Zero DS 2012 Owner'S Manual Download Page 86

Page: 86 / 120

5-29

30A

80V

30A

80V

AMP

VOLTS

CIRCUIT

QUICK CHRGR

CHRGR

DC/DC CONV

MBB

7.5A

80V

7.5A

80V

80 Volt:

The 80 volt fuse center (A) is located on the back
upper right corner of the power pack.

To access the 80 volt fuse center:

•

Remove the cover to access the fuse.

•

Replace the fuse.

•

Reinstall the cover.

FUSE #

AMP

CIRCUITS

CONTROLLED

Quick Charger

Charger

7.5

DC/DC Converter

7.5

Main Bike
Board/Controller

Summary of Contents for DS 2012

Page 1: ...2012 Owner s Manual ZERO S ZERO DS...

Page 2: ...Specifications 1 8 Vehicle Range 1 10 Optimizing Your Range By Adapting Your Riding Style 1 11 Public Charging Stations 1 12 Emissions Information 1 12 Transporting 1 13 Safety Information 2 1 Genera...

Page 3: ...per Use 7 4 Purchaser s Responsibilities 7 4 Warranty Procedures 7 5 Transfer Of Ownership And Warranty 7 6 General Operation 4 3 Pre Ride Inspection 4 3 Key Switch Steering Lock Positions 4 4 Power P...

Page 4: ...emember to hand over this manual 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 zerom...

Page 5: ...lities and the reliability of this motorcycle Disregarding the aforementioned however may render the warranty invalid High voltage cable or wiring has an orange covering Do not probe tamper with cut o...

Page 6: ...odel Key Code Date of Purchase VIN Telephone No E mail Power Pack Serial Number Name Motor Serial Number Owner Information Record important information pertaining to your motorcycle here When contacti...

Page 7: ...k Serial Number The Power Pack serial number is located on the upper right rear of the power pack Motor Serial Number The motor serial number is stamped on the motor housing Key Code Number The key co...

Page 8: ...345 538 On Road World Manufacturer Identifier C California Model Line Model Year Plant Location A 11 12 MY S B 11 12 MY DS Model Net Brake Horsepower C A VIN Break Down The VIN is a 17 digit number st...

Page 9: ...ity ZF6 5 3 kWh ZF9 7 9 kWh Charge Time standard ZF6 6 0 hours 100 charged 5 3 hours 95 charged ZF9 9 0 hours 100 charged 8 0 95 charged POWER SYSTEM Quick 2X Charger Time accessory ZF6 3 0 hours 100...

Page 10: ...17 in Rear Tire 130 70 17 in Front Wheel 17 x 3 0 in Rear Wheel 17 x 3 5 in Front Suspension 38 mm inverted forks with adjustable compression and rebound damping CHASSIS SUSPENSION BRAKES Rear Suspens...

Page 11: ...d max 129 km h 80 mph Estimated Top Speed sustained 113 km h 70 mph POWER SYSTEM Type High efficiency double stator axial flux permanent magnet brushless motor with integrated forced air cooling Maxim...

Page 12: ...0 Chain CHASSIS SUSPENSION BRAKES Front Suspension Travel 240 mm 9 4 in Rear Suspension Travel 195 mm 7 69 in CHASSIS SUSPENSION BRAKES Front Brakes 2 Piston Hydraulic 310 x 4 mm Floating Rotor Hand A...

Page 13: ...at you ride conservatively when you first get your Zero S DS motorcycle and get to know your motorcycle and your commute Once you become familiar with the range versus performance of your motorcycle t...

Page 14: ...ng See technical specification charts on page 1 6 through 1 10 for these ranges Optimizing Your Range By Adapting Your Riding Style Apply the throttle slowly and try to match the motorcycle s accelera...

Page 15: ...S runs solely on electricity it is the only kind of vehicle which actually gets cleaner in terms of air pollution each year as the electricity grid gets cleaner and more renewable Zero Emissions Vehic...

Page 16: ...but do not remove Once all the air is out tighten the bleed screw When the fork is released with no weight on the front tire the screw must be opened again to allow for stabilization Ensure that the s...

Page 17: ...CONV MBB 7 5A 80V 7 5A 80V A The electrical system must be disconnected when transporting or shipping Remove the 80 volt fuses A from the fuse center The 80 volt fuse center is located on the back upp...

Page 18: ...mit a guest to ride your electric motorcycle without proper instruction These are performance motorcycles and should be treated with extreme caution 6 Do not ride on frozen oily or pitted surfaces Avo...

Page 19: ...se it is silent An accident can occur if the motorcycle is left powered up while getting on or off the motorcycle 2 Turn the motor stop switch OFF when backing up or pushing the motorcycle while dismo...

Page 20: ...ng GVWR Gross Axle Weight Rating GAWR Front and Rear Vehicle Identification Number VIN Rim Size Tire Pressure Date of Manufacture 6 The power pack does not require or tolerate deep discharging To get...

Page 21: ...2 4 A A Anti Tamper Control Label Europe Only Located on frame next to the fuse center Throttle And Speed Control Label...

Page 22: ...1 1 2 4 5 3 MO4 MOTOR 2 CO4 CONTROLLER 3 FS 28T 28T FR SPROCKET 4 FS 25T 25T FR SPROCKET OPT 4 RS132T 132T RR SPROCKET 5 TRADE NAME ZERO MOTORCYCLES VEHICLE CATEGORY B BO4 BATTERY MODEL DS 1 1 2 4 5 3...

Page 23: ...2 6 NOTES...

Page 24: ...rcycle Controls A Mirrors B Performance Level Switch C Key Switch Steering Lock D Instrument Panel E Front Brake Fluid Reservoir F Front Brake Lever G Throttle Control H Motor Stop Switch I Left Handl...

Page 25: ...cription and operation see page 3 10 C Key Switch Steering Lock For description and operation see page 4 4 D Instrument Panel For description and operation see pages 3 7 through 3 9 E Front Brake Flui...

Page 26: ...3 3 A B C D E F G H Left Side View A Headlight B Front Turn Signal C Brake Tail Light D AC Charger Power Connection E Integrated Power Pack Charger F Kickstand G Kickstand Switch H Rear Turn Signal...

Page 27: ...page 5 20 D AC Charger Power Connection For description and operation see Charging The Power Pack on page 4 10 E Integrated Power Pack Charger For description and operation see Power Pack Charger on p...

Page 28: ...3 5 A B C F E D A Rear Brake Fluid Reservoir B Auxiliary Power Pack Charging Port C Power Pack D Brushless Motor Controller E Rear Brake Pedal F Drive Chain Belt Tension Adjuster Right Side View...

Page 29: ...rake 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 applied F Drive Chain Belt Tension Adjuster See D...

Page 30: ...Indicator B Temperature Indicator C High Beam Indicator D Speedometer E Main Power Indicator F Charge Indicator Instrument Panel G Right Turn Signal Indicator H Odometer I Trip Odometer J Adjust Butt...

Page 31: ...of the motor and power pack See Temperature Indicator on page 6 12 for more information Indicators C High Beam Indicator When the headlight high beam is on this indicator will illuminate blue and will...

Page 32: ...ual trip mileage and is reset by pressing and holding the adjust button J Adjust Button By pressing the adjust button you can toggle between the trip odometer settings Holding it down will clear the t...

Page 33: ...he 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...

Page 34: ...3 11 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 E Motor Stop Switch F Turn Signal Switch G Horn Button...

Page 35: ...tch 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...

Page 36: ...itch is ON the corresponding turn signal indicator on the instrument panel will illuminate Always signal your turns and other maneuvers as required by law Unlike an automobile the turn signals must al...

Page 37: ...3 14 NOTES...

Page 38: ...s See Tire Inflation on page 5 10 5 Inspect the hydraulic brake system Follow the hydraulic line from the reservoirs to the calipers and verify that there are no leaks or damage to the brake lines Ver...

Page 39: ...ew stabilizer bar from handlebar end and remove Unscrew lower crate cover retaining screws and washers Lift or cut outer box away from motorcycle Inner Assembly Carefully remove plastic cover from mot...

Page 40: ...sure the motorcycle is secure and intact Power Pack Make sure the instrument panel charge indicator is indicating a charged power pack If the charge indicator reads below 6 bars 1 2 we suggest you re...

Page 41: ...ition 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 dama...

Page 42: ...in 3 Remove the key To Unlock 1 Install the key and turn clockwise 2 Remove the key The key should be removed from the motorcycle when parked to prevent theft The key can be removed in either the OFF...

Page 43: ...itting 80 capacity yielding as much as 495 000 km 308 000 miles on the Zero S ZF9 original power pack Up to 95 higher energy density power packs that yield significant range and performance advantages...

Page 44: ...e power pack for a host of predefined conditions and then takes actions according to these conditions Some of these conditions are listed below Also see Understanding BMS Flash Code Patterns on page 6...

Page 45: ...Zero motorcycle plugged in whenever possible Warning Charge the Zero power pack with the Zero charger The charger is located under the power pack When charging the motorcycle s power pack the charger...

Page 46: ...ndicator If it is on solid the bulk charge phase is complete 80 charged Charger is now in absorption phase If the indicator is flashing there are two issues that can cause this to occur The charger an...

Page 47: ...as just been run hard it may internally be above 52 C 125 F even if the ambient temperature is lower C 100 Charge The 100 Charge LED is a green indicator If it is on solid the charging is complete and...

Page 48: ...hesitate to charge frequently If you experience a power pack that will not take a charge you should ensure the internal temperature is below 52 C 125 F If the power pack was recently run and it will...

Page 49: ...ging time will vary with the number of chargers used see technical specifications on pages 1 6 through 1 10 for charging times The auxiliary standalone charging connector is located under a cover on t...

Page 50: ...nger than 7 6 m 25 ft The charger can be used on 120 V AC or 240 V AC current The voltage does not change the amount of time that the motorcycle takes to charge 5 Connect the integrated charger See Ch...

Page 51: ...ottle toward you counter clockwise to increase speed When the throttle is twisted away from you clockwise the speed will decrease Braking On the right handlebar is the hand operated brake lever The br...

Page 52: ...3 Bleeding the fork Bleed the fork regularly 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 f...

Page 53: ...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 bum...

Page 54: ...nt will quickly determine if your rear spring is approximately correct for your weight This adjustment is a recommended guideline personal riding preference may vary from the specifications given Chec...

Page 55: ...tract the second measurement M2 from the first measurement M1 Example The total sag is 50 mm 1 97 in Refer to the chart below for the correct sag If the sag is not correct the spring pre load should b...

Page 56: ...spring 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 I...

Page 57: ...ting 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 consecutiv...

Page 58: ...aintenance of 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 coun...

Page 59: ...unt 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 bolts 26 N m 19 lb ft Use LOCTITE 242 G Rear axle pinch bolts 26 N m 19 lb ft Use LOCTITE 242 H Con...

Page 60: ...xle pinch bolts 18 N m 13 lb ft Use LOCTITE 244 O Rear sprocket to cast wheel 4 bolts S model 34 N m 25 lb ft Use LOCTITE 242 P Rear brake master cylinder to frame bolts 23 N m 17 lb ft Use LOCTITE 24...

Page 61: ...5 4 B C D A E F See Bolt Torque Table on page 5 2...

Page 62: ...5 5 K L M G I N H J O P Q See Bolt Torque Table on page 5 2...

Page 63: ...xcessive heat The lithium ion cells should not get above 71 C 160 F 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 acc...

Page 64: ...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...

Page 65: ...nsuring that it is free of any wear or damage then reinstall the cap Brake Pad Inspection The brake pads must be inspected when specified in the maintenance schedule See Maintenance Schedule on pages...

Page 66: ...o explode causing personal injury or death To adjust the shock see Rear Shock Adjustment on page 4 17 Wheels And Tires Inspect both wheels for the following Bent loose or missing spokes DS only Bent o...

Page 67: ...ng tread separation blowout or unexpected loss of motorcycle control causing personal injury and possible death Tire pressure should be checked and adjusted before each ride Tire pressure is checked u...

Page 68: ...procket teeth Signs of puncture or cracking at the base of the belt teeth If any of the above conditions are found the belt should be replaced Checking Drive Belt Tension Proper belt tension is essent...

Page 69: ...tester as this would change the results of the measurement The measurement should be in the range of 20 30 kg The Tension Tester has a plastic measurement arm located in a slot Along this slot there i...

Page 70: ...len bolts See Bolt Torque Table on page 5 2 6 Tighten the 13 mm jam nut on the belt tensioner 7 Test ride the motorcycle 8 Recheck the belt for proper adjustment after the test ride and readjust if ne...

Page 71: ...below are the general guidelines 1 Remove the key from the key switch Lubricating The Drive Chain CAUTION Wear safety glasses when lubricating the chain to prevent eye injuries Never have the motor sp...

Page 72: ...d 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 moto...

Page 73: ...when motor mounts bolts are fully torqued 5 Turn the adjuster bolt D a 1 4 turn at a time until the chain adjustment is within specification 6 Tighten all motor mount hex bolts See Bolt Torque Table o...

Page 74: ...n be adjusted vertically If the vertical adjustment is off it will cause the beam to point too close to or too far ahead of the motorcycle With the headlight on the low beam position the motorcycle pe...

Page 75: ...agments 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...

Page 76: ...or WARNING Do not touch the glass portion of the headlight bulb Keep the headlight bulb free of contaminants Oil from your fingers or contaminants will shorten the life of the bulb Thoroughly clean an...

Page 77: ...b 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...

Page 78: ...rom the headlight using a rocking motion 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 stop...

Page 79: ...ctrical components Avoid spraying water of great force around the instrument panel power pack or controller Avoid using strong acidic wheel cleaners especially on spoked wheels If such products are us...

Page 80: ...After gently washing the motorcycle be sure to allow all of the electrical components to dry prior to operation If the motorcycle is ridden immediately after being washed apply both brakes several ti...

Page 81: ...i or 1 month 7 000 km 4 000 mi or 6 months 13 000 km 8 000 mi or 12 months 19 000 km 12 000 mi or 18 months 25 000 km 16 000 mi or 24 months 31 000 km 20 000 mi or 30 months 1 Front Brake Check operat...

Page 82: ...ain Check chain slack alignment and condition Adjust and lubricate chain with chain lubricant thoroughly Replace worn chain Every 1 000 km 600 mi and after washing the motorcycle or riding in the rain...

Page 83: ...000 mi or 18 months 25 000 km 16 000 mi or 24 months 31 000 km 20 000 mi or 30 months 11 Front Brake Lever Pivot Shaft Apply silicon grease lightly 12 Front Fork Check operation and for oil leakage S...

Page 84: ...ses Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit Fuses are a one time protection device and must be...

Page 85: ...removed to gain access to the fuses To remove the cover squeeze the tabs A together and lift off the cover To access the 12 volt fuse center Turn the forks to full lock Remove the cover from inside t...

Page 86: ...olt The 80 volt fuse center A is located on the back upper right corner of the power pack To access the 80 volt fuse center Remove the cover to access the fuse Replace the fuse Reinstall the cover FUS...

Page 87: ...5 30 Follow the maintenance schedules on pages 5 24 through 5 26 After a scheduled service or routine is performed record the information on the chart below DATE ITEM SERVICE ROUTINE DESCRIPTION...

Page 88: ...possible repair it yourself If you are unable to solve an issue with your Zero S DS electric motorcycle take it to an authorized dealer at your convenience If there is no dealer in your area call Zero...

Page 89: ...g i h s n o i t c e n n o c k c e h C t n e i b m a r e w o l a t a r e g r a h c e t a r e p O e r u t a r e p m e t 4 e l k c i r t e b t o n d l u o c k c a p r e w o P e g a t l o v m u m i n i m...

Page 90: ...ack 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 flash The window is located on the front...

Page 91: ...ly 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...

Page 92: ...process first all lights will flash then 1 through 4 will flash depending on the power pack s state of charge 1 Red 2 Green 3 Green 4 Green ON OFF MEANING SOLUTION 1 sec 5 sec Charge Complete Unplug...

Page 93: ...ode 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 Pac...

Page 94: ...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...

Page 95: ...ired 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...

Page 96: ...wer pack has charged for two hours contact a 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 des...

Page 97: ...Pack Unbalanced 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 1 Throttle Disable The BMS will disable the...

Page 98: ...topped There are two conditions that will cause the BMS to disable charging One of these conditions is also reported by a self test result beep pattern the other is not Too Hot If the BMS detects high...

Page 99: ...r controller In the unlikely event that you exceed the motorcycle s performance capabilities the temperature indicator will provide you with an instrument panel illumination warning indicator A PATTER...

Page 100: ...ce interruptions You should reduce speed this will lower power output and the motor temperature to eliminate the flashing warning indicator Power Pack Full High Power Pack Voltage If the BMS detects t...

Page 101: ...Instrument Panel System Warning Indicator If a fault has been detected count the number of times the red LED A flashes Refer to the tables on pages 6 15 and 6 16 for possible cause and solution to the...

Page 102: ...ble 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 C...

Page 103: ...15 Board Temperature Sensor Out of Range Problem sensing temperature of board Contact your dealer 16 High Current Disable Turn the ignition OFF and ON If problem persists contact Zero or your dealer...

Page 104: ...t working A C power missing Fault code set Check A C outlet for power A C source check fuse voltage See Charge Fault Code chart on page 6 2 or see Understanding BMS Flash Code Patterns on pages 6 4 to...

Page 105: ...6 18 NOTES...

Page 106: ...le identification number VIN Date of purchase Power Pack serial number Motor serial number Phone 888 786 9376 Monday Friday 8am to 5pm Pacific Time E mail support zeromotorcycles com 24 hours Zero Mot...

Page 107: ...ies This warranty covers Zero manufactured accessories installed at the time of purchase Standard Warranty Exclusions This warranty does not apply to tire wear chain or sprocket condition brake pads o...

Page 108: ...red to other persons and will indemnify Zero Motorcycles Inc from any claims against it for original owner s failure to do so Zero Motorcycles Inc does not assume or authorize anyone to assume for the...

Page 109: ...Purchaser s Responsibilities Read and understand the Owner s Manual and all product warnings before operating your Zero Motorcycles Inc electric motorcycle Serious injury or death may result from impr...

Page 110: ...cator on www zeromotorcycles com for the nearest location In the event that a dealer is not in your state province or country you can contact Zero Motorcycles Inc directly at 888 786 9376 or via e mai...

Page 111: ...ail support zeromotorcycles com U S Manufacture Zero Motorcycles 170 Technology Circle Scotts Valley CA 95066 All illustrations and specifications contained in this Owner s Manual are based on the lat...

Page 112: ...your Zero Motorcycles dealer Further information can be obtained from your authorized Zero dealer or Zeromotorcycles com 2012 Zero Motorcycles Inc Not to be reproduced wholly or in part without writt...

Page 113: ...7 8 NOTES...

Page 114: ...de 6 5 Idle Mode 6 4 Run Mode 6 7 Bolt Torque Table 5 2 Brake Fluid Level Inspection 5 7 Brake Pad Inspection 5 8 Brakes 4 4 5 7 Brake Fluid Level Inspection 5 7 Brake Pad Inspection 5 8 Front Brake 5...

Page 115: ...ive Chain 5 14 Drive Chain Adjustment Procedure 5 16 E Electrical System 4 4 Emissions Information 1 12 F First Time Set Up 4 1 Front Brake 5 7 Front Fork Adjustment 4 15 Fuse Center Locations 5 28 Fu...

Page 116: ...ht Bulb Replacement 5 18 I Important Operating Information 2 2 Indicators 3 8 Instrument Panel 3 7 6 14 Introduction 1 1 K Key Code Number 1 4 Key Switch Positions 4 4 L Left Side View 3 3 Location Of...

Page 117: ...wer Pack TM 1 2 Power Pack 4 3 4 6 5 6 Power Pack And Charger 6 1 Power Pack Charger 4 8 Power Pack Empty 6 8 Power Pack Full High Power Pack Voltage 6 13 Power Pack Serial Number 1 4 Pre Ride Inspect...

Page 118: ...6 Temperature Indicator 6 12 Power Pack Full High Power Pack Voltage 6 13 Tension Tester 5 12 Throttle And Speed Control Label 2 4 Throttle Disable Interlock 6 10 Tire Inflation 5 10 Tires 4 4 Torque...

Page 119: ...IN Break Down 1 5 VIN Location 1 4 Vehicle Range 1 10 W Warranty 7 2 Disclaimers 7 3 Standard Warranty 7 2 Transfer Of Ownership And Warranty 7 6 Warranty Customer Assistance 7 1 Warranty Information...

Page 120: ...TAKE CHARGE www zeromotorcycles com...

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