Zero DS 2013 Page 7 Owner'S Manual Download

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Power Pack Serial Number

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Zero Owner's Manual (S and DS).book Page 3 Friday, April 26, 2013 4:55 PM

Summary of Contents for DS 2013

Page 1: ...ZERO S ZERO DS 2013 OWNER S MANUAL Zero Owner s Manual S and DS book Page 1 Friday April 26 2013 4 55 PM...

Page 2: ...Zero Owner s Manual S and DS book Page 2 Friday April 26 2013 4 55 PM...

Page 3: ...nge 1 11 Emissions Information 1 14 Transporting 1 15 Safety Information 2 1 Controls and Components 3 1 Controls and Components 3 1 Motorcycle Controls 3 2 Left Side View 3 4 Right Side View 3 6 Inst...

Page 4: ...5 26 Zero Motorcycles Accessories 5 26 Troubleshooting 6 1 Troubleshooting 6 1 Electric Motorcycle Precautions 6 1 Troubleshooting Your Motorcycle 6 1 Battery Management System 6 2 Cold and Hot Weath...

Page 5: ...made on the basis of data in this manual When it comes time to sell your Zero S DS please remember to hand over this manual it is by law an important part of the vehicle If you have any questions con...

Page 6: ...afely enjoy the capabilities and the reliability of this motorcycle Disregarding the aforementioned however may render the warranty invalid This symbol is located in various locations on the motorcycl...

Page 7: ...rcycle here When contacting your dealer you may need to provide this information Dealer Information Motorcycle Information Address Model Key Code Date of Purchase VIN Telephone No E mail Power Pack Se...

Page 8: ...igit number used to create duplicate keys This number is located on a tag that accompanies the original keys Vehicle Identification Number VIN The VIN is a 17 digit number stamped on the head tube of...

Page 9: ...e it when contacting Zero or ordering parts S S DS Platform Motorcycle Type M4 13 MY S D4 13 MY DS Z2 16 kW 22 HP D 2013 Check Digit Calculated 538 Zero Motorcycles Inc World Manufacturer Identifier C...

Page 10: ...5 7 5 kWh ZF11 4 10 0 kWh Supplemental Charger Quick Charge Time accessory ZF8 5 3 6 hours 100 charged 3 1 hours 95 charged ZF11 4 4 6 hours 100 charged 4 1 hours 95 charged CHAdeMO Recharge Time 0 t...

Page 11: ...um slider forks with adjustable compression and rebound damping Rear Suspension Piggy back reservoir shock with adjustable spring preload compression and rebound DIMENSION Wheel Base 55 4 in 1 406 mm...

Page 12: ...F11 4 7 9 hours 100 charged 7 4 hours 95 charged CHAdeMO Recharge Time 0 to 95 1 0 hour CHAdeMO Recharge Time 0 to 100 1 5 hours Input Standard 110 V AC or 220 V AC Charger Type 1 3 kW Integrated Esti...

Page 13: ...le compression and rebound damping Rear Suspension Piggy back reservoir shock with adjustable spring preload compression and rebound damping DIMENSION Wheel Base 56 5 in 1 435 mm Seat Height 34 4 in 8...

Page 14: ...familiar with the range versus performance of your motorcycle then you can adjust your riding characteristics if you so desire This applies mainly to riders with trip profiles which are at the edge o...

Page 15: ...information contact your Zero Motorcycles dealer Maximizing Your Range Range varies in electric motorcycles similarly to how it varies in gas motorcycles However the big difference between electric a...

Page 16: ...SPEED HIGH SPEED FEWER STOPS STOP GO FLAT ELEVATION CHANGES SMOOTH PAVEMENT SOFT GRAVEL MODULATED RIDING AGGRESSIVE RIDING STREAMLINED FULLY UPRIGHT ROUTE IDER Zero Owner s Manual S and DS book Page 1...

Page 17: ...RES UNDERINFLATED TIRES LUBED CHAIN DRY CHAIN ADJUSTED CHAIN STRETCHED CHAIN WARM WEATHER COLD WEATHER NO WINDS HIGH HEAD WINDS DRY ROADS SLIPPERY ROADS WEATHER BIKE Zero Owner s Manual S and DS book...

Page 18: ...ly gets cleaner in terms of air pollution each year as the electricity grid gets cleaner and more renewable Zero Emissions Vehicles ZEV s offer greater efficiency and can help solve the serious air po...

Page 19: ...ely on a stand or balanced on the kickstand with the front tire in the air then It is recommended that the motorcycle be tied down using ratchet straps Place the ratchet straps around a frame contact...

Page 20: ...Notes Zero Owner s Manual S and DS book Page 16 Friday April 26 2013 4 55 PM...

Page 21: ...lcohol or mind altering drugs before operating your electric motorcycle Persons unwilling or unable to take responsibility for their actions should not use this motorcycle You Prior to each use the ri...

Page 22: ...r motorcycle is sitting in storage or if it will be sitting unused for more than 30 days The power pack must be charged within 24 hours if fully discharged and must be charged within 90 days if stored...

Page 23: ...Location of Important Labels Location of Important Labels The vehicle could contain the following information for both North American and European models A B C Zero Owner s Manual S and DS book Page 3...

Page 24: ...f Important Labels Anti Tamper Control Label Europe only The anti tamper control label shown below is located on the left side of the frame Zero Owner s Manual S and DS book Page 4 Friday April 26 201...

Page 25: ...Location of Important Labels High Voltage Warning Label Affixed to battery Zero Owner s Manual S and DS book Page 5 Friday April 26 2013 4 55 PM...

Page 26: ...Notes Zero Owner s Manual S and DS book Page 6 Friday April 26 2013 4 55 PM...

Page 27: ...Controls and Components Controls and Components Controls and Components THIS PAGE INTENTIONALLY LEFT BLANK Zero Owner s Manual S and DS book Page 1 Friday April 26 2013 4 55 PM...

Page 28: ...Controls and Components Motorcycle Controls A C B D A G H I E F Zero Owner s Manual S and DS book Page 2 Friday April 26 2013 4 55 PM...

Page 29: ...and operation see Performance Level Switch on page 3 11 C Key Switch Steering Lock For description and operation see Key Switch Steering Lock Positions on page 4 4 D Instrument Panel For description...

Page 30: ...Controls and Components Left Side View A B C Zero Owner s Manual S and DS book Page 4 Friday April 26 2013 4 55 PM...

Page 31: ...LED Replacement on page 5 23 D AC Charger Power Connection For description and operation see page 4 5 E Integrated Power Pack Charger For description and operation see page 4 5 G Kickstand Switch This...

Page 32: ...Controls and Components Right Side View A B C Zero Owner s Manual S and DS book Page 6 Friday April 26 2013 4 55 PM...

Page 33: ...on page 4 5 D Drive Chain Belt Tension Adjuster See Drive Chain Optional on page 5 17 or Checking Drive Belt Tension on page 5 15 for additional information E Brushless Motor Controller Precisely mete...

Page 34: ...Controls and Components Instrument Panel A C D E B K F G H I J L M Zero Owner s Manual S and DS book Page 8 Friday April 26 2013 4 55 PM...

Page 35: ...per hour km h or miles per hour mph The analog display portion provides the tachometer E Main Power Indicator Indicates the motorcycle is live or ready to move if the throttle is actuated For troubles...

Page 36: ...lashes slowly when the motorcycle is accepting a charge The indicator flashes rapidly when a charging error is detected The indicator is solid green when the battery is completely charged M System War...

Page 37: ...PORT 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 position are likely to see a sligh...

Page 38: ...Controls and Components Handlebar Controls A B C E D G Zero Owner s Manual S and DS book Page 12 Friday April 26 2013 4 55 PM...

Page 39: ...r The front brake lever controls the front brake when the lever is squeezed When braking the throttle should be in the closed position The brake light also illuminates D Throttle Control Twist the thr...

Page 40: ...pushed in the left or right position the corresponding front and rear turn signals flash When the turn signal switch is ON the corresponding turn signal indicator on the instrument panel illuminates A...

Page 41: ...smartphone application that lets you perform the following tasks related to your motorcycle Adjust the ECO mode for performance gains Collect and email logs to Zero support staff Examine the precise S...

Page 42: ...Notes Zero Owner s Manual S and DS book Page 16 Friday April 26 2013 4 55 PM...

Page 43: ...or damage DS only 4 Check the tire pressure and adjust to proper specifications See Tire Inflation on page 5 14 5 Inspect the hydraulic brake system Follow the hydraulic line from the reservoirs to t...

Page 44: ...shers 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 d...

Page 45: ...motorcycle to see if it rolls You should be able to lock up the wheels completely by applying the brakes Throttle With the key switch in the OFF position apply the throttle and release to verify that...

Page 46: ...Steering Lock A OFF B ON C Steering Lock Using the steering lock when parked prevents unauthorized use and helps prevent theft To operate the steering lock 1 Turn the handlebar all the way to the lef...

Page 47: ...integrated onboard charger minimizes charge time and can work in parallel with Zero s quick charge accessories to cut charge times by as much as 70 The charging time will remain the same if the onboa...

Page 48: ...As a rider you don t need to think much about the BMS it just silently does its job as you charge ride and store your motorcycle Add On Electrical Equipment WARNING Do not add anything electrical to...

Page 49: ...o ensure that the power pack is charged check the charge indicator on the instrument panel prior to riding If the power pack terminates the charge before the charger reaches the state previously menti...

Page 50: ...if the ambient temperature is lower If you experience a power pack that will not take a charge you should ensure the internal temperature is below 131 F 55 C If the power pack was recently run and it...

Page 51: ...argers draw as much as 10 amps from the 120 V AC circuit when charging 3 The charging icon A flashes as the battery is being charged Once charging is complete the icon stays illuminated 4 Charging a f...

Page 52: ...ging time by up to 70 Note The time for charging the motorcycle using quick charging will vary with the number of chargers used The accessory charging connector is located above the motor For more inf...

Page 53: ...er to the power pack connector 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 off board accessory charger See Quick Charg...

Page 54: ...orption phase is complete and the charger is in finish phase D AC ON The AC ON LED is an amber indicator It it is on solid the AC power is good If it is flashing the AC voltage is low Check for proper...

Page 55: ...herefore practice is recommended to safely perfect emergency stops Stopping Your Motorcycle To stop your motorcycle 1 With the throttle in the closed position press the motor stop switch to the OFF po...

Page 56: ...ou encounter the strategy due to a different sustained high power event such as continued powering through a low traction surface power will simply be reduced to ensure the continued safe operation of...

Page 57: ...the slotted brass adjuster screw B on the top of both fork legs Next to the screw are the letters S F meaning Slow and Fast The adjuster has 18 stages of adjustment This determines how quickly the fo...

Page 58: ...t turn the adjuster one click at a time until the bottom out stops Adjust each fork leg evenly Replace the rubber dust cover after the adjustment Note Adjusters should never be forced completely Fast...

Page 59: ...ing is approximately correct for your weight This adjustment is a recommended guideline personal riding preference may vary from the specifications given To Check the Sag value 1 Support your motorcyc...

Page 60: ...in 50 mm Refer to the chart below for the correct sag If the sag is not correct the spring pre load should be adjusted Measurement Operator Value M1 23 62 in 600 mm M2 21 65 in 550 mm Sag 1 97 in 50 m...

Page 61: ...ing by turning the spring nut B clockwise on the shock Rebound Adjustment The rebound adjuster knob A is at the bottom of the shock It has 8 stages of adjustment Printed on the knob is S F meaning Slo...

Page 62: ...pression from there Proper compression allows 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...

Page 63: ...h S Models DS Models ADJUSTMENT SETTING Rear Shock Compression 10 clicks out from fully closed Rear Shock Rebound 4 clicks out from fully closed Rear Shock Spring Preload 135mm ADJUSTMENT SETTING Rear...

Page 64: ...Notes Zero Owner s Manual S and DS book Page 22 Friday April 26 2013 4 55 PM...

Page 65: ...ssories The operator is responsible for learning and obeying all country federal state and local laws governing the operations of an electric motorcycle Always wear a regionally approved helmet goggle...

Page 66: ...i 1K km or 1 month 4K mi 7K km or 6 months 8K mi 13K km or 12 months 12K mi 19K km or 18 months 16K mi 25K km or 24 months 20K mi 31K km or 30 months 1 Front Brake Check operation and for fluid leakag...

Page 67: ...ring Bearings Check all chassis fittings and fasteners Correct if necessary Repack 9 Chassis Fasteners Check all chassis 10 Front Brake Lever Pivot Shaft Apply silicon grease lightly Check operation a...

Page 68: ...d Pivots Check operation Apply silicon grease lightly 15 Kickstand Switch Check operation and replace if necessary ITEM ROUTINE EVERY RIDE INITIAL INITIAL ODOMETER MILEAGE READING 600 mi 1K km or 1 mo...

Page 69: ...LOCTITE 242 or equivalent F Rear axle nut 75 lb ft 20 Nm Use LOCTITE 242 or equivalent G Rear axle pinch bolts 19 lb ft 26 Nm Use LOCTITE 242 or equivalent H Controller heat sink to frame bolts rear...

Page 70: ...Maintaining Your Motorcycle Left Side of Motorcycle A B C D D S E F Zero Owner s Manual S and DS book Page 6 Friday April 26 2013 4 55 PM...

Page 71: ...Maintaining Your Motorcycle Right Side of Motorcycle G I J K L M N H S Zero Owner s Manual S and DS book Page 7 Friday April 26 2013 4 55 PM...

Page 72: ...Maintaining Your Motorcycle Handlebars Refer to Torque table page 5 5 Zero Owner s Manual S and DS book Page 8 Friday April 26 2013 4 55 PM...

Page 73: ...e plugged in whenever possible 1 The power pack is a lithium ion power system While it does require charging it does not require maintenance 2 The power pack should be kept away from excessive heat Th...

Page 74: ...and rear brakes Your motorcycle uses Nissin brake pads for stopping power Both front and rear pad examples are shown below Front Brake Pads An example of the front brake pads is shown below Rear Brake...

Page 75: ...ct 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...

Page 76: ...the level of the rear brake fluid through the reservoir housing If the fluid level is visibly below the low Unscrew the cap and add new DOT 4 brake fluid Inspect the cap seal ensuring that it is free...

Page 77: ...ed for thickness The minimum thickness is 0 15 in 3 85 mm Suspension Front For maintenance see Maintenance Schedule on page 5 2 To adjust the fork see Suspension Adjustment on page 4 15 Rear CAUTION T...

Page 78: ...found to have any of the above conditions replace the wheel and tire immediately Tire Inflation CAUTION Under inflation is the most common cause of tire failure and may result in severe tire cracking...

Page 79: ...e base of the belt teeth Checking Drive Belt Tension Proper belt tension is essential for optimum operation of the drive system Lack of belt tension can lead to ratcheting The teeth of the belt slide...

Page 80: ...e pressure after the tester has clicked 4 Remove the tester carefully from the belt Avoid rough movements of the tester as this would change the results of the measurement The measurement should Drive...

Page 81: ...inning the wheel Turn the wheel only by hand Failure to do so could result in serious personal injury Follow the manufacturer s instructions for the chain cleaner you are using below are the general g...

Page 82: ...ntaminated with lubricant it will impair the motorcycle s ability to stop This could result in serious personal injury Follow the manufacturer s instructions for the chain lubricant you are using belo...

Page 83: ...the adjuster bolt B a 1 4 turn at a time until the chain adjustment is within specification 4 Tighten the 13 mm jam nut on the chain tensioner 5 Test ride the motorcycle 6 Recheck the chain for proper...

Page 84: ...vertical adjustment is off it causes the beam to point too close to or too far ahead of the motorcycle With the headlight on the low beam position the motorcycle perpendicular to the ground and the op...

Page 85: ...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 tou...

Page 86: ...rtion of the headlight bulb Keep the headlight bulb free of contaminants Oil from your fingers or contaminants will shorten the life of 5 Install the headlight bulb retainer and turn it clockwise unti...

Page 87: ...pull the bulb out 3 Insert the new bulb into the socket push in and turn clockwise until it stops 4 Install the lens and screw tighten the screw Do not over tighten the screw Brake Tail LED Replaceme...

Page 88: ...hind the headlight remove the bulb socket A from the headlight by squeezing the metal clip 2 Pull the old bulb straight out from the socket 3 Push the new bulb into the socket and push the socket A Ze...

Page 89: ...cleaning products solvent or thinner fuel gasoline rust removers 1 Gently wash your motorcycle with a sponge or a clean soft cloth mild detergent and plenty of water 2 Use care when cleaning the plas...

Page 90: ...e page 4 13 WARNING Opening of the power pack is for trained Zero Motorcycles technicians Please be aware that incorrect handling of a Zero power pack can be dangerous DO Zero Motorcycles Accessories...

Page 91: ...ueeze the tabs together and lift off the cover To access the 12 volt fuse center 3 Squeeze the tabs A on the fuse center to remove the cover 4 Replace the fuse s The 12 volt fuse values are listed bel...

Page 92: ...the high voltage fuse center 1 Remove the two bolts securing the seat to the motorcycle frame The high voltage fuse values are listed below ZOM0116 1 3 4 2 FUSE RATING CIRCUITS CONTROLLED 1 ATM30 Quic...

Page 93: ...he maintenance schedules on page 5 2 After a scheduled service or routine is performed record the information on the chart below DATE ITEM SERVICE ROUTINE DESCRIPTION Zero Owner s Manual S and DS book...

Page 94: ...Notes Zero Owner s Manual S and DS book Page 30 Friday April 26 2013 4 55 PM...

Page 95: ...Your motorcycle uses high voltage System components can be hot to touch during and after starting and when the motorcycle is shut off Be careful of both the high voltage and the high temperature Obey...

Page 96: ...A to provide visual notification about the status of the power pack There are four LED lamps that will flash one red and three green lamps The window is located on the front of the power pack behind t...

Page 97: ...ED 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 Se...

Page 98: ...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 Charger Charging 250 ms 25 Continue Charging...

Page 99: ...on 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...

Page 100: ...he BMS will terminate charging itself to Power Pack Too Hot The power pack contains internal temperature sensors If the BMS measures excessive internal temperatures it flashes an error code and disabl...

Page 101: ...re problem and must be repaired or replaced by a dealer BMS Error Beep Pattern It is possible to encounter the power ON self test result error beeps from a badly malfunctioning or damaged power pack I...

Page 102: ...low 22 F 30 C which is the absolute lowest discharge temperature prescribed by the cell manufacturer Storage of the motorcycle for the winter in a non heated garage is acceptable as long as 1 the cold...

Page 103: ...for 2013 Model Year the charger reduces its charge current to the battery increasing charge time accordingly the hotter the ambient temperature the greater the effect Above a battery temperature of 1...

Page 104: ...at 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 di...

Page 105: ...nates immediately When the charger is disabled the indicator lights on the charger displays that charging has stopped There are two conditions that cause the BMS to disable charging 1 Too hot The BMS...

Page 106: ...If a fault has been detected count the number of times the red LED A flashes Refer to the table starting on the next page for possible causes and solutions to the issue A Zero Owner s Manual S and DS...

Page 107: ...4 Charger Connected Throttle is ON or throttle connection is bad Verify throttle action and or check connection 5 High Throttle Disable Could not pre charge motor controller Contact your dealer 6 Low...

Page 108: ...ition OFF and ON If problem persists contact Zero or your dealer 17 Temperature Protection Error Turn the ignition OFF and allow to cool off and then restart If problem persists contact Zero or your d...

Page 109: ...g fault code set Check A C outlet for power A C source check fuse voltage See Charge Fault Code chart on page 6 4 or see Understanding BMS Flash Code Patterns on page 6 4 Handlebars wobbly shimmy Inco...

Page 110: ...Notes Zero Owner s Manual S and DS book Page 16 Friday April 26 2013 4 55 PM...

Page 111: ...lled at the time of purchase Standard Warranty Exclusions This warranty does not apply to tire wear sprocket and belt condition brake pads or rotors fork seals grips foot pegs the seat or any other pa...

Page 112: ...nyone to assume for them any other obligation Some states provinces or countries do not allow limitations on certified service center expense of delivering it back to the owner mechanic s travel time...

Page 113: ...ectric motorcycle Serious injury or death may result from improper operation or failure to observe warnings and safety instructions on any motorized motorcycle or vehicle Submit the warranty registrat...

Page 114: ...s com Service may also be available from a local Zero Motorcycles Certified Service Center please see the locator on www zeromotorcycles com for the nearest location In any written or telephonic commu...

Page 115: ...formed to allow Zero Motorcycles the ability to contact the new owner in the unlikely event of a safety related issue Use the email address below or feel free to contact the Zero Motorcycles Customer...

Page 116: ...telephone number Vehicle identification number VIN Date of purchase Motor serial number if visible An owner information chart is provided on page 1 3 to record this information Zero Motorcycles Inc c...

Page 117: ...nvestigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your d...

Page 118: ...Notes Zero Owner s Manual S and DS book Page 8 Friday April 26 2013 4 55 PM...

Page 119: ...g Your Motorcycle 5 25 Contact information NHTSA 7 7 D Drive Belt 5 15 E Emissions Information 1 14 F First Time Set Up 4 1 Fuses 5 26 High Voltage Fuse Center 5 28 G General Operation 4 3 Key Switch...

Page 120: ...P Parking 5 26 Parts Maintenance Items 5 1 Performance Level Switch 3 11 Serial Number 1 4 Pre Ride Inspection 4 3 Public Charging Stations 1 11 Q Quick Charging 4 10 R Reporting safety defects 7 7 S...

Page 121: ...tem BMS 6 2 Charge Mode 6 4 Run Mode 6 5 Turn Signal Light Bulb Replacement 5 23 U Unpacking Your Zero Motorcycle 4 2 Recycling 4 2 V Vehicle Identification Number VIN Location 1 4 W Warning Lights 3...

Page 122: ...Notes Zero Owner s Manual S and DS book Page 4 Friday April 26 2013 4 55 PM...

Page 123: ...r death High voltage cables and components may remain energized for up to 10 seconds after disabling DO NOT CUT DO NOT CUT COLORED COLORED ZONES ZONES WARNING WARNING First Responder Information High...

Page 124: ...Zero Owner s Manual S and DS book Page 1 Friday April 26 2013 4 55 PM...

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