trim ring screws Running Light Bulb Replacement 1 Remove the three screws A from the headlight trim ring 2 Pivot the bulb contact B to either side of the bulb and remove the bulb ...

Page 96: ... dirt do not leave the cleaner on the affected area any longer than instructed Thoroughly rinse the area off with water immediately dry it and then apply a corrosion protection spray WARNING Improper cleaning can damage electrical components cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic Do not use any harsh chemical pro...

Page 97: ... checked every 72 hours remove over extended periods of time 3 To prolong the life of your power pack you should store your motorcycle in a cool area Storing your motorcycle in a hot area will cause your power pack s life to be shortened 4 If for some reason your motorcycle was not plugged in for several days you should always charge it up before operation For more information on the power pack an...

Page 98: ...ME INTERVALS 1 month 6 months 12 months 18 months 24 months 30 months 1 Front Brake Check operation and for fluid leakage Replace brake pads if necessary 2 Rear Brake Check operation and for fluid leakage Replace brake pads if necessary 3 Brake Hoses Check for cracks or damage Replace if necessary 4 Wheels Check runout and for damage Replace if necessary 5 Tires Check tread depth and for damage Re...

Page 99: ...se Brush inspection replacement 8 Drive Chain Check chain slack alignment and condition Adjust and lubricate chain with chain lubricant thoroughly Replace worn chain and sprockets Every month and after washing the motorcycle or riding in the rain 9 Steering Bearings Check bearing assembly for looseness Moderately repack with Teflon grease every 24 months Repack 10 Chassis Fasteners Check all chass...

Page 100: ...4 months 30 months 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 Front Brake Lever Pivot Shaft Apply silicon grease lightly ...

Page 101: ...1 000 km 20 000 mi or 30 months 1 Front Brake Check operation and for fluid leakage Replace brake pads if necessary 2 Rear Brake Check operation and for fluid leakage Replace brake pads if necessary 3 Brake Hoses Check for cracks or damage Replace if necessary 4 Wheels Check runout and for damage Replace if necessary 5 Tires Check tread depth and for damage Replace if necessary Check air pressure ...

Page 102: ...Brush Assembly X only Blow out with a high pressure air hose Brush inspection replacement 9 Drive Chain Check chain slack alignment and condition Adjust and lubricate chain with chain lubricant thoroughly Replace worn chain and sprockets Every 1 000 km 600 mi and after washing the motorcycle or riding in the rain 10 Steering Bearings Check bearing assembly for looseness Moderately repack with Tefl...

Page 103: ...2 000 mi or 18 months 25 000 km 16 000 mi or 24 months 31 000 km 20 000 mi or 30 months 12 Front Fork Check operation and for oil leakage Service rebuild if necessary 13 Rear Shock Absorber Assembly Check operation and for oil leakage Replace if necessary 14 Throttle Grip Check operation and free play 15 Kickstand Pivots Check operation Apply silicon grease lightly 16 Kickstand Switch Check operat...

Page 104: ...ed each time the circuit is overloaded Replace the fuse with one of equal current and voltage rating Do NOT interchange 12 volt and 80 volt fuses If the fuse melts repeatedly have the electrical system inspected by your dealer Fuse Center Locations 12 Volt X XU Street Legal The 12 volt fuse center is located behind the right front trim panel The fuse center has a protective cover that must first b...

Page 105: ...lt fuses one controls the cooling fan and the other controls the instrument panel Remove the cover to access the fuses X Street Legal and MX Dirt The cooling fan inline fuse A is located between the front right lower frame rail in front of the motor FUSE AMP CIRCUITS CONTROLLED 5 Cooling Fan ...

Page 106: ...Remove the cover to access the fuse See image on page 5 32 X Street Legal The instrument panel inline fuse A is located behind the right trim panel above the fuse center FUSE AMP CIRCUITS CONTROLLED 5 Instrument Panel FUSE AMP CIRCUITS CONTROLLED 1 7 5 Main Bike Board Converter 2 7 5 DC DC Converter Do NOT interchange 12 volt and 80 volt fuses ...

Page 107: ...5 32 1 2 If your XU is equipped with the quick charge option there is an 80 volt 25 amp fuse This fuse is located under the seat ...

Page 108: ...5 33 Follow the maintenance schedules on pages 5 23 through 5 28 After a scheduled service or routine is performed record the information on the chart below DATE ITEM SERVICE ROUTINE DESCRIPTION ...

Page 109: ...5 34 NOTES ...

Page 110: ...d if possible repair it yourself If you are unable to solve an issue with your Zero electric motorcycle take it to an authorized dealer at your convenience If there is no dealer in your area call Zero Motorcycles customer service Power Pack And Charger If a fault occurs during charging count the number of times the red LED A flashes on the charger in between pauses See the table on page 6 2 for th...

Page 111: ... 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 your dealer 5 Over temperature charger shut down due to high internal temperature Ensure sufficient cooling air flow and reset charger interrupt AC power for 15 seconds 6 Charger internal fault Reset charger ...

Page 112: ...fitted with a window A to provide visual notification about the status of the power pack There are four LED lamps one red and three green that will blink The window is located on the end of the power pack below the charger connector See Understanding BMS Light Patterns for the meanings of these patterns A ...

Page 113: ...nly monitoring the battery 1 Red 2 Green 3 Green 4 Green ON OFF MEANING SOLUTION 50 ms 5 sec Healthy BMS OK 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 ...

Page 114: ...g process first all lights will blink then 1 through 4 will blink 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 Charging Complete ...

Page 115: ...Mode cont d 1 Red 2 Green 3 Green 4 Green ON OFF MEANING SOLUTION Balancing 500 ms Power Pack Unbalanced Leave on Charger for 72 Hours 500 ms Temperature Disable 100 ms 500 ms Too Hot Let the Power Pack Cool Down ...

Page 116: ...e 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 ...

Page 117: ...aired or replaced Power Pack Unbalanced The power pack contains many individual 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 flash a Power Pack Unbalanced error code and disable the throttle You cannot ride the motorcycle until the problem is resolved The solution to the p...

Page 118: ...power pack has charged for two hours contact your dealer Your power pack may need to be repaired or replaced Other Error Flash Patterns 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 It is possible to encounter th...

Page 119: ... 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 als...

Page 120: ...for a description of the Too Hot error beep and the solutions Power Pack Full High Pack Voltage If the BMS detects that the power pack is already full it will disable further charging to prevent damage to the power pack This is not an error condition it is the result of a successful charging cycle There is no self test error beep which reports this condition During an ordinary charging cycle when ...

Page 121: ...e Disable Throttle is ON or throttle connection is bad Verify throttle action and or check connection 5 Pre Charge Failed 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 Cont...

Page 122: ...ard Temperature Sensor Out of Range Problem sensing temperature of board Contact your dealer 16 High Current Disable Turn the key switch OFF and ON If the problem persists contact Zero or your dealer 17 Temperature Protection Error Turn the key switch OFF and allow to cool off Then restart if problem persists contact Zero or your dealer 18 Throttle Output Error Turn the key switch OFF and ON If th...

Page 123: ...the motorcycle s performance capabilities it will provide you with an instrument panel illumination warning indicator A MX Dirt PATTERN MEANING Slow Constant Flash Motor Temperature Warning Stage 1 Power Pack Temperature Warning Stage 1 Motor Controller Temperature Warning Stage 1 Indicator Always ON Motor Temperature Warning Stage 2 Power Pack Temperature Warning Stage 2 Motor Controller Temperat...

Page 124: ... continues to heat up A fast blink is clearly seen on the warning indicator The power to the motor begins to drop off resulting in a noticeable reduction in available torque This provides tactile feedback to the rider and also helps prevent the component from heating further As the component cools again full power will be restored At this point it is strongly recommended that you reduce your speed...

Page 125: ... problem is not found contact your dealer High Power Pack Temperature If you see two fast blinks followed by two fast blinks this indicates you need to let the power pack cool in a well ventilated location If the high power pack temperature still exists after the power pack has had time to cool off contact your dealer The next stage is the temperature warning indicator is blinking rapidly please p...

Page 126: ...atterns on pages 6 4 through 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 Charger Fault Code chart on pages 6 12 and 6 13 or see Understanding BMS Flash Code Patterns on pages 6 4 through 6 7 Handlebars wobbly shimmy Incorrect tire pressure Inflate to correct tire pressure See page 5 9 Deformed front tire Replace balance fron...

Page 127: ...6 18 NOTES ...

Page 128: ...ntification Number PIN or Vehicle Identification Number VIN Date of purchase Power pack serial number An owner information chart is provided on page 1 3 to record this information Zero Motorcycles 170 Technology Circle Scotts Valley California 95066 USA Phone 888 786 9376 Monday Friday 8am to 5pm Pacific Time E mail support zeromotorcycles com 24 hours For 24 hour updates and additional informatio...

Page 129: ...assemblies This warranty covers Zero manufactured accessories installed at the time of purchase MX X Zero Motorcycles Inc expressly warrants all 2012 MX and X models from defects in material and workmanship to the original owner under normal operating conditions and according to proper use for 1 year unlimited miles from the In Service Date which is the date your Zero Motorcycle dealer performed a...

Page 130: ...rotors fork seals grips foot pegs the seat or any other parts subject to normal wear and tear Wheels are excluded from this standard warranty on off road bikes once they have been ridden This standard warranty excludes aftermarket accessory kits which may be subject to their own warranties This standard warranty excludes parts and components damaged by use or operation under abnormal circumstances...

Page 131: ...ire routine care and maintenance by the purchaser of the Zero Motorcycles Inc electric motorcycle and power pack Disclaimers Applicable to Standard Warranty The purchaser acknowledges that there is an inherent risk in the operation of Zero motorcycles and all other Zero Motorcycles Inc products and herewith assumes liability for any injury arising from all operation of any Zero Motorcycles Inc pro...

Page 132: ...gs and safety instructions on any motorized motorcycle or vehicle Submit the warranty registration card for your Zero motorcycle within the required time period as printed on the registration card Perform routine care and maintenance of your Zero Motorcycles Inc electric motorcycle and power pack as detailed in the Owner s Manual The rider is responsible for learning and obeying all federal state ...

Page 133: ... 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 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 contact the Zero Motorcycles Custom...

Page 134: ...tured may contain non U S equipment Some models may be shown with optional equipment While Zero Motorcycles makes all reasonable efforts to provide accurate information in this Owner s Manual there is no guarantee or warranty of accuracy Furthermore we do not assume any liability for the accuracy of completeness of information presented This Owner s Manual shall not be used or relied upon as a sub...

Page 135: ...7 8 NOTES ...

Page 136: ...5 6 Brake Lever 3 17 3 19 Brake Pad Inspection 5 7 Brake Tail Light Bulb Replacement 5 19 Braking 4 20 C Chain 5 12 Checking The Drive Chain 5 14 Cleaning The Drive Chain 5 12 Drive Chain Adjustment Procedure 5 14 Lubricating The Drive Chain 5 13 Charge Indicator 3 11 3 13 Charger Disable Interlock 6 11 Charger LED Indicators 4 11 4 12 Charging The Power Pack 4 13 Checking The Drive Chain 5 14 Cle...

Page 137: ...cifications 1 7 Zero XU Technical Specifications 1 11 General Maintenance 5 6 Brakes 5 6 Brake Tail Light Bulb Replacement 5 19 Cleaning 5 21 Drive Belt 5 9 Drive Chain 5 12 Headlight Alignment 5 15 Headlight Bulb Replacement 5 16 Motor 5 6 Running Light Bulb Replacement 5 20 Suspension 5 8 Tire Inflation 5 9 Turn Signal Light Bulb Replacement 5 18 Wheels And Tires 5 8 General Operation 4 4 Key Sw...

Page 138: ...rol Label 2 4 Low Power Pack Warning 6 8 Lubricating The Drive Chain 5 13 M Maintaining Your Motorcycle 5 1 Bolt Torque Table 5 2 Fuses 5 29 General Maintenance 5 6 Owner s Responsibilities 5 1 Power Pack 5 5 Maintenance Schedule 5 23 Motor Serial Number 1 4 Motorcycle Controls MX Dirt 3 1 Motorcycle Controls X XU Street Legal 3 3 O Operating Information 2 2 Operating Your Motorcycle 4 20 Braking ...

Page 139: ...Chain 4 4 Electrical System 4 4 Power Pack 4 4 Throttle 4 4 Tires 4 4 Public Charging Stations 1 14 Purchaser s Responsibilities 7 5 Q Quick Charging 4 17 R Rear Brake 5 7 Rear Shock Adjustment 4 23 Right Side View MX Dirt 3 5 Right Side View X Street Legal 3 7 Right Side View XU Street Legal 3 9 Running Light Bulb Replacement 5 20 S Safe Riding 1 2 Safety Information 2 1 Safety Interlocks 6 10 Po...

Page 140: ...14 Throttle And Speed Control Label 2 4 Throttle Control 3 18 3 20 Throttle Disable Interlock 6 10 Tire Inflation 5 9 Torque Table 5 2 Transfer Of Ownership And Warranty 7 6 Transporting 1 15 Troubleshooting 6 1 General Troubleshooting 6 17 Power Pack And Charger 6 1 Safety Interlocks 6 10 Temperature Indicator 6 14 Turn Signal Light Bulb Replacement 5 18 U Understanding BMS Flash Code Patterns 6 ...

Page 141: ...INDEX 6 W Warranty 7 2 Disclaimers 7 4 Standard Warranty 7 2 Transfer Of Ownership And Warranty 7 6 Warranty Customer Assistance 7 1 Warranty Information 7 2 Warranty Procedures 7 5 Wheels And Tires 5 8 ...

Page 142: ...TAKE CHARGE www zeromotorcycles com ...

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