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5-23

Parts/Maintenance Items

The proper replacement parts, fluids, and lubricants
to use are listed in the chart below.

PART

NUMBER

Headlamp Bulb-55 watt

H4

Turn Signal Bulb

1156

Stop/Tail Lamp Bulb

1157

Front Running Lamp Bulb

194

Brake Fluid

DOT 4

Accessories

Zero accessories are designed to complement and
function with other systems on your motorcycle. Your
CSC can accessorize the motorcycle using genuine
Zero accessories.

A full line of Parts, Accessories, and Apparel can be
found on the Zero Motorcycles website.

Fuses

Whenever there is an excessive amount of current
flowing through a circuit the fusible element will melt
and create an open or incomplete circuit. Fuses are
a one-time protection device and must be replaced
each time the circuit is overloaded. Replace the fuse
with one of equal current rating. If the fuse melts
repeatedly, have the electrical system inspected by
your CSC.

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Содержание DS 2010

Страница 1: ......

Страница 2: ...g Your Riding Style 1 9 Public Charging Stations 1 10 Emissions Information 1 10 Transporting 1 11 Safety Information 2 1 General Safety Precautions 2 1 Important Operating Information 2 2 Location Of...

Страница 3: ...r Pack And Charger 6 1 Understanding Beep Sequences 6 3 Safety Interlocks 6 6 General Troubleshooting 6 11 Right Side View 3 5 Instrument Panel 3 7 Indicators 3 8 Handlebar Controls 3 9 Starting And O...

Страница 4: ...orcycles Limited Warranties 7 3 Standard Warranty 7 3 Extended Warranty 7 4 No Fault Warranty 7 5 Disclaimers Applicable to Standard Warranty Extended Warranty and No Fault Warranty 7 5 Proper Use 7 6...

Страница 5: ...TOC 4 NOTES...

Страница 6: ...Because of this your motorcycle may differ from the information supplied in this owner s manual No legal claims can be made on the basis of data in this manual When it comes time to sell your Zero mot...

Страница 7: ...rating features and until you have been trained in safe and proper riding techniques Regular inspections and careful maintenance along with good riding skills will help you to safely enjoy the capabil...

Страница 8: ...ress Model Date of Purchase VIN Telephone No E mail Battery Serial Number Owner Information Record important information here pertaining to your motorcycle When contacting your Certified Service Cente...

Страница 9: ...n Number VIN See Location Of Important Labels on page 2 3 VIN Break Down VIN Location The VIN is a 17 digit number stamped on the head tube of the frame Do not alter or remove this number as it is the...

Страница 10: ...cle Type 2 168 Cell 3 2nd Generation 4 336 Cell M Mars P Perm Z Z Motor Force A Agni 05 0 50 HP 51 50 100 HP 10 100 HP 9 2009 A 2010 B 2011 Production Number S 3 9 1 M 9 05 123456 Model Line Motor Typ...

Страница 11: ...nless Rotor Foot Actuated Front Tire 110 70 16 in Rear Tire 140 70 16 in Front Wheel 16 x 3 0 in Rear Wheel 16 x 4 0 in MOTOR Type Brushed permanent magnetic electric Est Top Speed 108 km h 67 mph POW...

Страница 12: ...pounds Power Pack 43 1 kg 95 pounds Curb Weight 123 8 kg 273 pounds GVWR 260 8 kg 575 pounds Carrying Capacity 136 0 kg 302 pounds ECONOMY Typical Cost to Recharge Less than 01 per mile or kilometer M...

Страница 13: ...Carrying Capacity 134 7 kg 297 pounds ECONOMY Typical Cost to Recharge Less than 01 per mile or kilometer DRIVETRAIN Transmission Clutchless one speed Drive System 16T 53T Sprockets 420 Chain CHASSIS...

Страница 14: ...tics if you so desire This applies mainly to riders with trip profiles which are at the edge of the performance envelope Those of you with relatively short commutes can expect to ride quite aggressive...

Страница 15: ...air pollution global warming and energy security problems facing the country and the world WARNING Please use only Zero approved parts and accessories for your Zero motorcycle Parts and products for y...

Страница 16: ...the screw slowly but do not remove Once all the air is out tighten the bleed screw It is recommended that the motorcycle be tied down using ratchet straps and a fork support A to prevent fork damage...

Страница 17: ...1 12 Use two ratchet straps in the front and two in the rear The tie down straps should be at a 45 angle from the motorcycle Follow the manufacturer s instructions for the ratchet straps you are using...

Страница 18: ...1 13 NOTES...

Страница 19: ...1 14 NOTES...

Страница 20: ...orcycle without proper instruction These are performance motorcycles and should be treated with extreme caution 6 Do not ride on wet frozen oily or pitted surfaces Avoid potholes surface cracks and ot...

Страница 21: ...e it is silent An accident can occur if the motorcycle is left powered up while getting on or off the motorcycle 2 Switch the power OFF when backing up or pushing the motorcycle while dismounted It is...

Страница 22: ...Axle Weight Rating GAWR Front and Rear Vehicle Identification Number VIN Rim Size Tire Pressures Manufactured Date 6 Always firmly apply the rear brake while turning the key switch ON or OFF In the ev...

Страница 23: ...2 4 Power Pack Information Label 7...

Страница 24: ...2 5 There is no engine braking A B Throttle And Speed Control Label Power Pack Labels A Power Pack Battery Fuse Label B Main Power Cut Off Label...

Страница 25: ...2 6 MAIN POWER CUT OFF ON OFF SLIDE DOWN SLIDE UP Power Pack Battery Fuse Label Main Power Cut Off Label...

Страница 26: ...bility to start from a standstill up a steep 10 grade when fully loaded It is not recommended that you stop on a grade of more than 10 with a fully loaded motorcycle Z ForceAir Induction System The ai...

Страница 27: ...fast blink is clearly seen on the dash mounted warning indicator The power to the motor begins to drop off resulting in a noticeable reduction in available torque This provides tactile feedback to th...

Страница 28: ...l have time to back off the throttle to reduce heat This will restore full power to the motor and eliminate the warning indicator Stage 3 If the critical temperature threshold of the brush carrier is...

Страница 29: ...2 10 NOTES...

Страница 30: ...0 A A C B E F D G I H Controls And Components Motorcycle Controls A Mirrors B Fork Lock C Instrument Panel D Warning Indicator E Front Brake Fluid Reservoir Master Cylinder F Front Brake Lever G Left...

Страница 31: ...operation see pages 3 7 and 3 8 D Warning Indicator See System Error Indicator on page 2 8 E Front Brake Fluid Reservoir Master Cylinder For description and operation see Brakes on page 5 6 F Front B...

Страница 32: ...C D B E F G H I Left Side View A Headlamp B Main Power Cut Off C Stop Tail Lamp D Rear Turn Signal E Front Turn Signal F AC Charger Power Connection G On Board Battery Charger H Kickstand Switch I Kic...

Страница 33: ...eplacement on page 5 16 F AC Charger Power Connection For description and operation see Charging The Power Pack on page 4 12 G On Board Battery Charger For description and operation see Battery Charge...

Страница 34: ...3 5 A B C D A Rear Brake Fluid Reservoir B Drive Chain Adjuster C Rear Brake Pedal D Power Pack Right Side View...

Страница 35: ...nt Procedure on page 5 12 C Rear Brake Pedal The rear brake pedal controls the rear brake when the pedal is pressed When braking the throttle should be in the neutral returned position The stop lamp w...

Страница 36: ...B A Left Turn Signal Indicator B High Beam Indicator C Speedometer D Main Power Indicator E Energy Gauge F Right Turn Signal Indicator G Select Button H Adjust Button I Warning Indicator J Trip Odome...

Страница 37: ...mp high beams are on this indicator will illuminate blue and will remain on until the high beams are turned off C Speedometer The speedometer is an analog and digital display in either kilometers per...

Страница 38: ...3 9 A B C E D F G H A High Beam Flash to Pass B Headlamp High Low Beam Switch C Front Brake Lever D High Beam Indicator E Horn Switch Handlebar Controls F Turn Signal Switch G Kill Switch H Throttle...

Страница 39: ...or other motorists of your presence F Turn Signal Switch When the turn signal switch is pushed in the left or right position the corresponding front and rear turn signal will flash When the turn sign...

Страница 40: ...e ON B button is pressed The switch does not turn off all electrical circuits just the operation of the motor H Throttle Control Twist the throttle in a counter clockwise rotation A to energize the mo...

Страница 41: ...3 12 NOTES...

Страница 42: ...pecifications See Tire Inflation on page 5 9 5 Inspect the hydraulic brake system Follow the hydraulic line from the reservoirs to the calipers and verify that there are no leaks or damage to the brak...

Страница 43: ...e Zero motorcycle It is possible during shipping that sharp edges or points may occur please use caution Retain the crate and all other shipping items for future shipping of the motorcycle Note The sh...

Страница 44: ...cle upright remove the ratchet straps B 4 Fold down the ramp A and lower the protective plastic 5 Remove the fork support A located between the wheel and front fender 6 Carefully roll the motorcycle o...

Страница 45: ...rake lever and press the brake pedal individually while pushing the motorcycle to see if it rolls You should be able to lock up the wheels completely by applying the brakes Throttle With the key switc...

Страница 46: ...The key B can be folded down Fork Lock CAUTION Do not operate the motorcycle with the fork locked This will prevent the motorcycle s ability to steer and could cause personal injury Using the fork loc...

Страница 47: ...This switch is used to connect or disconnect the Z Force power pack from the motorcycle When the switch is slid down to OFF disconnected all electricity to the motorcycle is turned off this includes t...

Страница 48: ...l turn off the motor controller outside of this range It is recommended that you leave the motorcycle on the charger if you expect it to sit in storage or unused for over 7 days The power pack must be...

Страница 49: ...is section explains the different beep patterns and their meanings Battery Management System BMS Every power pack contains a Battery Management System BMS which monitors the condition of the cells and...

Страница 50: ...rner of the power pack The BMS will beep under only two circumstances When the motorcycle key switch is turned from OFF to ON When the motorcycle is turned ON the BMS will perform a self test It will...

Страница 51: ...at the power pack is full it will continue to attempt to fully charge the power pack In this event the green light may not illuminate however the power pack may be fully charged To ensure that the pow...

Страница 52: ...phase complete 80 charged In Absorption phase With no power pack connected indicates algorithm selected by number of flashes Flashing Also displays algorithm 1 6 for 11 seconds if no power pack is con...

Страница 53: ...hen not under load the power pack needs to be charged Frequent top off charging is good for the power pack s life span so do not hesitate to charge frequently 2 Ensure that the key switch is in the OF...

Страница 54: ...with an Emergency Energy Reserve Beep When your power pack makes an audible beep it has only a few miles of range left This beep tells you your power pack is dangerously low on energy and needs to be...

Страница 55: ...the OFF position and remove the key To prevent theft the key should be removed anytime the motorcycle is left unattended 3 Be sure to charge the power pack after each ride See Charging The Power Pack...

Страница 56: ...g on page 1 11 Bleeding the fork Bleed the fork regularly let any excess air out after each ride 2 Rebound Damping The rebound damping is adjusted by turning the slotted brass adjuster screw B on the...

Страница 57: ...n turn the adjuster counter clockwise Start with a middle setting and fine tune the compression from there Proper compression will allow the tire to track the ground over consecutive bumps Compression...

Страница 58: ...rect for your weight This adjustment is a recommendation guideline personal riding preference may vary from the specifications given Checking Sag 1 Support your motorcycle on a stand with the rear whe...

Страница 59: ...in the spring pre load should be adjusted See Spring Pre load Adjustment M1 600 mm 23 6 in M2 500 mm 19 6 in Sag 100 mm 4 in 8 Have a second assistant take a measurement using the same locations as in...

Страница 60: ...the spring nut B clockwise on the shock 4 Recheck the sag If the sag is correct tighten the lock nut A Rebound Adjustment The rebound adjuster knob C is at the bottom of the shock It has 8 stages of...

Страница 61: ...4 20 NOTES...

Страница 62: ...re and maintenance of your electric motorcycle as detailed in this owner s manual 3 Use only genuine Zero approved parts and accessories 4 The operator is responsible for learning and obeying all coun...

Страница 63: ...Use LOCTITE 242 Front axle end bolts 18 20 N m 13 15 lb ft F Front caliper mount bolts 11 13 N m 8 10 lb ft Use LOCTITE 242 G Charger bolts 5 6 N m 44 53 lb in Use LOCTITE 242 H Main pivot bolt nut sw...

Страница 64: ...5 3 B C J I H F E D G See Bolt Torque Table on page 5 2...

Страница 65: ...5 4 L M K See Bolt Torque Table on page 5 2...

Страница 66: ...e heat The lithium ion cells should not get above 71 C 160 F Do not store in a hot car or trailer or leave the power pack in direct sunlight 3 Only an authorized service agent is qualified to have acc...

Страница 67: ...immediately Low fluid levels may indicate worn brake pads or a leak in the hydraulic system Inspect the brake pads for wear and or the hydraulic system for leaks Use only new DOT 4 brake fluid from a...

Страница 68: ...w DOT 4 brake fluid Inspect the cap seal ensuring that it is free of any wear or damage then reinstall the cap Brake Pad Inspection The brake pads must be inspected when specified in the maintenance s...

Страница 69: ...to explode causing personal injury or death To adjust the shock see Rear Shock Adjustment on page 4 17 Wheels And Tires Inspect both wheels for the following Bent loose or missing spokes Bent or crac...

Страница 70: ...ons replace the wheel and tire immediately Tire Inflation CAUTION Under inflation is the most common cause of tire failure and may result in severe tire cracking tread separation blowout or unexpected...

Страница 71: ...in serious personal injury Follow the manufacturer s instructions for the chain cleaner you are using below are the general guide lines 1 Remove the key from the key switch 2 Set the motorcycle on a s...

Страница 72: ...d spray the inside of the chain on the inside of the links 2 Turn the wheel backwards slowly and spray the outside of the chain on the outside of the links Checking The Drive Chain 1 Remove the key fr...

Страница 73: ...t after the test ride and readjust if necessary 1 Remove the key from the key switch 2 Loosen both rear motor mount Allen bolts A 4 Loosen the 13 mm jam nut C on the chain tensioner 5 Turn the adjuste...

Страница 74: ...ill point too far off to one side If the vertical adjustment is off it will cause the beam to point too close to or too far ahead of the motorcycle With the headlamp on the low beam position the motor...

Страница 75: ...avoid personal injury Turn off the key switch and allow the bulb to cool before changing the bulb Leave the key switch OFF until the bulb change is complete Always wear eye protection when changing a...

Страница 76: ...hing to the side 5 Lift up on the spring clip and remove the headlamp bulb A 2 1 WARNING Do not touch the glass portion of the headlamp bulb Keep the headlamp bulb free of contaminants Oil from your f...

Страница 77: ...placement 1 Remove the turn signal lens screw A and remove the lens 2 Push in on the bulb turn the bulb counter clockwise and then pull the bulb out 3 Insert the new bulb into the socket push in and t...

Страница 78: ...using a rocking motion see image on page 5 18 2 Push in on the bulb and turn the bulb counter clockwise then pull the bulb out 3 Insert the new bulb into the socket push in and turn clockwise until i...

Страница 79: ...electrical components Avoid spraying water of great force around the instrument panel Avoid using strong acidic wheel cleaners especially on spoked wheels If such products are used on hard to remove d...

Страница 80: ...ing and continues to monitor the power pack This ensures that electricity is not wasted in maintaining an optimized power pack 3 To prolong the life of your power pack you should store your motorcycle...

Страница 81: ...or 6 months 13 000 km 8 000 mi or 12 months 19 000 km 12 000 mi or 18 months 25 000 km 16 000 mi or 24 months 31 000 km 20 000 mi or 30 months 1 Front Brake Check operation and for fluid leakage Repla...

Страница 82: ...grease Ensure main pivot bolt is properly torqued See Bolt Torque Table on page 5 2 9 8 Drive Chain Check chain slack alignment and condition Adjust and lubricate chain with chain lubricant thoroughly...

Страница 83: ...30 months 12 Front Fork Check operation and for oil leakage Service rebuild if necessary Refer to the service manual for more information 9 9 9 9 9 9 13 Rear Shock Absorber Assembly Check operation an...

Страница 84: ...torcycle Your CSC can accessorize the motorcycle using genuine Zero accessories A full line of Parts Accessories and Apparel can be found on the Zero Motorcycles website Fuses Whenever there is an exc...

Страница 85: ...ty is considered to be melted Remove the fuse by pushing in on the plastic cap and turning counter clockwise Install the fuse by pushing in and turning clockwise For more information about the fuse la...

Страница 86: ...Not Used C 10 Turn Signals Horn D 5 Instrument Panel Tail Stop Lamp A B C D 4 2 3 1 E S U F P M A S T I U C R I C D E L L O R T N O C 1 0 1 A D M r o t c a t n o C 2 0 2 A D M r e t r e v n o C C D 3...

Страница 87: ...ODOMETER MILEAGE READING ITEM SERVICE ROUTINE DESCRIPTION Follow the maintenance schedules on pages 5 20 through 5 22 After a scheduled service or routine is performed record the information on the ch...

Страница 88: ...5 27 NOTES...

Страница 89: ...5 28 NOTES...

Страница 90: ...repair it yourself If you are unable to solve an issue with your Zero S DS electric motorcycle take it to an authorized Certified Service Center CSC at your convenience If there is no CSC in your area...

Страница 91: ...e Charger output was reduced due to high temperatures Check connections Operate charger at a lower ambient temperature 4 Power pack could not be trickle charged up to minimum voltage Contact CSC 5 Ove...

Страница 92: ...on on the meaning of the beep sequences PATTERN WHEN MEANING SOLUTION 1 Short Key on Self Test Pass BMS OK Ready to ride 1 Trill 2 Long Key on Charger Still Plugged In Unplug charger try again 2 Long...

Страница 93: ...ividual cells The BMS continuously monitors the cells and tries to keep them all in balance at the same level of charge If any of the cells are grossly out of balance the BMS will sound a Power Pack U...

Страница 94: ...repaired or replaced by a CSC BMS Appendix There are other beeps which may occur under two circumstances that operators will normally never see Unlike many electronic systems the BMS essentially neve...

Страница 95: ...ower pack is empty or if the BMS detects certain serious internal problems You cannot ride the motorcycle until the problem is resolved 2 Charger Disable The BMS will prevent charging if it detects ce...

Страница 96: ...er Still Plugged In Power Pack Empty Too Hot Power Pack Unbalanced The Charger Disable Interlock When the charger is attached and plugged in to AC power the BMS communicates with the charger The BMS c...

Страница 97: ...are balanced the charger not the BMS will sense that the power pack is full and terminate the charging cycle with a green light The BMS does have a redundant back up mechanism to prevent overcharging...

Страница 98: ...t y f i r e V s n o i t c e n n o c r o e l t t o r h t d a B n o i t c e n n o c k c e h c r o d n a n o i t c a 5 t o n r o s n e s e r u t a r e p m e t r o t o M d e t c e t e d r o r o s n e s e...

Страница 99: ...lure Could not pre charge motor controller Contact CSC 10 Current sensor error Problem with current sensor or connection Contact CSC 11 Board temperature sensor error Problem sensing temperature of bo...

Страница 100: ...e UP ON position Press the Kill Switch ON button Charger not working A C power missing Main power cut off engaged Check A C outlet for power A C source check fuse voltage Move the main power cut off t...

Страница 101: ...6 12 NOTES...

Страница 102: ...nswer your questions or resolve your concerns Owner s name and address Owner s telephone number Vehicle identification number VIN Date of purchase Battery serial number An owner information chart is p...

Страница 103: ...PARTS COVERED STANDARD EXTENDED Replaces 2nd Year of the Standard Warranty NO FAULT Replacement Parts are 50 of Retail Cost Unless Noted First Year Second Year Excluding Shipping and Labor Motor 35 Di...

Страница 104: ...f this standard limited warranty covers parts only for these same major components Standard Warranty Exclusions This warranty does not apply to tire wear chain or sprocket condition brake pads or roto...

Страница 105: ...luded from this extended warranty on off road bikes once they have been ridden This extended warranty excludes aftermarket accessory kits which may be subject to their own warranties This extended war...

Страница 106: ...warranties and are not included in this no fault coverage Modifications or alterations to major components of the manufacturer s original product or its sub components void all warranties including t...

Страница 107: ...product during the time the warranty service is being preformed travel loss or damage to personal property loss of revenue loss of use of the product loss of time or inconvenience Some states do not a...

Страница 108: ...is responsible for learning and obeying all federal state and local laws governing the operations of an electric motorcycle Always wear a helmet knee and elbow guards goggles appropriate boots and all...

Страница 109: ...and warranty form This must be performed to allow Zero Motorcycles the ability to contact the new owner in the unlikely event of a safety related issue Use the URL address below or feel free to conta...

Страница 110: ...7 9 NOTES...

Страница 111: ...7 10 NOTES...

Страница 112: ...4 8 Beeps 4 9 BMS Appendix 6 5 Bolt Torque Table 5 2 Brake Fluid Level Inspection 5 6 Brake Pad Inspection 5 7 Brakes 4 4 5 6 Brake Fluid Level Inspection 5 6 Brake Pad Inspection 5 7 Front Brake 5 6...

Страница 113: ...4 F First Time Set Up 4 1 Fork Lock 4 5 Front Brake 5 6 Front Fork Adjustment 4 15 Fuse Center Location 5 24 Fuses 5 23 G General Information 1 6 General Maintenance 5 6 Brakes 5 6 Chain 5 10 Headlam...

Страница 114: ...K Key Switch Positions 4 5 L Left Side View 3 3 Limited Warranties 7 3 Location Of Important Labels 2 3 Main Power Cut Off Label 2 6 Power Pack Battery Fuse Label 2 6 Power Pack Information Label 2 4...

Страница 115: ...5 Power Pack Battery Fuse Label 2 6 Power Pack And Charger 6 1 Low Power Pack Warning 6 4 Other Error Beep Patterns 6 5 Power Pack Empty 6 4 Power Pack Unbalanced 6 4 Too Hot 6 4 Power Pack Empty 6 4...

Страница 116: ...ntrol Label 2 5 Throttle Disable 6 6 Tire Inflation 5 9 Tires 4 4 Transfer Of Ownership And Warranty 7 8 Transporting 1 11 Troubleshooting 6 1 Turn Signal Bulb Replacement 5 16 U Uncrating Your Motorc...

Страница 117: ...INDEX 6 Z Z Force Air Induction System 2 7 Z Force Power Pack Battery Fuses 5 24 Zero Motorcycles Limited Warranties 7 3...

Страница 118: ......

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