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2009 ZERO S / DS OWNER'S MANUAL

23

MAINTENANCE SCHEDULE

The scheduled maintenance must be done in accordance with this chart to keep the Zero S/DS motorcycle in 
good running condition. The initial maintenance is vitally important and must not be neglected.

NOTE:

 From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months.

NO.

ITEM

ROUTINE

INITIAL

ODOMETER READINGS

600 mi/1000 km

or

 

1 month

4000 mi/7000 km

or

6 months

8000 mi/13000 km

or

12 months

12000 mi/19000 km

or

18 months

16000 mi/25000 km

or

24 month

20000 mi/31000 km

or

30 month

1

Front Brake

• Check operation, fluid level, and for fluid leakage.

• Replace brake pads if necessary

2

Rear Brake

• Check operation, fluid level, and for fluid leakage.

• Replace brake pads if necessary

3

Brakes Hoses

• Check for cracks or damage.

• Replace

Every 4 years

4t

Wheels

• Check runout and for damage.

• Replace if necessary

5

Tires

• Check tread depth and for damage.

• Replace if necessary

• Check air pressure (S–35 psi, DS–32 psi)

• Correct if necessary

6

Wheel  

Bearings

• Check bearings for smooth operation.

• Replace if necessary

7

Swingarm Pivot 

Bearings

• Check bearing assemblies for looseness.

• Moderately repack with lithium grease.

• Ensure main pivot bolt is properly torqued (see 

torque table - page 22

8

Drive Chain

• Check chain slack / alignment and condition.

• Adjust and lubricate chain with chain lubricant 

thoroughly.

• Replace worn chain.

Every 600 mi/1000 km and after washing the motorcycle or riding in the rain

9

Steering Bearings

• Check bearing assembly for looseness.

• Moderately repack with lithium grease every 16000 

mi (25000 km) or 24 months.

Repack

10

Chassis Fasteners

• Check all chassis fittings and fasteners.

• Correct if necessary

11

Front Brake Lever 

Pivot Shaft

• Apply lithium grease (all-purpose grease) lightly

12

Rear Brake Pedal 

Pivot Shaft

• Apply lithium grease (all-purpose grease) lightly

13

Sidestand Pivots

• Check operation.

• Apply lithium grease (all-purpose grease) lightly

14

Sidestand Switch

• Check operation and replace if necessary.

15

Front Fork

• Check operation and for oil leakage.

• Replace if necessary

16

Rear Shock 

Absorber Assembly

• Check operation and for oil leakage.

• Replace if necessary.

17

Throttle Grip  

Housing and Cable

• Check operation and free play.

MAI

NTE

NAN

C

E AN

D R

E

P

AI

R

Содержание S 2009

Страница 1: ...ZERO MOTORCYCLES 2009 S DS OWNER S MANUAL...

Страница 2: ......

Страница 3: ...re while this manual contains the most current product information available at the time of printing there may be minor discrepancies between your motorcycle and this manual If you have any questions...

Страница 4: ...2009 ZERO S DS OWNER S MANUAL 2...

Страница 5: ...harger Led Indicators 21 Maintenance and Repair 21 Power Pack Care and Technical Information 22 Bolt Torque Table 23 Maintenance Schedule 24 General Maintenance 24 Motor Maintenance 24 Suspension 24 W...

Страница 6: ...2009 ZERO S DS OWNER S MANUAL 4...

Страница 7: ...that allows for using freeways or highways for a few miles when necessary You can expect to achieve 40 miles of average range under normal use stop and go city traffic with a maximum range of 60 miles...

Страница 8: ...ck warning to the rider in the form of a rapid acceleration deceleration pulsing of the motorcycle At this point it is strongly recommended that you reduce your speed and consider finding a safe area...

Страница 9: ...unable to take responsibility for their actions should not use this motorcycle You assume all responsibility while operating your motorcycle The seller will assume no liability for misuse or operator...

Страница 10: ...S DS connected to the charger when your motorcycle is sitting in storage or if it will be sitting unused for more than 7 days 6 Always firmly apply the rear brake while turning the master switch on o...

Страница 11: ...2009 ZERO S DS OWNER S MANUAL 9 1 EPA Label Shown Actual Size LOCATION OF IMPORTANT LABELS 1 SAFETY INFORMATION...

Страница 12: ...2009 ZERO S DS OWNER S MANUAL 10...

Страница 13: ...l Module 3 Front Brake Lever 4 Key Switch 5 Right Handlebar Control Module 6 Front Brake Fluid Reservoir and Master Cylinder 7 Mirrors 8 Warning Indicator CONTROLS AND COMPONENTS MOTORCYCLE CONTROLS 2...

Страница 14: ...Headlight 2 Tail Light Brake Light License Plate Light 3 On Board Power Connection 4 Kickstand Sidestand 5 Main Power Coupling 6 Sidestand Switch 7 Onboard Charger CONTROLS AND COMPONENTS LEFT VIEW 4...

Страница 15: ...ERO S DS OWNER S MANUAL 13 1 Drive Chain 2 Rear Brake Fluid Reservoir 3 Rear Brake Master Cylinder 4 Chain Tensioner 5 Rear Brake Pedal 6 Zero S DS Power Pack RIGHT VIEW 4 1 3 2 5 6 CONTROLS AND COMPO...

Страница 16: ...10 1 2 4 5 6 3 7 8 9 8 Shown Actual Size 1 Main Power Indicator 2 Energy Gauge 3 Speedometer 4 Odometer 5 Trip Odometer 6 Warning Indicator 7 High Beam Indicator 8 Turn Signal Indicator 9 Select Adju...

Страница 17: ...ZERO S DS OWNER S MANUAL 15 20 30 40 50 60 70 80 90 100 1 10 120 10 1 Headlight Hi Low Beam Selector 2 Turn Signal Switch 3 Horn 4 High Beam Flasher LEFT HANDLEBAR CONTROLS 1 4 2 3 CONTROLS AND COMPON...

Страница 18: ...009 ZERO S DS OWNER S MANUAL 16 20 30 0 90 100 1 10 120 10 1 Motor Stop Switch Kill Switch 2 Front Brake Lever 3 Throttle CONTROLS AND COMPONENTS RIGHT HANDLEBAR CONTROLS CONTROLS AND COMPONENTS 1 2 3...

Страница 19: ...raulic line from the reservoirs to the calipers and verify that there are no leaks or damage to the brake lines Verify that the brakes function properly 7 Make sure the motorcycle is off then twist th...

Страница 20: ...riding in dusty or wet areas BRAKE Squeeze the brake lever and push the motorcycle to see if it rolls You should be able to lock up the wheels up completely using the brakes Check for sufficient brake...

Страница 21: ...AWG cord no longer than 25ft 7 5 m 5 AVOID connecting the Zero S DS motorcycle charger and another device to a single 15A 20A circuit or the circuit may become overloaded 6 Charging a fully discharged...

Страница 22: ...6 for 11 seconds if no battery is connected 80 Charge Amber Solid Flashing Bulk charge phase complete 80 charged In Absorption phase With no battery connected indicates algorithm selected by number o...

Страница 23: ...nced and complete charge at all times without wasting any electricity 2 Over extended periods of time the power pack is checked every 72 hours to ensure that the cells are balanced and that the power...

Страница 24: ...threadlocker D Shock mount bolts 13 15 N m Use grease E Rear axle bolts 18 20 N m Use grease F Motor mount bolt 30 N m Use anti sieze paste G Rear Caliper mount bolts 11 13 N m Use grease H Triple cla...

Страница 25: ...eel Bearings Check bearings for smooth operation Replace if necessary 7 Swingarm Pivot Bearings Check bearing assemblies for looseness Moderately repack with lithium grease Ensure main pivot bolt is p...

Страница 26: ...s preload and rebound damping adjustments Preload is altered by loosening the lock ring on the spring and turning the adjuster to either compress or decompress the spring Rebound damping is adjusted u...

Страница 27: ...or mounting bolts Do not over tighten the motor mounting bolts since the motor adapter plate is aluminum A worn chain will damage the sprockets so it is advisable to replace the chain before it is too...

Страница 28: ...2009 ZERO S DS OWNER S MANUAL 26...

Страница 29: ...pounds 36 3 kg Total weight 270 pounds 122 5 kg ECONOMY Typical cost to recharge Less than 01 per mile or kilometer MOTOR Type Brushed permanent magnetic electric Top Speed 55 mph 90 kph POWER SYSTEM...

Страница 30: ...patterns and their meanings SAFETY INTERLOCKS The BMS can disable the bike s throttle control if the pack is fully discharged or in case of other errors The BMS can also disable charging under certain...

Страница 31: ...ycle and your commute Once you become familiar with the range versus performance of your motorcycle then you can adjust your driving characteristics if you so desire This applies mainly to drivers wit...

Страница 32: ...l warming and energy security problems facing the country and the world EMISSIONS The Zero S and DS do not require any gasoline and as a result do not get miles per gallon For the sake of emissions co...

Страница 33: ...d be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold 2 Read and understand the owner s manual and all product warnings before opera...

Страница 34: ...2009 ZERO S DS OWNER S MANUAL 32...

Страница 35: ...power for 15 seconds 3 Charge Timeout caused by battery pack not reaching required voltage Charger output was reduced due to high temperatures Check connections Operate charger at a lower ambient temp...

Страница 36: ...tle You cannot ride the bike until the pack cools down Place the bike in a cool well ventilated location and wait a few minutes before riding again If the Too Hot error beep still sounds after the pac...

Страница 37: ...ed off or b The throttle control is disabled for any reason which includes the pack being completely empty The Low Pack warning beep will sound when you can still ride the bike but the remaining range...

Страница 38: ...BMS can send a signal to the main bike controller requesting that the throttle control on the bike be disabled When the throttle control is disabled the drivetrain will not deliver power to the rear...

Страница 39: ...is also reported by an error beep pattern after BMS self test when the bike is turned on See Understanding Beep Sequences page 34 for a description of the Too Hot error beep and the remedies PACK FULL...

Страница 40: ...result with a beep pattern Note that this sanity check and the resulting beep patterns is different from the key on self test The sanity test and the beeps happen immediately when the board is first...

Страница 41: ...up ON position page 12 item 5 Flip Kill Switch to the ON position page 16 item 1 Charger not working A C power missing Main power coupling not engaged Check A C outlet for power A C source check fuse...

Страница 42: ...2009 ZERO S DS OWNER S MANUAL 40...

Страница 43: ...s and electrical sub assemblies The second year of this limited warranty covers parts only for these same major components Should the EXTENDED WARRANTY be purchased the coverage level from the first y...

Страница 44: ...the above limitation or exclusion may not apply to you Zero Motorcycles Inc reserves the right to change or improve the design of any electric motorcycle product without assuming any obligation to mo...

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Страница 47: ...TES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU This warranty gives you specific legal rights and you also...

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