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Zero SR/S, Service Manual

The Zero SR/S is an innovative electric sport motorcycle that revolutionizes exhilarating rides. Discover its full potential with the comprehensive Service manual, available for free download at manualshive.com. Explore detailed instructions, maintenance tips, and troubleshooting guidance to keep your SR/S performing at its best. Get your manual now!

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Table of Contents

1

i

 1 

General Information

How To Use This Manual ...................................................................................... 1-1
Important Repair Information ................................................................................ 1-2

 10 

Maintenance and Safety

Lockout Procedure

Lockout Procedure ...........................................................................................................10-1

Adjust Drive Belt

Adjust Drive Belt ...............................................................................................................10-2

Brake Maintenance Procedures

Brake Bleeding Procedure (Front) ..................................................................................10-5
Brake Bleeding Procedure (Rear) ...................................................................................10-6
Brake Bedding ..................................................................................................................10-7

Key Programming

Key Programming .............................................................................................................10-8

Motor Commissioning

Motor Commissioning ................................................................................................... 10-10

Motor Controller Firmware Update

Motor Controller Firmware Update............................................................................... 10-14

 20 

Power Pack

Power Pack

Power Pack .......................................................................................................................20-1
BMS (Battery Management System) [Before 2022MY] .................................................20-6
Battery Management Unit (BMU) [22MY Onwards] .................................................... 20-14
Power Pack Battery Signal Harness [Before 2022MY] ............................................... 20-15
Power Pack Accessory Power Bus [Before 2022MY]................................................. 20-20
Power Pack Heat Sink Skins [Before 2022MY] ........................................................... 20-28
Service Cover [22MY Onwards].................................................................................... 20-31
Front Cover [22MY Onwards] ....................................................................................... 20-31
Rear Cover [22MY Onwards] ........................................................................................ 20-32
Mid Pack Protection Unit [22MY Onwards] ................................................................. 20-32
Top Cover [22MY Onwards] ......................................................................................... 20-33
Cooling Fan [22MY Onwards]....................................................................................... 20-34
Assembly Cell Management Unit (CMU) [22MY Onwards]........................................ 20-35
Power Leads - Positive & Negative [22MY Onwards].................................................. 20-37
Contactor [22MY Onwards] .......................................................................................... 20-38
Controller BUS Set [22MY Onwards] ........................................................................... 20-39
12 Volt Harness [22MY Onwards] ................................................................................ 20-41
BCB Main BUS Set [22MY Onwards]........................................................................... 20-42

Summary of Contents for SR/S

Page 1: ...subject to the copyright and other intellectual property rights of Zero Motorcycles Inc No part of this document may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise These materials must not be modified or reposted to other sites without the prior expressed written permission of the copyright holder ...

Page 2: ......

Page 3: ... Pack Power Pack 20 1 BMS Battery Management System Before 2022MY 20 6 Battery Management Unit BMU 22MY Onwards 20 14 Power Pack Battery Signal Harness Before 2022MY 20 15 Power Pack Accessory Power Bus Before 2022MY 20 20 Power Pack Heat Sink Skins Before 2022MY 20 28 Service Cover 22MY Onwards 20 31 Front Cover 22MY Onwards 20 31 Rear Cover 22MY Onwards 20 32 Mid Pack Protection Unit 22MY Onward...

Page 4: ...ch 30 14 Throttle Throttle Without Heated Grips 30 18 Throttle With Heated Grips 30 22 Controller Motor Controller Before 2022MY 30 27 Motor Controller Carrier Before 2022MY 30 39 Motor Controller with Heatsink 22MY Onwards 30 42 Rear Sprocket Rear Sprocket 30 43 40 Suspension Wheel Speed Sensor WSS Wheel Speed Sensor Front 40 1 Wheel Speed Sensor Rear 40 6 Front Suspension Steering Stem 40 11 Rea...

Page 5: ...heel 50 1 Rear Wheel Rear Wheel 50 4 60 Body Trim Rider s Seat 60 1 Body Headlight Upper Fairing 60 2 Headlight Inner Fairing 60 3 Hela Bracket 60 6 Tank Removal 60 10 Side Fairings Outer 60 14 Side Fairings Inner 60 19 Tank Disassembly and Reassembly 60 22 Grab Handles Right and Left 60 32 Tank Storage Liner 60 34 Tail Tail Assembly 60 36 70 Electrical High Voltage Fuses High Voltage Fuses 70 1 1...

Page 6: ...r 70 16 Instruments Dash 70 19 Key Switch Key Switch 70 21 Mode Switch Mode Switch Without Heated Grips 70 23 Mode Switch With Heated Grips 70 26 Heated Grip Heated Grips Left 70 29 Kickstand Switch Kickstand Switch 70 33 Cellular Connectivity Module CCM Cellular Connectivity Module CCM 70 36 Main Bike Board MBB Main Bike Board MBB 70 39 ...

Page 7: ...numbers on the illustrations refer to the relevant numbered action after the illustration For reference purposes an illustration number is shown in the bottom left hand corner of each illustration Important Information Types The following words are used within this manual to call your attention to specific types of information WARNING An action or information which must be followed precisely to av...

Page 8: ...ue and clamping force as well as damage the fastener Coatings can also affect the operation of electrical components Lifting and Supporting the Motorcycle CAUTION DO NOT LIFT THE MOTORCYCLE BY JACKING UP THE CONTROLLER DO NOT SUPPORT THE WEIGHT OF THE MOTORCYCLE BY SUPPORTING THE CONTROLLER Doing so will damage the controller and other components AC Alternating current Amp A Ampere AUX Auxiliary C...

Page 9: ...ndled and stored safely All work on Zero Motorcycles and their components must be carried out in compliance with safety instructions supplied by Zero Motorcycles and all applicable local standards and e vehicle requirements Testing After a Repair Operations covered in this Manual do not include reference to testing the motorcycle after repair It is essential that work is inspected and tested after...

Page 10: ...2 4 General Information ...

Page 11: ... and for the safety of others perform the following steps prior to performing work on the Zero Motorcycle Lockout Procedure Steps 1 Set up safety barricades around your work area 2 Confirm your work area is equipped with a high voltage safety hook 3 Inspect your high voltage safety gloves are not damaged and are properly certified ...

Page 12: ...raise rear tire off the ground using a motorcycle stand 3 Loosen rear axle nut Tool 27mm socket 4 The alignment marks stamped on the swingarm are for initial alignment but are not equal on both sides of the swingarm and should not be used as final adjustment marks 5 Turn the left and right belt tension adjustment bolts a 1 4 turn at a time until the belt adjustment is within specification Tool T45...

Page 13: ...m gap between the belt side face of the rear sprocket and the drive belt 8 Tighten the rear axle nut Torque 75 lb ft 102 Nm Tool 27mm socket 9 After the axle is torqued properly rotate the belt two full turns and confirm that the belt still has a 1 2mm gap between the belt side face of the rear sprocket and the drive belt 10 Using the Gates Carbon Drive application on a Smartphone confirm the micr...

Page 14: ...10 4 Adjust Drive Belt Maintenance and Safety 10 12 Recheck the belt adjustment after the test ride and readjust if necessary ...

Page 15: ...fluid can damage plastic as well as painted and coated surfaces Handle with care and wipe up spills and wash the surfaces immediately Tools Required 8mm hex wrench 9mm hex wrench Vacuum bleeder Fluid Required DOT4 Brake Fluid Bleeding 1 Fill the front master cylinder brake fluid reservoir with DOT4 brake fluid Keep the reservoir full during this procedure CAUTION Do not allow air to enter the syst...

Page 16: ...water CAUTION Brake fluid can damage plastic as well as painted and coated surfaces Handle with care and wipe up spills and wash the surfaces immediately Tools Required 9mm hex wrench Vacuum bleeder Fluid Required DOT4 Brake Fluid Bleeding 1 Fill the rear master cylinder brake fluid reservoir with DOT4 brake fluid Keep the reservoir full during this procedure CAUTION Do not allow air to enter the ...

Page 17: ... brake rotor CAUTION With new brake systems or just new pads the first few braking applications will result in very little braking power Gently use the brakes a few times at low speeds 25 mph to develop proper braking friction Process 1 From 50 mph apply the brakes firmly but do not lock up the tires or engage ABS Slow down to 10 mph Do not come to a complete stop as this can cause the pad materia...

Page 18: ...a replacement yellow key using the key number Note Each key switch has its own exclusive yellow key If the yellow key is lost the entire key switch must be replaced to get a replacement yellow key 1 Insert the yellow key into the key switch 2 Turn the yellow key to the ON position and the to the OFF position This takes motorcycle out of programming mode 3 Remove the yellow key 4 Insert one black k...

Page 19: ...ack key to the ON position 9 Turn the second black key to the OFF position 10 Remove the second black key 11 Re insert the yellow key 12 Turn the yellow key to the ON position 13 Turn the yellow key to the OFF position This removes the motorcycle from programming mode ...

Page 20: ...in 30 seconds of key turned to the ON position Run Mode is kickstand up and kill switch in run position Green Check Engine Light on the dash must be illuminated during the process Procedure 1 Use a motorcycle stand to raise the rear tire off the ground WARNING The motorcycle must be on a motorcycle stand with the rear tire raised off the ground and you must stand clear of the rear tire rear wheel ...

Page 21: ... USBs from your computer and remove the OBDII diagnostic cable from the motorcycle Restart the ZDU Reconnect the cable and reattempt 8 Set the motorcycle to run mode kickstand up and the Motor Stop Switch in the run position 9 Select device and 500k baud rate 10 Turn the key to the ON position 11 Click on Controller id 1 square 12 Check firmware is up to date FW M19 007 00A located on the left Con...

Page 22: ...SION button Note If the COMMISSION button has greyed out cycle the key OFF and then back ON again and navigate back to the COMMISION button 17 Wait until the commission has finished 18 Turn key to the OFF position 19 Turn the key to the ON position 20 Test the throttle Note Roll throttle to max speed and confirm full throttle control and smooth operation ...

Page 23: ...e eu zeromotorcycles com B If encoder controller motor were not touched then the offset should be 0 5 degree change due to thermal shift 23 Take note of the Offset again then commission a second time by repeating the procedure Make sure that the offset difference is less than 0 5 degrees Note if commissioning timed out cycle the key OFF and back ON again CAUTION If the offset is more than 0 5 degr...

Page 24: ...ontroller Firmware Update Motor Controller Firmware Update Process 1 To update the Motor Controller Firmware contact Zero Motorcycles Customer Service department for assistance North America support zeromotorcycles com Zero Motorcycles Europe service eu zeromotorcycles com ...

Page 25: ...y 1 Removal 1 PERFORM LOCKOUT PROCEDURE See Lockout Procedure page 10 1 2 Remove high voltage DCDC and CONT fuses See High Voltage Fuses page 70 1 3 Unbolt the negative battery terminal eyelet Cover eyelet with insulating material Use cable tie to secure negative battery wire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 CAUTION Cover protect battery terminal eyelet to red...

Page 26: ...e 25 1 9 Remove controller See Motor Controller Before 2022MY page 30 27 10 Disconnect battery signal harness connector 11 Remove bolt securing power pack ground strap Tool T30 Torque 5 lb ft 7 Nm 12 Take note of the placement and position of harness ground wires prior to removing bolt 13 Disconnect DC DC converter harness connector 14 Release grey locking clip from the DC DC converter harness con...

Page 27: ...or the power pack could tip over and cause serious injury and or damage the power pack CAUTION Do not lift the power pack without the proper tool Do not lift or support the power pack by the power pack side plates The power pack side plates are not designed to support the weight of the power pack Disregarding this caution will cause damage to the power pack 18 Remove bolts x2 securing the left sid...

Page 28: ...er 23 Lower power pack until right side plate is almost touching the rear brake master cylinder bracket then move the power pack to the left side to clear the bracket 24 Move the motorcycle backward to increase clearance to between the motor and the back of the power pack 25 With the jack all the way down the power pack will still not slide out from under the motorcycle 26 With lift straps around ...

Page 29: ...otorcycle Installation 1 Installation is the reverse of the removal procedure 2 A replacement power pack from Zero Motorcycles should come pre programmed and ready for use If this is not the case email Zero Motorcycles Customer Service department North America support zeromotorcycles com Zero Motorcycles Europe service eu zeromotorcycles com ...

Page 30: ... Specialty Tools Required includes tools required for parent jobs Power Pack fixture New Seals Required Controller cable seals quantity 5 Controller cable O rings quantity 5 New Fasteners Required Cable ties quantity 3 Double loop cable tie quantity 1 Removal 1 PERFORM LOCKOUT PROCEDURE See Lockout Procedure page 10 1 2 Prior to starting the BMS replacement procedure obtain the yellow key and both...

Page 31: ...eadlight upper fairing See Headlight Upper Fairing page 60 2 6 Remove left and right outer side fairings See Side Fairings Outer page 60 14 7 Remove left and right inner side fairings See Side Fairings Inner page 60 19 8 Sparingly use canned air to remove dirt and debris from around the BMS harness connector before disconnecting it 9 Remove bolts x2 securing the corners of the front cover to the l...

Page 32: ...TION Be very careful with the bolt lengths during installation 12 Remove bolts x2 securing the middle of the front cover to the right side of the power pack Bolt M5x10 Tool T20 Torque 18 in lb 2 3 Nm CAUTION Be very careful with the bolt lengths during installation 13 Remove front cover 14 Disconnect BMS signal harness connector 15 Move BMS signal harness connector up ...

Page 33: ...S Collect washers x2 Tool T20 Torque 12 in lb 1 36 Nm Note If plastic connector cover is loose remove it 18 Remove bolts x7 securing the BMS to the power pack Collect flat washers x6 and star washer x1 Tool T20 Torque 12 in lb 1 36 Nm Note Discard BMS attaching bolts and washers Replace attaching bolts and washers upon installation 19 Remove BMS Installation 1 Installation is the reverse of the re...

Page 34: ...sket surfaces with CP70 5 Protect test port from corrosion with a liberal amount of CP70 6 Only threading two turns install middle bolt and flat washer on the right side securing the BMS to the power pack Bolt M4x16 Note Do not tighten bolt yet 7 Only threading two turns install middle bolt and star washer on the top securing the BMS to the power pack Bolt M4x16 Note Do not tighten bolt yet ...

Page 35: ...stall the last five bolts securing the BMS Bolt M4x16 Tool T20 Torque 12 in lb 1 36 Nm 11 Torque all seven bolts securing the BMS Bolt M4x16 Tool T20 Torque 12 in lb 1 36 Nm 12 If the BMS flex ribbon is not bonded to the BMS clean debris from header clamps gaskets and gasket surface Re grease gasket surfaces with CP70 13 If BMS flex ribbon header clamp is not bonded to the BMS circuit board fasten...

Page 36: ... gaskets and gasket surface Re grease gasket surfaces with CP70 CAUTION Before continuing to the next step the High Voltage fuses 12 volt negative battery cable and signal harness must be disconnected 16 Only thread two turns of the bolts x2 and flat washers x2 securing the header clamp to the lower battery cell Tool T20 CAUTION Before performing this step the High Voltage fuses 12 volt negative b...

Page 37: ...tion go to step 25 If the BMS doesn t work after installation continue to the following step 21 Do not remove but loosen bolts x2 and flat washers x2 securing the header clamp to the lower battery cell Tool T20 22 Pick a new position 1 2 or 3 The flex ribbon cable pins may require realignment during the installation process There are three possible positions for the header clamp 1 left 2 center an...

Page 38: ... 10 8 Battery Management Unit BMU 22MY Onwards CAUTION Always perform the High Voltage Discharging procedure prior to servicing any High Voltage component or connection Proper procedures must be followed To protect electrical components perform the following tasks in the order given Do not deviate from the repair procedure processes NOTICE Before carrying out any work on the electrical system remo...

Page 39: ...ols Required includes tools required for parent jobs T20 T25 T27 T30 T40 3 16 standard screwdriver 2mm hex wrench 7mm combination wrench 10mm socket and ratchet 14mm socket 22mm 6 point socket Non marring trim removal pry tool O ring pick Scissor jack Ratchet straps x2 Hoist Zero Motorcycles Specialty Tools Required includes tools required for parent jobs Power Pack fixture New Seals Required Cont...

Page 40: ...ge components CAUTION Secure battery terminal wire to reduce the risk of arcing and damaging electrical components 4 Remove headlight upper fairing See Headlight Upper Fairing page 60 2 5 Remove left and right outer side fairings See Side Fairings Outer page 60 14 6 Remove left and right inner side fairings See Side Fairings Inner page 60 19 7 Remove power pack See Power Pack page 20 1 8 Remove bo...

Page 41: ...AUTION Be very careful with the bolt lengths during installation Accidentally installing the incorrect bolts in the incorrect locations will damage your power pack 13 Remove the power pack rear cover 14 Disconnect contactor harness connector 15 Remove nut securing the MBB Main Bike Board Contactor fuse holder to the high voltage fuse bracket and capture plastic washer Tool 14mm socket Torque Hand ...

Page 42: ...fuse Note Replace self amalgamating tape during the installation process 18 Release bead type thermistor 19 Release orange sheathed harnesses x2 from between the B buss and upper right heat sink skin 20 Cut cable ties x2 securing Battery Signal B Sense Line to Battery Signal B Sense Line harness Note Replace cable tie during the installation process 21 Disconnect battery signal B Sense Line grey h...

Page 43: ...arness Installation 1 Installation is the reverse of the removal procedure with the exception of the following 2 Maneuver both B and B orange sheathed signal harnesses between the B high voltage battery wire and the power pack heat sink skin 3 When installing the rear cover only use proper length bolt in the location shown Bolt M5x16 WARNING Installing a bolt longer than 16mm will cut through the ...

Page 44: ...ie quantity 1 Self amalgamating tape Removal 1 PERFORM LOCKOUT PROCEDURE See Lockout Procedure page 10 1 2 Remove high voltage DCDC and CONT fuses See High Voltage Fuses page 70 1 3 Unbolt the negative battery terminal eyelet Cover eyelet with insulating material Use cable tie to secure negative battery wire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 CAUTION Cover prote...

Page 45: ...uring installation 9 Remove bolts x4 securing center of the front cover to the power pack Bolt M5x10 Tool T20 Torque 18 in lb 2 3 Nm CAUTION Be very careful with the bolt lengths during installation 10 Remove front cover 11 Disconnect BMS signal harness connector 12 Remove bolts x9 securing rear cover to the power pack Bolt M5x16 Tool T20 Torque 18 in lb 2 3 Nm CAUTION Be very careful with the bol...

Page 46: ...move nut securing the DC DC Converter fuse holder to the high voltage fuse bracket and capture plastic washer Tool 14mm socket Torque Hand 16 Cut cable tie securing Battery Signal B Sense Line harness Note Replace cable tie during the installation process 17 Cut cable tie securing Battery Signal B Sense Line harness Note Replace cable tie during the installation process 18 Disconnect Battery Signa...

Page 47: ...hers x2 Bolt M4x10 Tool T20 Torque 12 in lb 1 36 Nm 22 Remove radsock connector clamp 23 Remove bolt securing cable tie to top of power pack Bolt M4x16 Tool T20 Torque 18 in lb 2 03 Nm 24 Cut cable tie securing the self amalgamating tape PN 81 08088 and bead type thermistor to the contactor fuse Note Replace cable tie during the installation process 25 Remove self amalgamating tape securing bead t...

Page 48: ...T25 Torque 28 in lb 3 16 Nm 29 Disconnect B radsock connector from the lower battery cell 30 Disconnect B radsock connector from the lower battery cell 31 Remove bolt securing signal harness ground strap to upper battery cell and collect star washer Bolt M5x8 Tool T25 Torque 24 in lb 2 71 Nm Note Star washer is located between ground strap and battery 32 Remove bolt securing signal harness ground ...

Page 49: ... B accessory radsock to upper battery cell and collect flat washers x2 Bolt M3x16 Tool 2 5mm hex wrench Torque 12 in lb 1 36 Nm 35 Remove bolt securing B accessory radsock to upper battery cell and collect flat washer Bolt M3x16 Tool 2 5mm hex wrench Torque 12 in lb 1 36 Nm 36 Remove B radsock from upper battery cell Note Wiggle radsock connector while pulling as necessary 37 Remove B radsock from...

Page 50: ...are routed behind the bus and under the fuse bracket see arrow 3 While installing the accessory power buss make sure the plastic shield is placed between the B and B high voltage accessories CAUTION The plastic shield protects the high voltage components from each other and it is very important that it is installed properly as shown upon reassembly 4 Leave all securing bolts loose until all the bo...

Page 51: ...h voltage battery wire and the power pack heat sink skin 6 When installing the rear cover only use proper length bolt in the location shown Bolt M5x16 WARNING Installing a bolt longer than 16mm will cut through the insulation of the high voltage wires and cause damage to the components and possible injury ...

Page 52: ...antity 1 Removal 1 PERFORM LOCKOUT PROCEDURE See Lockout Procedure page 10 1 2 Remove high voltage DCDC and CONT fuses See High Voltage Fuses page 70 1 3 Unbolt the negative battery terminal eyelet Cover eyelet with insulating material Use cable tie to secure negative battery wire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 CAUTION Cover protect battery terminal eyelet t...

Page 53: ...lengths during installation 9 Remove bolts x4 securing center of the front cover to the power pack Bolt M5x10 Tool T20 Torque 18 in lb 2 3 Nm CAUTION Be very careful with the bolt lengths during installation 10 Remove front cover 11 Remove bolts x9 securing rear cover to the power pack Tool T20 Torque 18 in lb 2 3 Nm CAUTION Be very careful with the bolt lengths during installation Accidentally in...

Page 54: ... bolt lengths during installation Accidentally installing the incorrect bolts in the incorrect locations will damage your power pack 15 Remove side heat sink skin Installation 1 Installation is the reverse of the removal procedure with the exception of the following 2 Maneuver both B and B orange sheathed signal harnesses between the B high voltage battery wire and the power pack heat sink skin 3 ...

Page 55: ...n 1 Installation is the reverse of removal procedure Front Cover 22MY Onwards CAUTION Always perform the High Voltage Discharging procedure prior to servicing any High Voltage component or connection Proper procedures must be followed To protect electrical components perform the following tasks in the order given Do not deviate from the repair procedure processes NOTICE Before carrying out any wor...

Page 56: ...Nm 3 Remove rear cover Installation 1 Installation is the reverse of removal procedure Mid Pack Protection Unit 22MY Onwards CAUTION Always perform the High Voltage Discharging procedure prior to servicing any High Voltage component or connection Proper procedures must be followed To protect electrical components perform the following tasks in the order given Do not deviate from the repair procedu...

Page 57: ...ctrical components perform the following tasks in the order given Do not deviate from the repair procedure processes NOTICE Before carrying out any work on the electrical system remove the key from the key switch Removal 1 Remove 6kW charger See 6KW Charger 22MY Onwards page 25 14 2 Remove rear cover See Rear Cover 22MY Onwards page 20 32 3 Remove BMU See Battery Management Unit BMU 22MY Onwards p...

Page 58: ...y High Voltage component or connection Proper procedures must be followed To protect electrical components perform the following tasks in the order given Do not deviate from the repair procedure processes NOTICE Before carrying out any work on the electrical system remove the key from the key switch Removal 1 Remove top cover See Top Cover 22MY Onwards page 20 33 2 Remove 2 5 mm Allen bolts x3 sec...

Page 59: ...omponents perform the following tasks in the order given Do not deviate from the repair procedure processes NOTICE Before carrying out any work on the electrical system remove the key from the key switch Removal 1 Remove positive and negative power leads See Power Leads Positive Negative 22MY Onwards page 20 37 2 Remove and discard cavity plugs covering 1 5 mm hex bolts Note Do Not reuse cavity pl...

Page 60: ...connector Note Make sure the gasket is correctly aligned The gasket only installs one orientation 3 Apply CP70 to terminals of CMU to increase weatherproofing 4 Make sure foam washers are installed between battery and CMU mounting tabs before installing CMU 5 Connect harness to CMU 6 Apply torque incrementally to each fastener Note Press CMU into battery cell box before installation of fixings 7 R...

Page 61: ...al 1 Remove left and right inner side fairings See Side Fairings Inner page 60 19 2 Safely support the motorcycle by using a motorcycle stand 3 Remove lower body panel 4 Remove bolts x4 securing controller carrier access panel to controller carrier 5 Remove controller carrier access panel 6 Remove bolts x4 securing positive and negative power leads to controller BUS set Torque 10 lb ft 13 5 Nm WAR...

Page 62: ...High Voltage component or connection Proper procedures must be followed To protect electrical components perform the following tasks in the order given Do not deviate from the repair procedure processes NOTICE Before carrying out any work on the electrical system remove the key from the key switch Removal 1 Remove top cover See Top Cover 22MY Onwards page 20 33 2 Remove bolts x2 securing BCB main ...

Page 63: ...roper procedures must be followed To protect electrical components perform the following tasks in the order given Do not deviate from the repair procedure processes NOTICE Before carrying out any work on the electrical system remove the key from the key switch Removal 1 Remove left and right inner side fairings See Side Fairings Inner page 60 19 2 Safely support the motorcycle by using a motorcycl...

Page 64: ...x4 securing controller carrier to battery unit Torque 3 5 lb ft 5 Nm 7 Using support lower the controller carrier 8 Remove bolts x3 securing motor leads x3 Note Dispose of gaskets x6 9 Disconnect signal harness connector 10 Remove bolts x2 securing controller BUS set to controller Torque 11 lb ft 15 Nm 11 Remove controller BUS set Installation 1 Installation is the reverse of the removal procedure...

Page 65: ... on the electrical system remove the key from the key switch Removal 1 Remove mid pack protection unit See Mid Pack Protection Unit 22MY Onwards page 20 32 2 Remove BMU See Battery Management Unit BMU 22MY Onwards page 20 14 3 Remove top cover See Power Pack page 20 33 4 Remove bolt securing ground loop from battery cell box 5 Disconnect harness connectors x3 from fan and both CMU units 6 Disconne...

Page 66: ... High Voltage component or connection Proper procedures must be followed To protect electrical components perform the following tasks in the order given Do not deviate from the repair procedure processes NOTICE Before carrying out any work on the electrical system remove the key from the key switch Removal 1 Remove positive and negative power leads See Power Leads Positive Negative 22MY Onwards pa...

Page 67: ...Power Pack Power Pack 20 43 20 4 Disconnect harness connector 5 Remove BCB main BUS set Installation 1 Installation is the reverse of the removal procedure ...

Page 68: ......

Page 69: ...trim removal pry tool New Fasteners Required Cable tie quantity 3 Removal 1 PERFORM LOCKOUT PROCEDURE See Lockout Procedure page 10 1 2 Remove high voltage DCDC and CONT fuses See High Voltage Fuses page 70 1 3 Unbolt the negative battery terminal eyelet Cover eyelet with insulating material Use cable tie to secure negative battery wire to the positive battery cable See 12 Volt Battery Disconnect ...

Page 70: ...BDII connector from tank storage liner 10 Disconnect USB power hub harness connector 11 Remove bolts x2 securing tank storage liner to storage liner support Tool T27 Torque 2 5 lb ft 3 Nm Note During installation do not snug storage liner bolts until tank is installed 12 Remove storage liner 13 Release harness connector anchor from charger port stand 14 Remove bolts x4 securing charger port stand ...

Page 71: ... Tool Non marring trim removal pry tool 18 Cut cable tie securing high voltage harness to harness anchor on left side of storage liner support Note Replace cable tie during the installation process 19 Position the released high voltage harness aside to gain access to storage liner support bolts on left side 20 Remove bolts x2 securing left side of storage liner support to frame Tool T30 Torque 7 8...

Page 72: ...tect rear portion of front fender and front closeout panel surfaces to reduce the possibility of scratching their surfaces 23 Remove bolts x2 securing right side of front closeout panel to frame Tool T25 Torque 3 5 lb ft 5 Nm 24 Remove front closeout panel Note Position front suspension straight forward to allow access for removing front closeout panel downward in front of power pack 25 Remove bol...

Page 73: ...unlock 28 Push tab upward to release connector and slide 29 Push secondary tab and disconnect connector from charger 30 Following the same connector disconnecting process disconnect right front high voltage connector from charger 31 Remove bolt securing charger to left front charger bracket Tool T20 Torque 4 5 lb ft 6 Nm ...

Page 74: ... right front charger bracket Tool T20 Torque 4 5 lb ft 6 Nm 33 Remove bolts x2 securing rear of charger to rear charger brackets Tool 7mm wrench Torque 4 5 lb ft 6 Nm 34 Remove charger from motorcycle Installation 1 Installation is the reverse of the removal procedure ...

Page 75: ...oval pry tool New Fasteners Required Cable tie quantity 3 Removal 1 PERFORM LOCKOUT PROCEDURE See Lockout Procedure page 10 1 2 Remove high voltage DCDC and CONT fuses See High Voltage Fuses page 70 1 3 Unbolt the negative battery terminal eyelet Cover eyelet with insulating material Use cable tie to secure negative battery wire to the positive battery cable See 12 Volt Battery Disconnect page 70 ...

Page 76: ...I connector from tank storage liner 10 Disconnect USB power hub harness connector 11 Remove bolts x2 securing tank storage liner to storage liner support Tool T27 Torque 2 5 lb ft 3 Nm Note During installation do not snug storage liner bolts until tank is installed 12 Remove tank storage liner 13 Release harness connector anchor from charger port stand 14 Remove bolts x4 securing charger port stan...

Page 77: ...al pry tool 18 To gain access to the left front bolt securing tank storage liner support to motorcycle frame move the brake hoses toward the tank storage liner support 19 Remove left front bolt securing tank storage liner support to motorcycle frame Tool T30 Torque 7 8 lb ft 11 Nm 20 Cut cable tie securing high voltage harness to harness anchor on left side of storage liner support Note Replace ca...

Page 78: ...e bolts x2 securing right side of storage liner support bolts to frame Tool T30 Torque 7 8 lb ft 11 Nm 24 Due to the brake hose routing on left side right side of tank liner support rear charger assembly has to come out first 25 Slightly rotate the tank liner support rear charger assembly clockwise to reduce interference between the mounting tabs and the motorcycle frame 26 Once the assembly is un...

Page 79: ...ease connector and slide 30 Push secondary tab and disconnect connector from charger 31 Following the same process for disconnecting the high voltage connector from the right side of the charger 32 Remove rear charger assembly 33 Remove bolts x2 securing rear charger to the left side of the tank liner support bracket Tool T25 Torque 4 5 lb ft 6 Nm ...

Page 80: ...nel surfaces to reduce the possibility of scratching their surfaces 36 Remove bolts x2 securing right side of front closeout panel to frame Tool T25 Torque 3 5 lb ft 5 Nm 37 Remove front closeout panel Note Position front suspension straight forward to allow access for removing front closeout panel downward in front of power pack 38 Remove bolt securing horn to motorcycle frame Tool T40 Torque 8 l...

Page 81: ...r disconnecting process disconnect right front high voltage connector from charger 44 Remove bolt securing charger to left front charger bracket Tool T20 Torque 4 5 lb ft 6 Nm 45 Remove bolt securing charger to right front charger bracket Tool T20 Torque 4 5 lb ft 6 Nm 46 Remove bolts x2 securing rear of charger to rear charger brackets Tool 7mm wrench Torque 4 5 lb ft 6 Nm ...

Page 82: ...mponent or connection Proper procedures must be followed To protect electrical components perform the following tasks in the order given Do not deviate from the repair procedure processes NOTICE Before carrying out any work on the electrical system remove the key from the key switch Removal 1 PERFORM LOCKOUT PROCEDURE See Lockout Procedure page 10 1 2 Remove high voltage DCDC and CONT fuses See Hi...

Page 83: ...emove left and right inner side fairings See Side Fairings Inner page 60 19 7 Remove tank assembly See Tank Removal page 60 10 8 Remove mid pack protection unit 9 Remove T30 bolts x2 securing tank unit to bike frame Torque 2 5 lb ft 3 5 Nm 10 Move bucket to the right side of the bike 11 Disconnect charge inlet harness connector 12 Disconnect battery signal harness connector 13 Remove T30 bolts x4 ...

Page 84: ...r 22 Remove T30 bolts x2 securing HCU bracket Torque 6 lb ft 8 Nm 23 Remove T30 bolts x2 securing HCU bracket Torque 6 lb ft 8 Nm 24 Loosen T30 bolts x2 securing charger connector brackets Torque 6 lb ft 8 Nm 25 Remove T25 bolt from each side of the charger mount Torque 6 lb ft 8 Nm 26 Remove T30 bolts x4 securing the charger support bracket to frame Torque 8 lb ft 11 Nm ...

Page 85: ...gh Voltage Discharging procedure prior to servicing any High Voltage component or connection Proper procedures must be followed To protect electrical components perform the following tasks in the order given Do not deviate from the repair procedure processes NOTICE Before carrying out any work on the electrical system remove the key from the key switch Tools Required includes tools required for pa...

Page 86: ...attery terminal wire to reduce the risk of arcing and damaging electrical components 4 Remove headlight upper fairing See Headlight Upper Fairing page 60 2 5 Remove left and right outer side fairings See Side Fairings Outer page 60 14 6 Remove left and right inner side fairings See Side Fairings Inner page 60 19 7 Remove tank assembly See Tank Removal page 60 10 8 Remove charger See 3KW Rapid Char...

Page 87: ...e charge port stand and collect washers x4 Tool T25 8mm socket Nut Torque 4 5 lb ft 6 Nm Note During installation do not snug storage liner bolts until tank is installed 13 Remove charge inlet from the charge port stand 14 Remove charge inlet from the motorcycle Installation 1 Installation is the reverse of the removal procedure ...

Page 88: ...ntity 2 Removal 1 PERFORM LOCKOUT PROCEDURE See Lockout Procedure page 10 1 2 Remove high voltage DCDC and CONT fuses See High Voltage Fuses page 70 1 3 Unbolt the negative battery terminal eyelet Cover eyelet with insulating material Use cable tie to secure negative battery wire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 CAUTION Cover protect battery terminal eyelet to...

Page 89: ...liner to storage liner plate Tool T27 Torque 2 5 lb ft 3 Nm Note During installation do not snug storage liner bolts until tank is installed 11 Remove storage liner 12 Disconnect DC DC converter harness connector 13 Remove bolts x4 securing DC DC converter to the HCU bracket Tool T30 Torque Hand 14 Remove DC DC converter Installation 1 Installation is the reverse of the removal procedure ...

Page 90: ......

Page 91: ...FORM LOCKOUT PROCEDURE See Lockout Procedure page 10 1 2 Remove high voltage DCDC and CONT fuses See High Voltage Fuses page 70 1 3 Unbolt the negative battery terminal eyelet Cover eyelet with insulating material Use cable tie to secure negative battery wire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 CAUTION Cover protect battery terminal eyelet to reduce the risk of a...

Page 92: ...motorcycle stand 10 Remove bolts x2 securing the rear inner fender to the rear swingarm Tool T25 Torque 3 5 lb ft 5 Nm 11 Center bolt secures the rear shock ground wire eyelet and star washer underneath it 12 Remove bolt securing the rear inner fender to the rear swingarm Tool T25 Torque 3 5 lb ft 5 Nm 13 Remove the rear inner fender 14 Rotate tucked license plate harness up to gain access to cabl...

Page 93: ... arm to the swingarm Collect the nuts x3 and washers x3 Tool T45and 13mm socket Torque in sequence shown 25 lb ft 34 Nm 17 Set ROF arm with license plate light harness still attached aside where it won t get damaged during the repair procedure 18 Remove rear axle nut and collect the rear axle adjuster Tool 27mm Torque 75 lb ft 102 Nm 19 Remove left adjuster bolt and collect the left swingarm end c...

Page 94: ...ightly and slide rear axle out of the swing arm 25 Raise rear tire and remove rear WSS wheels speed sensor and set aside Note Make sure the WSS is supported and not straining the WSS harness 26 Lower the rear tire carefully to keep from damaging painted surfaces 27 Place rag over the left side of the swingarm between the rear sprocket and the swing arm to protect painted surfaces ...

Page 95: ...ear brake hose on top of clip 31 Tip the top of the rear tire to the left 32 Slide rear caliper assembly toward wheel and slide caliper bracket off of the bracket alignment pin 33 Tie caliper up to the foot peg bracket Note Make sure the brake caliper is hung up and not straining the brake hose 34 Roll the rear wheel out of the swing arm ...

Page 96: ... of the motorcycle with a hoist CAUTION Use two ratchet straps to distribute the load Using a single ratchet strap is unsafe due to being a single point of failure 37 Raise rear of bike by the rear subframe with the hoist just enough to remove the load from the rear shock 38 Remove bolt securing shock to swingarm Collect nut flat steel washer and composite washers x2 Tools T50 and 17mm socket Torq...

Page 97: ...2 lb ft 3 Nm 42 Remove bolt securing ground wire to bottom of rear shock and collect star washer between wire eyelet and shock body Tool T20 Torque 2 lb ft 3 Nm 43 Remove rear shock 44 Release rear WSS harness from metal retaining clip 45 Release brake hose and rear WSS harness from metal retaining clip 46 Tie rear brake caliper wrapped in a rag to protect painted surfaces and WSS to the side of t...

Page 98: ...t peg bracket Tool T20 Torque 2 lb ft 2 7 Nm 50 Remove encoder cover 51 Remove bolts x3 securing right foot peg bracket to right doubler plate Tool T40 Torque 20 lb ft 27 Nm 52 Remove right foot peg bracket 53 Remove bolts x4 securing swingarm to left outer bearing cover Tool 13mm socket Torque 25 lb ft 34 Nm 54 Remove bolts x4 securing swingarm to right outer bearing cover Tool 13mm socket Torque...

Page 99: ...e bolts x2 securing kickstand to the left doubler plate Tool T50 Torque 25 lb ft 34 Nm 59 Tie kickstand aside 60 Remove bolt securing rear brake master cylinder reservoir and clamp to the right doubler plate Tool T25 Torque 2 lb ft 2 7 Nm 61 Tie up rear brake master cylinder reservoir and brake hose 62 Disconnect thermistor harness connector 63 Remove bolt securing HV cable guard to right doubler ...

Page 100: ...ylinder engagement pin while depressing locking pin 68 Raise brake pedal to access bolts Remove bolts x2 securing rear master cylinder to master cylinder bracket Tool T30 Torque 7 lb ft 9 Nm 69 Remove bolts x2 securing left doubler plate to the motorcycle frame Tool T50 Torque 30 lb ft 41 Nm 70 Remove bolts x2 securing right doubler plate to the motorcycle frame Tool T50 Torque 30 lb ft 41 Nm ...

Page 101: ...e Tool T40 Torque 19 lb ft 26 Nm 73 Remove inner countersunk bolts x2 securing the rear master cylinder bracket to the right doubler plate Tool T40 Torque 19 lb ft 26 Nm 74 Remove rear brake pedal assembly 75 Tie up rear master cylinder 76 Move motor assembly towards rear and away from the motorcycle 77 Remove bolts x3 securing left doubler plate to the motor Tool T40 Torque 25 lb ft 34 Nm Tool T4...

Page 102: ... lb ft 3 Nm 80 Remove encoder from the motor Installation 1 Installation is the reverse of the removal procedure but take note of the following installation steps 2 Remove plastic bushing from left side sprocket side of the wheel 3 When installing the WSS sensor make sure the alignment tab is positioned against the top edge of the rear brake bracket as shown 4 The order of shock ground wire fasten...

Page 103: ... System Motor 30 13 30 5 The order of fasteners and washers to mount the rear shock to the swingarm 6 Adjust drive belt See Adjust Drive Belt page 40 39 7 Perform Motor Commissioning See Motor Commissioning page 10 10 ...

Page 104: ...trim removal pry tool New Fasteners Required Cable ties quantity 5 Specialty low profile cable tie quantity 1 Removal 1 Remove high voltage DCDC and CONT fuses See High Voltage Fuses page 70 1 2 Unbolt the negative battery terminal eyelet Cover eyelet with insulating material Use cable tie to secure negative battery wire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 CAUTIO...

Page 105: ...tie during the installation process 8 Cut cable tie bundling the motor stop switch harness brake switch electrical harness and throttle harness Note Replace cable tie during the installation process 9 Cut cable tie securing motor stop switch connector to the throttle connector Note Replace cable tie during the installation process 10 Disconnect motor stop switch harness connector 11 Cut cable tie ...

Page 106: ...e attempting to keep the throttle spring from being sprung do not remove the throttle s front cover 15 Tape the throttle and grip to keep the throttle s front cover from popping off the throttle assembly 16 Slide the throttle assembly on the handlebar to gain access to the motor stop switch bolts 17 Loosen the front master cylinder clamp bolts x2 securing the master cylinder assembly to the handle...

Page 107: ... 18 Remove bolts x2 securing the bottom cover to the motor stop switch Tool 2 Phillips screwdriver 19 Remove the bottom cover to the motor stop switch 20 Remove the motor stop switch Installation 1 Installation is the reverse of the removal procedure ...

Page 108: ...quired Cable ties quantity 5 Specialty low profile cable tie quantity 1 Removal 1 Remove high voltage DCDC and CONT fuses See High Voltage Fuses page 70 1 2 Unbolt the negative battery terminal eyelet Cover eyelet with insulating material Use cable tie to secure negative battery wire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 CAUTION Cover protect battery terminal eyele...

Page 109: ...nchor Note Replace cable tie during the installation process 9 Cut cable tie bundling the motor stop switch harness brake switch electrical harness and throttle harness Note Replace cable tie during the installation process 10 Cut cable tie securing motor stop switch connector to the throttle connector Note Replace cable tie during the installation process 11 Disconnect throttle harness connector ...

Page 110: ... remove the throttle s front cover 15 Slide the throttle and grip off the end of the handlebar 16 Carefully remove throttle assembly from the throttle assembly cover Note Take note of the position of the spring on the cover and how the grip assembly interlocks with the throttle assembly Installation 1 Installation is the reverse of the removal procedure but follow the proceeding steps to install t...

Page 111: ...nto throttle mechanism so the assembly will sit down inside the cover 5 While holding the throttle mechanism from popping out of the throttle cover use a non marring trim removal tool to slide the spring tang until the tang drops into the slot Tool Non marring trim removal pry tool 6 A properly installed throttle return spring will be preloaded as shown Take care not to pull the assembly out of th...

Page 112: ...ed Cable ties quantity 5 Specialty low profile cable tie quantity 1 Removal 1 Remove high voltage DCDC and CONT fuses See High Voltage Fuses page 70 1 2 Unbolt the negative battery terminal eyelet Cover eyelet with insulating material Use cable tie to secure negative battery wire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 CAUTION Cover protect battery terminal eyelet to...

Page 113: ...nchor Note Replace cable tie during the installation process 9 Cut cable tie bundling the motor stop switch harness brake switch electrical harness and throttle harness Note Replace cable tie during the installation process 10 Cut cable tie securing motor stop switch connector to the throttle connector Note Replace cable tie during the installation process 11 Disconnect throttle harness connector ...

Page 114: ...g right side of front closeout panel to frame Tool T25 Torque 3 5 lb ft 5 Nm 15 Remove front closeout panel Note Position front suspension straight forward to allow access for removing front closeout panel downward in front of power pack 16 Unhook retaining clip to release tension on harnesses 17 Slide key switch harness connector out to gain access to heated grip harness connectors 18 Disconnect ...

Page 115: ...e end of the handlebar 22 Carefully remove throttle assembly from the throttle assembly cover Note Take note of the position of the spring on the cover and how the grip assembly interlocks with the throttle assembly Installation 1 Installation is the reverse of the removal procedure but follow the proceeding steps to install the throttle spring 2 If the motorcycle is equipped with heated grips pla...

Page 116: ...to the throttle cover Push spring into throttle mechanism so the assembly will sit down inside the cover 6 While holding the throttle mechanism from popping out of the throttle cover use a non marring trim removal tool to slide the spring tang until the tang drops into the slot Tool Non marring trim removal pry tool 7 A properly installed throttle return spring will be preloaded as shown Take care...

Page 117: ...he key switch Tools Required includes tools required for parent jobs T25 T30 3 16 standard screwdriver 2mm hex wrench 3mm hex wrench 10mm socket and ratchet 22mm 6 point socket Non marring trim removal pry tool Scissor jack New Seals Required HV cable seals quantity 5 HV cable O rings quantity 5 New Fasteners Required Cable tie quantity 2 Double loop cable tie quantity 1 Component Identification T...

Page 118: ...erial Use cable tie to secure negative battery wire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 CAUTION Cover protect battery terminal eyelet to reduce the risk of accidentally contacting the negative battery terminal which can inadvertently power up the 12 volt system and damage components CAUTION Secure battery terminal wire to reduce the risk of arcing and damaging el...

Page 119: ...e controller Damage to the controller and the controller carrier will occur 10 Remove bolts x2 securing controller carrier to power pack left side Tool T25 Torque 3 lb ft 4 Nm 11 Remove bolts x2 securing controller carrier to power pack right side Tool T25 Torque 3 lb ft 4 Nm 12 Lower the scissor jack approximately 1 inch below the controller and carrier assembly Note The controller assembly will ...

Page 120: ...orm 15 With the controller assembly released from the power pack lower the jack to gain access to the phase lead terminal bolts CAUTION Use jack to control the distance the controller assembly drops Do not allow the controller assembly to hang and stress the signal harness 16 Remove terminal bolts x2 securing busbars x2 to the top of the controller Discard O rings x2 Tool 22mm 6 point socket Torqu...

Page 121: ...ble loop cable tie securing the encoder harness connector to the controller harness connector Note Replace double loop cable tie upon installation 22 Cut cable tie section blocking the removal of the controller signal harness connector 23 Release controller signal harness connector from controller 24 Remove controller assembly 25 Remove bolts x4 and nuts x4 securing the controller to the controlle...

Page 122: ...ector 2 Inside the 35 pin connector 3 Inside the controller s 35 pin socket 4 Inside the power pack s radsock connectors Cleaning Controller Before Installation Note Prior to reinstalling the existing controller use the following methods to clean its surfaces Clean with ISO70 isopropyl rubbing alcohol 70 paper towels and a vacuum cleaner 1 Place controller off to the side of the motorcycle This pr...

Page 123: ...ls x5 must be clean and in good condition no severe pitting or evidence of arcing 5 Vacuum out the debris around the controller 6 Apply ISO70 isopropyl rubbing alcohol 70 to a paper towel and clean the top of the controller It is not critical to remove all the dirt inside of the pocket see arrow CAUTION Do not spray the ISO70 directly on the controller or terminals Spray ISO70 on a paper towel and...

Page 124: ...s x5 completely DO NOT COAT THE TERMINAL BOLTS PRIOR TO INSTALLATION Replace any damaged or worn terminal bolts 10 Confirm that the radsock cups x2 do not contain debris Installation 1 Installation is the reverse of the removal procedure 2 Replace orange terminal gaskets and terminal bolt O rings prior to installation 3 Place controller assembly on scissor jack under the power pack 4 Connect contr...

Page 125: ...ad locking compound CAUTION Install the terminal bolts without any CP70 or any type of insulating lubricant gel paste Note Phase lead W1 has to be torqued before moving to the next step It will be unaccessible after the following step Note Confirm that the phase leads are positioned clocked as shown on top of the controller Once the terminal bolts are torqued you will not be able to reposition re ...

Page 126: ... thread locking compound CAUTION Install the terminal bolts without any CP70 or any type of insulating lubricant gel paste 14 Place the B busbar on to the controller 15 Place a new O ring x3 on the B busbar 16 Install terminal bolt Tool 22mm 6 point socket Torque 11 lb ft 15 Nm CAUTION Install the terminal bolts without any thread locking compound CAUTION Install the terminal bolts without any CP7...

Page 127: ...loop the cable tie end through the anchor point on the controller to the rear of the 35 pin controller signal harness connector and then through the second hole in the body of the double loop cable tie 20 DO NOT PINCH SIGNAL HARNESS OR PHASE WIRES WHILE INSTALLING THE CONTROLLER Pay close attention to the placement of the cables during the entire installation process 21 The controller must be inst...

Page 128: ...ates loosely start one bolt at a time This will allow adjustability for each of the additional bolts Additional Note Installing the front bolts may require lifting with force 24 Install bolts x2 securing controller carrier to power pack left side Tool T25 Torque 3 lb ft 4 Nm 25 Install bolts x2 securing controller carrier to power pack right side Tool T25 Torque 3 lb ft 4 Nm 26 After finishing the...

Page 129: ...ing trim removal pry tool Scissor jack New Fasteners Required Cable tie quantity 2 Removal 1 PERFORM LOCKOUT PROCEDURE See Lockout Procedure page 10 1 2 Remove high voltage DCDC and CONT fuses See High Voltage Fuses page 70 1 3 Unbolt the negative battery terminal eyelet Cover eyelet with insulating material Use cable tie to secure negative battery wire to the positive battery cable See 12 Volt Ba...

Page 130: ... Do not lift motorcycle by jacking up the controller Damage to the controller and the controller carrier will occur 11 Remove bolts x2 securing controller carrier to power pack left side Tool T25 Torque 3 lb ft 4 Nm 12 Remove bolts x2 securing controller carrier to power pack right side Tool T25 Torque 3 lb ft 4 Nm 13 Lower the scissor jack approximately 1 inch below the controller and carrier ass...

Page 131: ...om the power pack Note This process will take a few minutes 15 With the controller assembly released from the power pack lower the jack to gain access to the fasteners 16 Remove bolts x4 and nuts x4 securing the controller to the controller carrier Collect the plastic controller safety stands left and right and washers x4 Tools T30 bolts and 10mm wrench nuts Torque 8 lb ft 11 Nm 17 Remove controll...

Page 132: ...wing tasks in the order given Do not deviate from the repair procedure processes NOTICE Before carrying out any work on the electrical system remove the key from the key switch Removal 1 Remove controller BUS set See Controller BUS Set 22MY Onwards page 20 39 2 Remove bolts x4 nuts x4 and washers x4 securing controller to carrier Torque 4 lb ft 5 5 Nm NOTE Always record quantity and fitted positio...

Page 133: ...ired Cable ties quantity 1 Removal 1 Remove drive belt See Replace Drive Belt page 40 35 2 Remove brake pads from the rear caliper See Brake Pads Rear page 45 5 3 Safely support the motorcycle by using a motorcycle stand 4 Release rear wheel speed sensor WSS harness from plastic retainer 5 Place rag over rear caliper to protect painted surfaces 6 Lift rear tire slightly and slide rear axle out of ...

Page 134: ...trical harness 8 Lower the rear tire carefully to keep from damaging painted surfaces 9 Place rag over the left side of the swingarm between the rear sprocket and the swing arm to protect painted surfaces 10 Roll rear tire forward 11 Release rear brake hose from the metal retaining clip 12 Position the rear brake hose on top of clip 13 Tip the top of the rear tire to the left ...

Page 135: ... 17 Remove plastic bushing from left side sprocket side of the wheel 18 Remove bolts x5 securing the brake rotor to the rear wheel Tool T45 Torque in sequence shown 26 lb ft 35 Nm Installation 1 Installation is the reverse of the removal procedure with the exception of the following 2 On the sprocket side of the rear wheel inspect the condition of the inner 1 and outer 2 bearings and the seal 3 Re...

Page 136: ... 2 Replace if necessary Note The bearing is a one time use parts If removed the part will need to be replaced 4 Install bolts x5 securing the rear sprocket to the rear wheel Tool T40 Torque in sequence shown 26 lb ft 35 Nm 5 When installing the WSS sensor make sure the alignment tab is positioned against the top edge of the rear brake bracket as shown ...

Page 137: ...wire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 CAUTION Cover protect battery terminal eyelet to reduce the risk of accidentally contacting the negative battery terminal which can inadvertently power up the 12 volt system and damage components CAUTION Secure battery terminal wire to reduce the risk of arcing and damaging electrical components 3 Remove headlight upper fa...

Page 138: ...side of front closeout panel to frame Tool T25 Torque 3 5 lb ft 5 Nm 10 Disconnect the front WSS harness connector 11 Cut cable tie securing the motor stop switch harness brake switch electrical harness throttle harness and front wheel speed sensor to hela bracket harness anchor Note Replace cable tie during the installation process 12 Release plastic clip retaining the WSS harness to front brake ...

Page 139: ...move left front caliper bolts x2 and collect retaining clip Tool T50 Torque 30 lb ft 41 Nm 17 Remove left front caliper from rotor 18 Wrap left front caliper and tie the caliper to the frame to eliminate strain on the brake hose 19 Remove right front caliper bolts x2 Tool T50 Torque 30 lb ft 41 Nm 20 Remove right front caliper from rotor 21 Wrap right front caliper and tie the caliper to the frame...

Page 140: ...CLE BY SUPPORTING THE CONTROLLER Doing so will damage the controller and other components 24 Safely loop straps around the motorcycle frame on the left shown and right 25 Safely hook the ends of the straps to a hoist 26 Using the hoist raise the front of the motorcycle until the front tire is slightly off the floor 27 Remove front axle and collect the front wheel Tool 17mm hex bit socket Torque 40...

Page 141: ...m the front wheel Installation 1 Installation is the reverse of the removal procedure but take note of the following installation step 2 When installing the front WSS make sure the alignment tab is positioned against the bottom edge of the left front shock as shown ...

Page 142: ...et Cover eyelet with insulating material Use cable tie to secure negative battery wire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 CAUTION Cover protect battery terminal eyelet to reduce the risk of accidentally contacting the negative battery terminal which can inadvertently power up the 12 volt system and damage components CAUTION Secure battery terminal wire to reduce...

Page 143: ...out of the swing arm 9 Raise rear tire and remove rear wheel speed sensor WSS and set aside Note Make sure the WSS sensor is supported and not straining the WSS electrical harness 10 Lower the rear tire carefully to keep from damaging painted surfaces 11 Place rag over the left side of the swingarm between the rear sprocket and the swing arm to protect painted surfaces 12 Roll rear tire forward ...

Page 144: ... top of clip 15 Position the rear brake hose on top of clip 16 Release rear brake hose and rear WSS harness from the metal retaining clip 17 Remove bolts x3 securing the left foot peg bracket to the left doubler plate Tool T40 Torque 20 lb ft 27 Nm 18 Remove bolts x2 securing the heel guard to the frame Tool T25 Torque 3 5 lb ft 5 Nm ...

Page 145: ...cable tie during the installation process 21 Cut cable tie securing kickstand harness to the kickstand harness connector and the WSS harness connector Note Replace cable tie during the installation process 22 Disconnect rear WSS connector 23 Release rear WSS harness from the plastic clip securing it to the rear brake caliper hose 24 Release rear brake master cylinder hose from metal clip ...

Page 146: ...allation 1 Installation is the reverse of the removal procedure with the exception of the following 2 When installing the rear WSS make sure the alignment tab is positioned against the top edge of the rear brake bracket as shown 3 Confirm that the aluminum bushing from left side sprocket side of the wheel is installed in the seal prior to installation of the wheel ...

Page 147: ...ative battery wire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 CAUTION Cover protect battery terminal eyelet to reduce the risk of accidentally contacting the negative battery terminal which can inadvertently power up the 12 volt system and damage components CAUTION Secure battery terminal wire to reduce the risk of arcing and damaging electrical components 3 DO NOT LIFT...

Page 148: ...nsor See Wheel Speed Sensor Front page 40 1 10 Remove bolts x2 securing left side of front fender to the left front shock Tool T25 Torque 3 5 lb ft 5 Nm 11 Remove bolts x2 securing right side of front fender to the left front shock Tool T25 Torque 3 5 lb ft 5 Nm 12 Loosen left front suspension upper clamp bolt Tool T45 Torque 16 lb ft 22 Nm 13 Loosen left front suspension lower clamp bolt Tool T45...

Page 149: ...ottom 18 Remove bolt capturing harness ground wire to the upper triple clamp Collect star washer located between ground cable eyelet and upper triple clamp Tool T30 Torque 8 lb ft 11 Nm 19 Wrap tape around handlebar and mark the parting line of the handlebar clamp to ensure the handlebars can be re installed in their original location and angle 20 Remove handlebar clamp bolts x4 securing handlebar...

Page 150: ...ceptable 24 Remove lower triple clamp and discard bearings x2 races x2 and seals x2 Note Replace bearings x2 races x2 and seals x2 upon installation Installation 1 Installation is the reverse of the removal procedure but take note of the following installation step 2 Pay close attention to the order of installation of the bearings races seals steering stem lock nut and steering stem nut CAUTION In...

Page 151: ...s upon installation CAUTION Lubricate the bearings prior to installation with appropriate bearing packing tool CAUTION Do not lubricate seals 4 When installing the front WSS make sure the alignment tab is positioned against the bottom edge of the left front shock as shown ...

Page 152: ... 2 Unbolt the negative battery terminal eyelet Cover eyelet with insulating material Use cable tie to secure negative battery wire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 CAUTION Cover protect battery terminal eyelet to reduce the risk of accidentally contacting the negative battery terminal which can inadvertently power up the 12 volt system and damage components CA...

Page 153: ... of the motorcycle with a hoist CAUTION Use two ratchet straps to distribute the load Using a single ratchet strap is unsafe due to being a single point of failure 6 Raise rear of bike by the rear subframe with the hoist just enough to remove the load from the rear shock 7 Remove bolt securing shock to swingarm Collect nut flat steel washer and composite washers x2 Tools T50 and 17mm socket Torque...

Page 154: ...bolt securing ground wire to bottom of rear shock and collect star washer between wire eyelet and shock body Tool T20 Torque 2 lb ft 3 Nm 12 Remove rear shock Installation 1 Installation is the reverse of the removal procedure with the exception of the following installation note 2 The order of shock ground wire fasteners bolt wire eyelet and steel star washer 3 The order of fasteners and washers ...

Page 155: ... Required Crush washers x2 Removal 1 Remove high voltage DCDC and CONT fuses See High Voltage Fuses page 70 1 2 Unbolt the negative battery terminal eyelet Cover eyelet with insulating material Use cable tie to secure negative battery wire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 CAUTION Cover protect battery terminal eyelet to reduce the risk of accidentally contacti...

Page 156: ...der to the rear swingarm Tool T25 Torque 2 lb ft 3 Nm 6 Center bolt secures the rear shock ground wire eyelet and star washer underneath it 7 Remove bolt securing the rear inner fender to the rear swingarm Tool T25 8 Remove the rear inner fender 9 Rotate tucked license plate harness up to gain access to cable ties Note Neatly tuck harness back in place during reinstallation process to protect harn...

Page 157: ... rear fender arm to the swingarm Collect the nuts x3 and washers x3 Tool T45 and 13mm Torque 25 lb ft 34 Nm 12 Set ROF arm with license plate light harness still attached aside where it won t get damaged during the repair procedure 13 Remove rear axle nut and collect the rear axle adjuster Tool 27mm Torque 75 lb ft 102 Nm 14 Remove left adjuster bolt and collect the left swingarm end cap Tool T45 ...

Page 158: ...ightly and slide rear axle out of the swing arm 20 Raise rear tire and remove rear WSS wheels speed sensor and set aside Note Make sure the WSS is supported and not straining the WSS harness 21 Lower the rear tire carefully to keep from damaging painted surfaces 22 Place rag over the left side of the swingarm between the rear sprocket and the swing arm to protect painted surfaces ...

Page 159: ...ar brake hose on top of clip 26 Tip the top of the rear tire to the left 27 Slide rear caliper assembly toward wheel and slide caliper bracket off of the bracket alignment pin 28 Tie caliper up to the foot peg bracket Note Make sure the brake caliper is hung up and not straining the brake hose 29 Roll the rear wheel out of the swing arm ...

Page 160: ...of the motorcycle with a hoist CAUTION Use two ratchet straps to distribute the load Using a single ratchet strap is unsafe due to being a single point of failure 32 Raise rear of bike by the rear subframe with the hoist just enough to remove the load from the rear shock 33 Remove bolt securing shock to swingarm Collect nut flat steel washer and composite washers x2 Tools T50 and 17mm socket Torqu...

Page 161: ... lb ft 3 Nm 37 Remove bolt securing ground wire to bottom of rear shock and collect star washer between wire eyelet and shock body Tool T20 Torque 2 lb ft 3 Nm 38 Remove rear shock 39 Release rear WSS harness from metal retaining clip 40 Release brake hose and rear WSS harness from metal retaining clip 41 Tie rear brake caliper wrapped in a rag to protect painted surfaces and WSS to the side of th...

Page 162: ...T20 Torque 2 lb ft 3 Nm 45 Remove encoder cover 46 Remove bolts x3 securing right foot peg bracket to right doubler plate Tool T40 Torque 20 lb ft 27 Nm 47 Remove right foot peg bracket 48 Remove bolts x4 securing swingarm to left outer bearing cover Tool 13mm socket Torque in sequence shown 24 5 lb ft 33 Nm 49 Remove bolts x4 securing swingarm to right outer bearing cover Tool 13mm socket Torque ...

Page 163: ...ket Torque in sequence shown 25 lb ft 34 Nm 3 Upon installation of the swingarm while it s still bare pivot the swingarm upwards and allow it to fall If it binds and doesn t fall check the condition of the bearings and if you installed the correct amount of shims CAUTION If the swingarm doesn t fall on its own during this test and you ve confirmed that both swingarm shims are installed and the bea...

Page 164: ...tioned against the top edge of the rear brake bracket as shown 6 The order of shock ground wire fasteners bolt wire eyelet and steel star washer 7 The order of fasteners and washers to mount the rear shock to the swingarm 8 Adjust drive belt after installation is complete See Adjust Drive Belt page 40 39 ...

Page 165: ...KOUT PROCEDURE See Lockout Procedure page 10 1 2 Remove high voltage DCDC and CONT fuses See High Voltage Fuses page 70 1 3 Unbolt the negative battery terminal eyelet Cover eyelet with insulating material Use cable tie to secure negative battery wire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 CAUTION Cover protect battery terminal eyelet to reduce the risk of accidenta...

Page 166: ... Installation is the reverse of the removal procedure but take note of the following installation steps 2 The inside seal for the outer bearing cover has a rib see arrow on one side that must be pressed into the seal groove in the outer bearing cover It must be pressed in evenly to seal properly 3 Thinking of the outer bearing cover as an analog clock face use a blunt tool to press the seal into t...

Page 167: ...e seal into the groove at the 9 o clock position 7 Press the seal into the groove about the 11 o clock position 8 Press the seal into the groove at about the 5 o clock position 9 Press the seal into the groove at about the 2 o clock position 10 Press the seal into the groove at about the 8 o clock position ...

Page 168: ...until the seal is completely seated 14 Follow the same process to evenly install the seal in the second outer bearing cover 15 After installing the outer bearing covers left and right on the doubler plates and installing the swingarm on the outer bearing plates then install the outer bearing cover exterior seals Note The exterior seals on the outer bearing covers will pop off the cover during the ...

Page 169: ...er the edge of the doubler plate Note The following photos show the doubler plate on a bench for instructional purposes only The seals should be installed after the doubler plate is installed on the motorcycle 19 Slide the seal around the doubler plate to center the seal over the outer bearing cover and the doubler plate 20 Thinking of the outer bearing cover as an analog clock face use a blunt to...

Page 170: ...he groove about the 1 to 2 o clock position 25 Press the seal into the groove at about the 7 to 8 o clock position 26 Continue alternating from side to side pressing the seal into the outer bearing cover evenly Continue pressing the seal into the groove until the seal is completely seated 27 Follow the same process to install the outer seal evenly in the left outer bearing cover ...

Page 171: ...y 2 Removal 1 Tape the swingarm to keep the brake caliper from damaging the painted surfaces 2 Place the new belt over the left side of the motorcycle stand 3 Safely raise rear tire off the ground using a motorcycle stand 4 Remove bolts x2 securing the rear inner fender to the rear swingarm Tool T25 Torque 3 5 lb ft 5 Nm 5 Center bolt secures the rear shock ground wire eyelet and star washer under...

Page 172: ...ce during reinstallation process to protect harness from damage while riding 9 Cut cable tie securing the protective sheathing to the license plate light harness Note Replace cable tie during the installation process 10 Cut cable tie securing the license plate harness to the ROF rear outer fender arm Note Replace cable tie during the installation process 11 Remove the protective sheathing from the...

Page 173: ...nd washers x3 Tool T45and 13mm socket Torque in sequence shown 25 lb ft 34 Nm 15 Remove rear fender arm 16 Remove rear axle nut and collect the rear axle adjuster Tool 27mm Torque 75 lb ft 102 Nm 17 Remove left adjuster bolt and collect the left swingarm end cap Tool T45 18 Remove left adjuster bolt and collect the right swingarm end cap Tool T45 19 Slide rear axle forward ...

Page 174: ...20 Slip belt off of the rear sprocket Installation 1 Installation is the reverse of the removal procedure but take note of the following installation step 2 Adjust drive belt after installation is complete See Adjust Drive Belt page 40 39 ...

Page 175: ...off the ground using a motorcycle stand 3 Loosen rear axle nut Tool 27mm socket 4 The alignment marks stamped on the swingarm are for initial alignment but are not equal on both sides of the swingarm and should not be used as final adjustment marks 5 Turn the left and right belt tension adjustment bolts a 1 4 turn at a time until the belt adjustment is within specification Tool T45 6 Rotate the ti...

Page 176: ...etween the belt side face of the rear sprocket and the drive belt 8 Tighten the rear axle nut Torque 75 lb ft 102 Nm Tool 27mm socket 9 After the axle is torqued properly rotate the belt two full turns and confirm that the belt still has a 1 2mm gap between the belt side face of the rear sprocket and the drive belt 10 Using the Gates Carbon Drive application on a Smartphone confirm the microphone ...

Page 177: ...Suspension Rear Suspension 40 41 40 12 Recheck the belt adjustment after the test ride and readjust if necessary ...

Page 178: ......

Page 179: ... or brake caliper s is are removed or while the brake system is disassembled NOTICE Before carrying out any work on the electrical system remove the key from the key switch Tools Required includes tools required for parent jobs 5mm hex wrench 8mm hex wrench 9mm hex wrench 14mm flare nut wrench New Fluid Required DOT 4 brake fluid New Seals Required Crush washers x2 Removal 1 Remove banjo bolt and ...

Page 180: ...olts x2 securing the master cylinder assembly to the handlebar Tool 5mm hex wrench Torque 8 lb ft 11 Nm Note hold front brake master cylinder while removing clamp bolts 5 Remove the front master cylinder Installation 1 Installation is the reverse of the removal procedure except for the following 2 Perform brake bleeding procedure See Brake Bleeding Procedure Front page 10 5 ...

Page 181: ...uired includes tools required for parent jobs T25 Removal 1 Remove brake caliper pin bolt clips x2 2 Remove brake caliper pin bolts x2 Tool T25 Torque 6 lb ft 8 Nm 3 Remove brake pad anti rattle spring plate 4 Remove brake pads Installation 1 Installation is the reverse of the removal procedure with the exception of the following 2 The anti rattle clip is installed with the arrow pointing up ...

Page 182: ...pad pin 1 capturing the anti rattle clip first Install the lower brake pad pin 2 capturing the anti rattle clip second Tool T25 Torque 6 lb ft 8 Nm 4 After installing new brake pads perform the brake pad bedding procedure See Brake Bedding page 10 7 ...

Page 183: ...rent jobs T25 Removal 1 Remove rear brake caliper pin retaining clip 2 Remove rear brake caliper pin bolt Tool T25 Torque 6 lb ft 8 Nm 3 The eyelet end of the brake pads need to drop in order to release it from the caliper 4 Remove both rear caliper brake pads Installation 1 Installation is the reverse of the removal procedure 2 After installing new brake pads perform the brake pad bedding procedu...

Page 184: ...move left front caliper banjo bolt and discard crush washers x2 Tool 14mm flare nut wrench Torque 20 lb ft 27 Nm CAUTION Plug all open connections to prevent ingress of moisture and debris CAUTION Brake fluid is extremely harmful to paint so if brake fluid contacts a painted surface wash the surface immediately Note Position a suitable container to contain fluid spillage Note Position absorbent ma...

Page 185: ...es Brakes 45 7 45 2 Perform brake bleeding procedure See Brake Bleeding Procedure Front page 10 5 3 If new brake pads have been installed perform the brake pad bedding procedure See Brake Bedding page 10 7 ...

Page 186: ...ar tire off the ground using a motorcycle stand 4 Remove rear caliper banjo bolt and discard crush washers x2 Tool 14mm flare nut wrench Torque 20 lb ft 27 Nm CAUTION Plug all open connections to prevent ingress of moisture and debris CAUTION Brake fluid is extremely harmful to paint so if brake fluid contacts a painted surface wash the surface immediately Note Position a suitable container to con...

Page 187: ...and not straining the WSS harness 8 Lower the rear tire carefully to keep from damaging painted surfaces 9 Place rag over the left side of the swingarm between the rear sprocket and the swing arm to protect painted surfaces 10 Roll rear tire forward 11 Release rear brake hose from the metal retaining clip 12 Position the rear brake hose on top of clip 13 Tip the top of the rear tire to the left ...

Page 188: ...ing 2 When installing the rear WSS make sure the alignment tab is positioned against the top edge of the rear brake bracket as shown 3 Confirm that the aluminum bushing from left side sprocket side of the wheel is installed in the seal prior to installation of the wheel 4 Perform brake bleeding procedure See Brake Bleeding Procedure Rear page 10 6 5 If new brake pads have been installed perform th...

Page 189: ... cable See 12 Volt Battery Disconnect page 70 3 CAUTION Cover protect battery terminal eyelet to reduce the risk of accidentally contacting the negative battery terminal which can inadvertently power up the 12 volt system and damage components CAUTION Secure battery terminal wire to reduce the risk of arcing and damaging electrical components 3 Remove headlight upper fairing See Headlight Upper Fa...

Page 190: ...ront closeout panel to frame Tool T25 Torque 3 5 lb ft 5 Nm 10 Remove front closeout panel 11 Release WSS harness from the left front brake hose clips x4 12 Remove left front caliper bolts x2 and collect retaining clip Tool T50 Torque 30 lb ft 41 Nm 13 Remove left front caliper from rotor 14 Wrap left front caliper and tie the caliper to the frame to eliminate strain on the brake hose 15 Remove ri...

Page 191: ...LIFT THE MOTORCYLE BY JACKING UP THE CONTROLLER DO NOT SUPPORT THE WEIGHT OF THE MOTORCYCLE BY SUPPORTING THE CONTROLLER Doing so will damage the controller and other components 20 Safely loop straps around the motorcycle frame on the left shown and right 21 Safely hook the ends of the straps to a hoist 22 Using the hoist raise the front of the motorcycle until the front tire is slightly off the f...

Page 192: ... Installation 1 Installation is the reverse of the removal procedure but take note of the following installation step 2 Install bolts x5 securing the brake rotor to the front wheel in a star pattern Tool T40 Torque 20 lb ft 27 Nm 3 When installing the front WSS make sure the alignment tab is positioned against the bottom edge of the left front shock as shown 4 After replacing a brake rotor perform...

Page 193: ... ties quantity 1 Removal 1 Remove drive belt See Replace Drive Belt page 40 35 2 Remove brake pads from the rear caliper See Brake Pads Rear page 45 5 3 Safely raise rear tire off the ground using a motorcycle stand 4 Release rear WSS harness from plastic retainer 5 Place rag over rear caliper to protect painted surfaces 6 Lift rear tire slightly and slide rear axle out of the swing arm ...

Page 194: ... the rear tire carefully to keep from damaging painted surfaces 9 Place rag over the left side of the swingarm between the rear sprocket and the swing arm to protect painted surfaces 10 Roll rear tire forward 11 Release rear brake hose from the metal retaining clip 12 Position the rear brake hose on top of clip 13 Tip the top of the rear tire to the left ...

Page 195: ...m 17 Remove aluminum bushing from left side sprocket side of the wheel 18 Remove bolts x5 securing the brake rotor to the rear wheel Tool T40 Torque 26 lb ft 35 Nm Installation 1 Installation is the reverse of the removal procedure with the exception of the following 2 Install bolts x5 securing the brake rotor to the rear wheel Tool T40 Torque 26 lb ft 35 Nm 3 When installing the rear WSS make sur...

Page 196: ...45 18 Brakes Brakes 45 4 After replacing the brake rotor perform the brake pad bedding procedure See Brake Bedding page 10 7 ...

Page 197: ...ositive battery cable See 12 Volt Battery Disconnect page 70 3 CAUTION Cover protect battery terminal eyelet to reduce the risk of accidentally contacting the negative battery terminal which can inadvertently power up the 12 volt system and damage components CAUTION Secure battery terminal wire to reduce the risk of arcing and damaging electrical components 3 Remove headlight upper fairing See Hea...

Page 198: ...bolts x2 securing right side of front closeout panel to frame Tool T25 Torque 3 5 lb ft 5 Nm 11 Remove front closeout panel 12 Remove bolt securing the front WSS harness cushion clamp and front brake hose Tool T30 Torque 5 lb ft 7 Nm 13 Unhook retaining clip to release tension on harnesses 14 Cut cable ties x2 securing CCM to the HCU bracket Note Replace cable ties x2 during the installation proce...

Page 199: ...ote Label mark connectors 18 Disconnect DC DC converter harness connector 19 Remove bolts x2 securing IMU to the HCU bracket Tool T30 Torque Hand tight 20 Release clip securing IMU harness to HCU bracket Tool O ring pick Note The locking tab is located on the lower portion of the clip 21 Tie IMU aside 22 Release grey locking clip from the DC DC controller harness converter Tool O ring pick ...

Page 200: ...Remove right front caliper from rotor 26 Remove bolt securing left front of HCU bracket to frame Tool T30 Torque 6 lb ft 8 Nm 27 Remove bolt securing right front of HCU bracket to frame Tool T30 Torque 6 lb ft 8 Nm 28 Remove bolts x2 securing rear of HCU bracket to frame Tool T30 29 Place a shallow tray under HCU bracket 30 Move HCU bracket assembly towards the rear enough to gain access to the fi...

Page 201: ...rface wash the surface immediately Note Position a suitable container to contain fluid spillage Note Position absorbent material around affected area to absorb possible fluid spillage Note Replace crush washers x2 upon installation 34 Remove brake banjo bolts x3 and discard crush washers x6 Tool 14mm flare wrench Torque 20 lb ft 27 Nm CAUTION Plug all open connections to prevent ingress of moistur...

Page 202: ...2 Tool T30 37 Remove the HCU CAUTION Brake fluid is extremely harmful to paint so if brake fluid contacts a painted surface wash the surface immediately Installation 1 Installation is the reverse of the removal procedure but take note of the following installation step 2 Perform brake bleeding procedure for the front and rear brake systems See Brake Maintenance Procedures page 10 5 ...

Page 203: ...SS harness to front brake hose 2 Remove bolt securing wheel speed sensor WSS harness cushion clamp and front brake hose Tool T30 Torque 5 lb ft 7 Nm 3 Cut cable tie securing the WSS sensor harness to the left front brake hose Note Replace cable tie during the installation process 4 Release WSS sensor harness from the left front brake hose clips x4 5 Remove left front caliper bolts x2 and collect r...

Page 204: ... right front caliper and tie the caliper to the frame to eliminate strain on the brake hose 11 Loosen front axle pinch bolts x2 Tool 6mm hex Torque 16 lb ft 22 Nm 12 DO NOT LIFT THE MOTORCYLE BY JACKING UP THE CONTROLLER DO NOT SUPPORT THE WEIGHT OF THE MOTORCYCLE BY SUPPORTING THE CONTROLLER Doing so will damage the controller and other components 13 Safely loop straps around the motorcycle upper...

Page 205: ...t the front wheel Tool 17mm hex bit socket Torque 40 lb ft 54 Nm 16 Release the WSS sensor from the front wheel Installation 1 Installation is the reverse of the removal procedure but take note of the following installation step 2 When installing the WSS sensor make sure the alignment tab is positioned against the bottom edge of the left front shock as shown ...

Page 206: ...5 2 Safely raise rear tire off the ground using a motorcycle stand 3 Release rear wheel speed sensor WSS harness from plastic retainer 4 Place rag over rear caliper to protect painted surfaces 5 Lift rear tire slightly and slide rear axle out of the swing arm 6 Raise rear tire and remove rear WSS sensor and set aside Note Make sure the WSS sensor is hung up and not straining the WSS electrical har...

Page 207: ... hose from the metal retaining clip 11 Position the rear brake hose on top of clip 12 Tip the top of the rear tire to the left 13 Slide rear caliper assembly toward wheel and slide caliper bracket off of the bracket alignment pin 14 Tie caliper up to the foot peg bracket Note Make sure the brake caliper is hung up and not straining the brake hose 15 Roll the rear wheel out of the swing arm ...

Page 208: ...he reverse of the removal procedure with the exception of the following 2 On the sprocket side of the rear wheel inspect the condition of the inner 1 and outer 2 bearings and the seal 3 Replace if necessary Note The bearings and seal are one time use parts Every part removed will need to be replaced 3 On the rotor side of the rear wheel inspect the condition of the wheel bearing 1 and the ABS magn...

Page 209: ...ool T40 Torque in sequence shown 20 lb ft 27 Nm 5 Install bolts x5 securing the rear sprocket to the rear wheel Tool T40 Torque in sequence shown 26 lb ft 35 Nm 6 When installing the WSS sensor make sure the alignment tab is positioned against the top edge of the rear brake bracket as shown ...

Page 210: ......

Page 211: ...uired for parent jobs T30 Removal 1 Insert the key into the lock and turn it clockwise to release the passenger seat 2 Remove bolt securing the rider s seat Tool T30 Torque 8 lb ft 11 Nm 3 Remove rider s seat Installation 1 Installation is the reverse of the removal procedure ...

Page 212: ...long bolts x2 securing headlight upper fairing to the dash center cover Tool T25 Torque Hand tight Do not over tighten 4 Remove short bolts x2 securing bottom of headlight upper fairing to the headlight inner fairing Tool T25 Torque 3 lb ft 4 Nm 5 Hold headlight upper fairing securely on both sides see arrows while lifting up to release mounting tabs from bodywork 6 Slide headlight upper fairing t...

Page 213: ...terminal eyelet Cover eyelet with insulating material Use cable tie to secure negative battery wire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 CAUTION Cover protect battery terminal eyelet to reduce the risk of accidentally contacting the negative battery terminal which can inadvertently power up the 12 volt system and damage components CAUTION Secure battery terminal w...

Page 214: ...h 2 layers of body panels Note Non shouldered body bolts designated with green arrows are present in this procedure 7 Remove long bolts x4 securing windscreen to the hela bracket Tool T25 Torque 3 lb ft 4 Nm 8 Remove windscreen 9 Remove short bolt securing dash center cover to the hela bracket Tool T25 Torque 3 lb ft 4 Nm 10 Disconnect dash harness connector from the dash 11 Remove bolts x4 securi...

Page 215: ...e wiring harness routing prior to removing the headlight inner fairing to assist during the installation process Note The headlight inner fairing is an interference fit take care during removal to prevent damage Installation 1 Installation is the reverse of the removal procedure ...

Page 216: ...al eyelet Cover eyelet with insulating material Use cable tie to secure negative battery wire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 CAUTION Cover protect battery terminal eyelet to reduce the risk of accidentally contacting the negative battery terminal which can inadvertently power up the 12 volt system and damage components CAUTION Secure battery terminal wire to...

Page 217: ...he right handlebar controls electrical harness to hela bracket Note Replace cable tie during the installation process 9 Cut cable tie securing the front turn signal electrical harnesses to hela bracket Note Replace cable tie during the installation process 10 Release harness cable tie anchor securing the main electrical harness to the hela bracket 11 Release harness connector anchor securing the m...

Page 218: ...lation process 13 Disconnect the throttle electrical harness connector 14 Disconnect the motor stop switch electrical harness connector 15 Disconnect the headlight switch electrical harness connector 16 Disconnect the mode switch electrical harness connector 17 Remove bolts x2 securing the left side of the hela bracket to the frame head tube Tool T30 Torque 8 lb ft 11 Nm ...

Page 219: ...0 9 60 18 Remove bolts x2 securing the right side of the hela bracket to the frame head tube Tool T30 Torque 8 lb ft 11 Nm 19 Remove hela bracket Installation 1 Installation is the reverse of the removal procedure ...

Page 220: ...ire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 CAUTION Cover protect battery terminal eyelet to reduce the risk of accidentally contacting the negative battery terminal which can inadvertently power up the 12 volt system and damage components CAUTION Secure battery terminal wire to reduce the risk of arcing and damaging electrical components 4 For the rest of this proce...

Page 221: ...m 9 Remove right mirror from motorcycle 10 Push the center of the panel retainer securing the left inner fairing arm to the headlight inner fairing inward to release it 11 Remove the left panel retainer 12 Push the center of the panel retainer securing the right inner fairing arm to the headlight inner fairing inward to release it 13 Remove the right panel retainer 14 Remove bolts x2 securing tank...

Page 222: ... to position the outer fairing arms low enough to pass under the handlebars without damaging the painted surfaces Installation 1 Installation is the reverse of the removal procedure with the exception of the following 2 Slightly spread the outer fairing arms around the headlight during installation to keep from damaging painted surfaces 3 Prior to installing the left outer side fairing install cab...

Page 223: ...ng the right turn signal harness insert it through the cable tie attached to the right outer fairing arm 7 After connecting the left front turn signal harness cinch the cable tie securing the harness to the left outer fairing arm 8 After connecting the right front turn signal harness cinch the cable tie securing the harness to the right outer fairing arm ...

Page 224: ...inal eyelet Cover eyelet with insulating material Use cable tie to secure negative battery wire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 CAUTION Cover protect battery terminal eyelet to reduce the risk of accidentally contacting the negative battery terminal which can inadvertently power up the 12 volt system and damage components CAUTION Secure battery terminal wire ...

Page 225: ...ight front turn signal harness connectors Note Take note of the wire insulation colors The turn signal wire colors match the colors of the main wire harness Right turn signal wire colors black and white 9 For the rest of this procedure there will be references to shouldered bolts securing body panels that are 2 different lengths Short bolts designated on photos with orange arrows used to attach a ...

Page 226: ...orque 3 lb ft 4 Nm Note Take note of length of the bolts 12 Remove right outer side fairing 13 While removing right outer side fairing guide the right front turn signal harness wires through their access hole in the right inner side fairing 14 Remove long bolts x2 blue arrows and short bolts x2 orange arrows securing the leading edge of the left outer side fairing to bodywork Tool T25 Torque 3 lb ...

Page 227: ...to installing the left outer side fairing install cable tie through the left outer fairing arm cable retainer hole 3 Prior to installing the right outer side fairing install cable tie through the right outer fairing arm cable retainer hole 4 While installing the left turn signal harness insert it through the cable tie attached to the left outer fairing arm 5 While installing the right turn signal ...

Page 228: ...ing the left front turn signal harness cinch the cable tie securing the harness to the left outer fairing arm 7 After connecting the right front turn signal harness cinch the cable tie securing the harness to the right outer fairing arm ...

Page 229: ...negative battery wire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 CAUTION Cover protect battery terminal eyelet to reduce the risk of accidentally contacting the negative battery terminal which can inadvertently power up the 12 volt system and damage components CAUTION Secure battery terminal wire to reduce the risk of arcing and damaging electrical components 4 Remove h...

Page 230: ... right inner side fairing Tool T25 Torque 3 lb ft 4 Nm 9 Remove the velocity tube assembly 10 Remove bolts x2 securing the lower half of the left inner side fairing to the motorcycle frame Tool T30 Torque 3 lb ft 4 Nm 11 Remove bolts x2 securing the lower half of the right inner side fairing to the motorcycle frame Tool T30 Torque 3 lb ft 4 Nm 12 Remove long bolt x1 blue arrow and short bolts x2 o...

Page 231: ...d short bolts x2 orange arrows securing the upper half of the left inner side fairing to the motorcycle frame and bodywork Tool T25 Torque 3 lb ft 4 Nm Note Take note of length of the bolts 15 Remove the left inner side fairing Installation 1 Installation is the reverse of the removal procedure ...

Page 232: ...s 2 Phillips screwdriver T30 Disassemble 1 Remove the tank assembly See Tank Removal page 60 10 2 Release the plastic cable retainer from the tank lock latch mechanism 3 Release the cable end from the tank lock latch mechanism 4 Release the lock cable end from the tank collar cable bracket 5 Release the cable end from the tank collar cable retainer 6 Release the cable end from the tank lock bracke...

Page 233: ... Torque Hand tighten Do not over tighten 9 Remove large screws x5 securing the right knee grip to the tank collar Tool 2 Phillips screwdriver Torque Hand tighten Do not over tighten 10 Remove small screws x7 securing the left fairing arm inner and left fairing arm outer to the tank collar Tool 2 Phillips screwdriver Torque Hand tighten Do not over tighten 11 Remove small screws x7 securing the rig...

Page 234: ... arrow 1 while pressing hinge pin arrow 2 out of tank collar Collect washer secured between the tank lid hinge and the tank collar Note Hold tank lid spring down toward top of tank collar while removing the hinge pin Note Take note of hinge spring location there is a right and a left spring 16 To remove the right tank lid hinge pin press locking pin arrow 1 while pressing hinge pin arrow 2 out of ...

Page 235: ...press locking pin arrow 1 while pressing hinge pin arrow 2 out of tank collar 19 Release locking tabs securing the left fairing arm inner to the left fairing arm outer 20 Release locking tabs securing the right fairing arm inner to the right fairing arm outer Assemble 1 Install bumpers in tank collar 2 Install bolts x2 securing the tank lid latch to the tank collar Tool T30 Torque 4 5 lb ft 6 Nm ...

Page 236: ...old the spring arrow 3 in place Note There is a left and a right tank lid spring so confirm by looking at the photos that you have the correct spring prior to installation 5 Apply pressure to the left tank lid spring arrow 1 while pressing hinge pin arrow 2 through hole in tank collar 6 Place washer arrow 1 between the tank lid hinge and the tank collar while pressing hinge pin arrow 2 through hol...

Page 237: ...nough that the hinge pin head seats against the tank collar 9 While installing the charge inlet lid place washer arrow 1 between the charge inlet lid hinge and the tank collar while pressing hinge pin arrow 2 through hole in tank collar Slide the pin arrow 2 far enough that the hinge pin head seats against the tank collar 10 For this procedure there will be references to screws securing body panel...

Page 238: ...tighten Do not over tighten 12 Install clip on U nut onto left inner fairing arm 13 Install clip on U nut onto right inner fairing arm 14 Install clip on U nut onto left outer fairing arm 15 Install clip on U nut onto right outer fairing arm 16 Insert locking tabs securing the left inner fairing arm to the left outer fairing arm ...

Page 239: ...ner hole 20 While assembling the left outer fairing arm confirm the alignment tab of the fairing outer arm fits under the edge of the tank rear 21 Install small screws x7 securing the left fairing arm inner and left fairing arm outer to the tank collar Tool 2 Phillips screwdriver Torque Hand tighten Do not over tighten 22 While assembling the right outer fairing arm confirm the alignment tab of th...

Page 240: ...5 securing the left knee grip to the tank collar Tool 2 Phillips screwdriver Torque Hand tighten Do not over tighten 25 Install large screws x5 securing the right knee grip to the tank collar Tool 2 Phillips screwdriver Hand tighten Do not over tighten 26 Release the cable end from the tank lock bracket 27 Release the cable end from the tank collar cable retainer 28 Release the cable end from the ...

Page 241: ...Body Body 60 31 60 29 Release the lock cable end from the tank collar cable bracket 30 Release the plastic cable retainer from the tank lock latch mechanism ...

Page 242: ...lease the passenger seat 3 Remove bolts x2 securing front of seat tray to tail frame assembly Tool T25 Torque 3 lb ft 4 Nm 4 Remove bolts x4 securing rear of seat tray to tail frame assembly Tool T30 Torque 5 lb ft 7 Nm 5 Remove seat tray 6 Remove bolts x3 securing left grab handle to tail frame assembly Tool T30 Torque 7 lb ft 9 5 Nm 7 Remove left grab handle 8 Remove bolts x3 securing right grab...

Page 243: ...Body Body 60 33 60 9 Remove right grab handle Installation 1 Installation is the reverse of the removal procedure ...

Page 244: ...hex wrench 10mm socket and ratchet New Fasteners Required Cable tie quantity 2 Removal 1 Remove high voltage DCDC and CONT fuses See High Voltage Fuses page 70 1 2 Unbolt the negative battery terminal eyelet Cover eyelet with insulating material Use cable tie to secure negative battery wire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 CAUTION Cover protect battery termina...

Page 245: ...ove MBB 7 Squeeze tabs to release OBDII connector from tank storage liner 8 Remove bolts x2 securing USB power hub to tank storage liner Tool T20 Torque 2 lb ft 2 7 Nm 9 Remove bolts x2 securing storage liner to storage liner plate Tool T27 Torque 2 5 lb ft 3 Nm Note During installation do not snug storage liner bolts until tank is installed 10 Remove storage liner Installation 1 Installation is t...

Page 246: ...he key from the key switch Removal 1 Remove tank See Grab Handles Right and Left page 60 32 2 Remove 12 Volt Battery See 12 Volt Battery Removal page 70 5 3 Remove T30 bolts x2 securing tank unit to bike frame Torque 2 5 lb ft 3 5 Nm 4 Move tank unit to right side of bike 5 Disconnect charge inlet harness connector 6 Disconnect battery signal harness connector 7 Remove T30 bolts x4 securing chargi...

Page 247: ...ing frame cover to frame 12 Remove frame cover from right hand side of the rider seat 13 Disconnect the tail pod signal harness connector 14 Release brake line WSS wire from clip on tail frame 15 Remove T40 bolts x2 securing tail to bike main frame Torque 20 lb ft 27 Nm 16 Support tail frame and remove T40 bolt securing tail to bike main frame Torque 20 lb ft 27 Nm ...

Page 248: ...0 38 Tail Body 60 17 Support tail frame and remove T40 bolt securing tail to bike main frame Torque 20 lb ft 27 Nm 18 Remove tail structure Installation 1 Installation is the reverse of removal procedure ...

Page 249: ... required for parent jobs 3 16 standard screwdriver 2mm hex wrench Removal 1 Remove screw securing fuse cover Tool 2mm hex wrench 2 High voltage fuses 3 Insert screwdriver into fuse cap and turn counterclockwise to release high voltage DC DC DCDC converter fuse 4 Remove high voltage DC DC DCDC converter fuse 5 Insert screwdriver into fuse cap and turn counterclockwise to release high voltage conta...

Page 250: ...70 2 High Voltage Fuses Electrical 70 6 Remove high voltage contactor fuse Installation 1 Installation is the reverse of the removal procedure ...

Page 251: ...ket and ratchet Removal 1 PERFORM LOCKOUT PROCEDURE See Lockout Procedure page 10 1 2 Remove rider s seat See Rider s Seat page 60 1 3 Remove screw securing fuse cover Tool 2mm hex Torque Hand tight 4 High voltage fuses 5 Insert screwdriver into fuse cap and turn counterclockwise to release high voltage DC DC DCDC converter fuse 6 Remove high voltage DC DC DCDC converter fuse 7 Insert screwdriver ...

Page 252: ...ative battery terminal eyelet with insulating material CAUTION Cover protect battery terminal eyelet to reduce the risk of accidentally contacting the negative battery terminal which can inadvertently power up the 12 volt system and damage components 12 Use cable tie to secure negative battery terminal eyelet to the positive battery cable CAUTION Secure battery terminal wire to reduce the risk of ...

Page 253: ...oval 1 PERFORM LOCKOUT PROCEDURE See Lockout Procedure page 10 1 2 Remove rider s seat See Rider s Seat page 60 1 3 Remove screw securing fuse cover Tool 2mm hex Torque Hand tight 4 High voltage fuses 5 Insert screwdriver into fuse cap push inward and turn counterclockwise to release high voltage DC DC DCDC converter fuse 6 Remove high voltage DC DC DCDC converter fuse 7 Insert screwdriver into fu...

Page 254: ...al eyelet with insulating material CAUTION Cover protect battery terminal eyelet to reduce the risk of accidentally contacting the negative battery terminal which can inadvertently power up the 12 volt system and damage components 12 Move protective cover to expose the positive terminal bolt Remove bolt securing the harness wire eyelet to the positive battery terminal and collect washer Tool 10mm ...

Page 255: ... Volt Battery 70 7 70 13 Disconnect the battery heater harness connector 14 Unhook the battery retaining strap 15 Remove the battery from the frame Installation 1 Installation is the reverse of the removal procedure ...

Page 256: ...tity 2 Removal 1 PERFORM LOCKOUT PROCEDURE See Lockout Procedure page 10 1 2 Remove high voltage DCDC and CONT fuses See High Voltage Fuses page 70 1 3 Unbolt the negative battery terminal eyelet Cover eyelet with insulating material Use cable tie to secure negative battery wire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 CAUTION Cover protect battery terminal eyelet to ...

Page 257: ...ge 60 3 9 Remove head light inner fairing See Headlight Inner Fairing page 60 3 10 Disconnect headlight harness connector 11 Remove bolts x2 securing left side of the headlight to the hela bracket Tool T30 Torque 3 7 lb ft 5 Nm 12 Remove bolts x2 securing right side of the headlight to the hela bracket Tool T30 Torque 3 7 lb ft 5 Nm 13 Remove headlight Installation 1 Installation is the reverse of...

Page 258: ...er s seat See Rider s Seat page 60 1 3 Remove bolts x2 securing front of seat tray to tail frame assembly Tool T25 Torque 3 lb ft 4 Nm 4 Remove bolts x4 securing rear of seat tray to tail frame assembly Tool T30 Torque 5 lb ft 7 Nm 5 Remove seat tray 6 Disconnect tail light harness connector 7 Remove nuts x2 securing tail light to tail frame assembly Tool 10mm socket Torque 3 5 lb ft 5 Nm 8 Remove...

Page 259: ... Cable tie quantity 2 Removal 1 PERFORM LOCKOUT PROCEDURE See Lockout Procedure page 10 1 2 Remove high voltage DCDC and CONT fuses See High Voltage Fuses page 70 1 3 Unbolt the negative battery terminal eyelet Cover eyelet with insulating material Use cable tie to secure negative battery wire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 CAUTION Cover protect battery term...

Page 260: ...charging procedure prior to servicing any High Voltage component or connection Proper procedures must be followed To protect electrical components perform the following tasks in the order given Do not deviate from the repair procedure processes NOTICE Before carrying out any work on the electrical system remove the key from the key switch Tools Required includes tools required for parent jobs T25 ...

Page 261: ...ntally contacting the negative battery terminal which can inadvertently power up the 12 volt system and damage components CAUTION Secure battery terminal wire to reduce the risk of arcing and damaging electrical components 4 Remove headlight upper fairing See Headlight Upper Fairing page 60 2 5 Cut cable tie securing right front turn signal electrical harness to hela bracket Note Replace cable tie...

Page 262: ...y bolts designated with green arrows are present in this procedure 8 Remove long bolts x2 securing bottom of right outer side fairing to bodywork Tool T25 Torque 3 lb ft 4 Nm 9 Remove long bolts x2 blue arrows and short bolts x2 orange arrows securing the leading edge of the right outer side fairing to bodywork Tool T25 Torque 3 lb ft 4 Nm Note Take note of length of the bolts 10 Remove right oute...

Page 263: ...ove nut securing right front turn signal to the right outer side fairing and collect star washer Tool 17mm wrench Torque 8 lb ft 11 Nm 13 Remove right front turn signal Installation 1 Installation is the reverse of the removal procedure ...

Page 264: ...e negative battery terminal eyelet Cover eyelet with insulating material Use cable tie to secure negative battery wire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 CAUTION Cover protect battery terminal eyelet to reduce the risk of accidentally contacting the negative battery terminal which can inadvertently power up the 12 volt system and damage components CAUTION Secure...

Page 265: ...l harness connectors Note Take note of the wire insulation colors The turn signal wire colors match the colors of the main wire harness Left turn signal wire colors black and white 10 Disconnect right rear turn signal harness connectors Note Take note of the wire insulation colors The turn signal wire colors match the colors of the main wire harness Right turn signal wire colors black and red 11 R...

Page 266: ...the tail frame 14 Remove nut securing the left rear turn signal Tool 17mm wrench Torque 8 lb ft 11 Nm 15 Remove nut from left rear turn signal harness and collect star washer 16 Remove left rear turn signal 17 Remove nut securing the right rear turn signal Tool 17mm wrench Torque 8 lb ft 11 Nm 18 Remove nut from right rear turn signal harness and collect star washer 19 Remove right rear turn signa...

Page 267: ...cludes tools required for parent jobs T25 T30 2mm hex wrench 3 16 standard screwdriver 10mm socket and ratchet Removal 1 Remove high voltage DCDC and CONT fuses See High Voltage Fuses page 70 1 2 Unbolt the negative battery terminal eyelet Cover eyelet with insulating material Use cable tie to secure negative battery wire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 3 Rem...

Page 268: ...struments Electrical 70 6 Remove dash display Installation 1 Installation is the reverse of the removal procedure Note Replacement dash panel from Zero Motorcycles will come preloaded with the correct firmware ...

Page 269: ...Required Cable ties quantity 4 Break away hex bolt set PN 90 0293701 quantity 1 package Removal 1 Remove high voltage DCDC and CONT fuses See High Voltage Fuses page 70 1 2 Unbolt the negative battery terminal eyelet Cover eyelet with insulating material Use cable tie to secure negative battery wire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 3 Remove headlight upper fai...

Page 270: ...for installation process 11 Remove bolts x2 securing key switch to the motorcycle frame Note Use a bolt extractor to extract the breakaway bolts Note Replace break away bolts x2 during the installation process 12 Remove key switch Installation 1 Installation is the reverse of the removal procedure 2 Perform the key programming procedure to program the keys to the motorcycle See Key Programming pag...

Page 271: ...ed Cable ties quantity 3 Specialty low profile cable tie quantity 1 Removal 1 Remove high voltage DCDC and CONT fuses See High Voltage Fuses page 70 1 2 Unbolt the negative battery terminal eyelet Cover eyelet with insulating material Use cable tie to secure negative battery wire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 CAUTION Cover protect battery terminal eyelet to...

Page 272: ...connect the headlight switch electrical harness connector 9 Disconnect the mode switch harness connector 10 Cut cable tie securing mode switch harness to the left side of the handlebar Note Replace cable tie during the installation process 11 Remove bolts x2 securing the mode switch s bottom to the top Tool 2 Phillips screwdriver 12 Remove mode switch assembly from the handlebar Note Confirm mode ...

Page 273: ...Electrical Mode Switch 70 25 70 Installation 1 Installation is the reverse of the removal procedure ...

Page 274: ... ties quantity 4 Specialty low profile cable tie quantity 1 Removal 1 Remove high voltage DCDC and CONT fuses See High Voltage Fuses page 70 1 2 Unbolt the negative battery terminal eyelet Cover eyelet with insulating material Use cable tie to secure negative battery wire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 CAUTION Cover protect battery terminal eyelet to reduce ...

Page 275: ...ess 9 Disconnect the headlight switch electrical harness connector 10 Disconnect the mode switch harness connector 11 Cut cable tie securing mode switch harness to the left side of the handlebar Note Replace cable tie during the installation process 12 Cut cable tie securing left heated grip harness to the bottom of the mode switch assembly Note Replace cable tie during the installation process 13...

Page 276: ...8 Mode Switch Electrical 70 14 Remove mode switch assembly from the handlebar Note Confirm mode switch shim is in place upon installation Installation 1 Installation is the reverse of the removal procedure ...

Page 277: ... 4 Specialty low profile cable tie quantity 1 Removal 1 Remove high voltage DCDC and CONT fuses See High Voltage Fuses page 70 1 2 Unbolt the negative battery terminal eyelet Cover eyelet with insulating material Use cable tie to secure negative battery wire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 CAUTION Cover protect battery terminal eyelet to reduce the risk of ac...

Page 278: ... during the installation process 10 Disconnect the headlight switch electrical harness connector 11 Disconnect the mode switch harness connector 12 Remove bolts x2 securing left side of front closeout panel to frame Tool T25 Torque 3 5 lb ft 5 Nm Note Protect rear portion of front fender and front closeout panel surfaces to reduce the possibility of scratching their surfaces 13 Remove bolts x2 sec...

Page 279: ... connectors 17 Disconnect heated grip harness connector Note Label mark connector if you re going to disconnect both connectors 18 Cut cable tie securing mode switch harness to the left side of the handlebar Note Replace cable tie during the installation process 19 Cut cable tie securing left heated grip harness to the bottom of the mode switch assembly Note Replace cable tie during the installati...

Page 280: ...lectrical 70 21 Remove second bolt securing the left heated grip to the handlebar Tool 2 Phillips screwdriver 22 Remove left heated grip to the handlebar Installation 1 Installation is the reverse of the removal procedure ...

Page 281: ...bolt the negative battery terminal eyelet Cover eyelet with insulating material Use cable tie to secure negative battery wire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 CAUTION Cover protect battery terminal eyelet to reduce the risk of accidentally contacting the negative battery terminal which can inadvertently power up the 12 volt system and damage components CAUTION...

Page 282: ...left doubler plate Tool T40 Torque 20 lb ft 27 Nm 6 Remove bolts x2 securing the heel guard to the frame Tool T25 Torque 3 5 lb ft 5 Nm 7 Release harness anchor clip from the frame 8 Cut cable tie securing the rear WSS harness and kickstand harness to the anchor clip Note Replace cable tie during the installation process 9 Cut cable tie securing kickstand harness to the kickstand harness connector...

Page 283: ... plate Note Replace cable tie during the installation process 12 Remove bolts x2 securing kickstand to the left doubler plate Tool T50 Torque both bolts 25 lb ft 34 Nm 13 Remove kickstand 14 Remove bolts x2 securing the brake stand switch Tool 2 5mm hex wrench Torque 2 lb ft 3 Nm Installation 1 Installation is the reverse of the removal procedure ...

Page 284: ...Removal 1 Remove high voltage DCDC and CONT fuses See High Voltage Fuses page 70 1 2 Unbolt the negative battery terminal eyelet Cover eyelet with insulating material Use cable tie to secure negative battery wire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 CAUTION Cover protect battery terminal eyelet to reduce the risk of accidentally contacting the negative battery ter...

Page 285: ... reverse of the removal procedure but follow the proceeding steps to complete the CCM installation 2 Insert the CCM harness connector 3 Roll the CCM rubber harness cover down over the CCM as far as it will go Note The satellite logo on the CCM is the side that needs to be facing up when installed on the motorcycle Confirm that the satellite logo and the THIS SIDE UP text on the rubber harness cove...

Page 286: ...te Do not capture the wiring harness located under the HCU bracket with the cable ties 8 Install the CCM back on the HCU bracket with the text THIS SIDE UP text facing upward 9 Follow the rest of the CCM Removal steps 3 2 and 1 to complete the installation of the CCM 10 Once the CCM is physically installed you must email Zero Motorcycles Customer Service department to complete the installation pro...

Page 287: ...ed Cable tie quantity 2 Removal 1 Remove high voltage DCDC and CONT fuses See High Voltage Fuses page 70 1 2 Unbolt the negative battery terminal eyelet Cover eyelet with insulating material Use cable tie to secure negative battery wire to the positive battery cable See 12 Volt Battery Disconnect page 70 3 CAUTION Cover protect battery terminal eyelet to reduce the risk of accidentally contacting ...

Page 288: ...n resistant rubber isolator nuts if they are damaged or worn Note Do not over tighten bolts 8 Remove MBB Installation 1 Installation is the reverse of the removal procedure Note After replacing the MBB the keys must be reprogrammed Locate your yellow key and black keys and follow the key programming procedure See Motor Controller Firmware Update page 10 14 ...

Page 289: ...Electrical Main Bike Board MBB 70 41 70 ...

Page 290: ......

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