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1-7

Zero DS Technical Specifications

DIMENSIONS

Wheel Base

144.3 cm (56.8 in)

Seat Height
(Standard)

86.4 cm (34 in)

Low Seat Height
(Option)

81.3 cm (32 in)

Rake

22 degrees

Steering Angle

+35 degrees, -35 degrees

Trail

82.8 mm (3.26 in)

WEIGHT

Frame

8.16 kg (18 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

MOTOR

Type

Brushed permanent magnetic electric

Est. Top Speed

108 km/h (67 mph)

POWER SYSTEM

Type

Patent-pending lithium ion array

Capacity

4 kwh (58 V @ 70 Ah)

Range

Up to 80 km (50 miles)

Recharge Time

Less than 4 hours

Input

Standard 110 V AC or 220 V AC

Содержание S 2010

Страница 1: ......

Страница 2: ...ng 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 Important Labels 2 3 Power Pack Information Label 2 4 Throttle And Speed Control Label 2 5 Power Pack Labels 2 5 Power Pack Battery Fuse Label 2 6 Main Power Cut Off Label 2 6 Performance Specificat...

Страница 3: ...er 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 Operating 4 1 First Time Set Up 4 1 Uncrating Your Motorcycle 4 2 General Operation 4 4 Pre Ride Inspection 4 4 Key Switch Positions 4 5 Fork Lock 4 5 Main Power Cut Off 4 6 Power Pack 4 7 Operating Y...

Страница 4: ...torcycles 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 Purchaser s Responsibilities 7 7 Warranty Procedures 7 7 Transfer Of Ownership And Warranty 7 8 ...

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 motorcycle please remember to hand over this manual it is by law an important part of the vehicle If you have any questions concerning the operation or maintenance of your motorcycle please contact Zero...

Страница 7: ...erating 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 capabilities and the reliability of this motorcycle Disregarding them may render the warranty invalid Plug in Your Power Pack WARNING Proper care of the motorcycle s power pack is essential When not in use ...

Страница 8: ...dress 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 Center CSC you may need to provide this information ...

Страница 9: ...on 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 legal identifier for your motorcycle A VIN Label ...

Страница 10: ...ycle 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 Type Model Year Net Brake Horse Power ...

Страница 11: ...inless 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 POWER SYSTEM Type Patent pending lithium ion array Capacity 4 kwh 58 V 70 Ah Range Up to 80 km 50 miles Recharge Time Less than 4 hours Input Standard 110 V AC or 220 V AC DRIVETRAIN Transmission Clutch...

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 MOTOR Type Brushed permanent magnetic electric Est Top Speed 108 km h 67 mph POWER SYSTEM Type Patent pending lithium ion array Capacity 4 kwh 58 V 70 Ah Range Up to 80 km 50 miles Recharge Time Less ...

Страница 13: ...s 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 SUSPENSION BRAKES Front Suspension Travel 228 6 mm 9 in Rear Suspension Travel 203 2 mm 8 in Front Brakes 2 Piston Hydraulic Stainless Rotor Hand Actuated Rear Brakes 1 Piston Hydraulic Stainless Ro...

Страница 14: ...stics 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 aggressively and reach your destination with energy to spare An average rider can expect to achieve 64 km 40 miles of average range under normal use stop and go traffic with a maximum range of 97 km 60 miles o...

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 your Zero motorcycle have been checked and tested for safety and suitability Zero is unable to accept any liability whatsoever for parts and accessories which have not been approved Emissions Informat...

Страница 16: ...n 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 Place the ratchet straps around the frame or a solidly mounted part Soft straps must be used to prevent scratches or other damage A When the fork is released with no weight on the front tire the scre...

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: ...torcycle 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 other obstacles 7 Never use alcohol or mind altering drugs before operating an electric motorcycle 8 Persons unwilling or unable to take responsibility for their actions should not use this motorcycle ...

Страница 21: ...se 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 possible to unintentionally twist the throttle resulting in unexpected acceleration 3 Use the rear brake when you are stopped on an incline Do not hold the motorcycle using partial throttle or damag...

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 event of a malfunction the firm application of the rear brake will help keep the motorcycle from running away 7 The power pack does not require or tolerate deep discharging To get the most power pack l...

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: ...ability 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 air induction system is a compact forced air delivery system It consists of a powerful low maintenance fan motor A located under the rear fender The fan is connected to the motor by means of a flexible...

Страница 27: ...A 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 the rider and also helps prevent the motor from heating further As the motor cools again full power will be restored WARNING A System Error Indicator The Zero S DS is equipped with a motor brush carrie...

Страница 28: ...ll 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 reached You will not reach this stage without knowingly ignoring stage 1 and stage 2 A ten second sequence of close intervals of rapid pulsing will be visible on the warning indicator and then power ...

Страница 29: ...2 10 NOTES ...

Страница 30: ...20 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 Handlebar Control H Key Switch I Right Handlebar Control ...

Страница 31: ...d 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 Brake Lever The front brake lever controls the front brake when the lever is squeezed When braking the throttle should be in the neutral returned position The stop lamp will illuminate when the brake ...

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 Kickstand ...

Страница 33: ...Replacement 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 Charger on pages 4 9 and 4 10 H Kickstand Switch This switch is a safety feature that prevents motor operation when the kickstand is down If the kickstand were down when riding it could contact the ground ...

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: ...ent 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 will illuminate when the rear brake pedal is applied D Power Pack For description and operation see page 4 7 ...

Страница 36: ...I 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 Odometer K Odometer Instrument Panel ...

Страница 37: ...amp 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 hour km h or miles per hour mph D Main Power Indicator The main power indicator is OFF any time the key is in the ON position If the main power indicator is flashing the system has detected a fault F...

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: ...s 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 signal switch is ON the corresponding turn signal indicator on the instrument panel will illuminate Always signal your turns and other maneuvers as required by law Unlike an automobile the turn signals m...

Страница 40: ...he 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 motor and start the motorcycle in a forward direction Release the throttle and it will snap back to the neutral returned position B de energizing the motor ...

Страница 41: ...3 12 NOTES ...

Страница 42: ...specifications 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 brake lines Verify that the brakes function properly 6 Make sure the motorcycle key switch is OFF then twist the throttle to make sure it s rotation is smooth and returns correctly 7 Inspect bolts and ma...

Страница 43: ...he 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 shipping crate may differ slightly than shown below are general guidelines for uncrating the motorcycle 1 Remove the crate clamps A and remove the crate end panel B 2 With the aid of an assistant lift ...

Страница 44: ...ycle 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 off of the crate base 7 Secure and adjust the mirrors ...

Страница 45: ...brake 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 switch in the OFF position apply the throttle and release to verify that the throttle is smooth and returns correctly Tires Check both tires for condition and tread depth Check cold tire pressure frequent...

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 lock when parked will prevent unauthorized use and help prevent theft The fork lock key is different from the key switch key To Lock 1 Turn the fork all the way to the left 2 Insert the key A into the l...

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 the charger When charging or operating the switch must be slid up to the ON connected position 2 Remove the key Never ride with the key in the fork lock This switch must be in the OFF position when tr...

Страница 48: ...ll 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 charged within 24 hours if fully discharged and charged within 60 days if stored fully charged Zero recommends you plug in your Zero motorcycle after 7 days even if fully charged Please leave your Z...

Страница 49: ...his 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 optimizes the charging process to provide the highest performance longest range and longest life for the power pack The BMS also monitors the battery for a host of predefined conditions and then tak...

Страница 50: ...orner 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 always sound a beep signal when the test finishes The beep pattern reports the self test result When the key switch is ON and the power pack is nearly empty The BMS will continuously sound a warning ...

Страница 51: ...hat 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 power pack is charged check the energy gauge prior to riding If the power pack terminates the charge before the charger reaches the state above then the charger will continue to cycle and will top off t...

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 connected Flashing 80 Charge Amber 100 Charge Green AC On Amber Fault Red Solid Charging complete Charger in Maintenance Mode Flashing Absorption phase complete In Finish phase Solid AC Power good Flash...

Страница 53: ...when 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 OFF position 3 Plug the supplied power cord A into the on board charger connector Always keep the power cord with the motorcycle WARNING Charge the Zero power pack with the Zero charger It is possible ...

Страница 54: ...d 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 recharged immediately Your power pack will continue to beep even when it s charging until it has recovered its Emergency Energy Reserve 8 When the power pack is fully charged disconnect the power co...

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 on page 4 12 2 Turn the key switch to the ON position 4 With the kickstand up release the brake and twist the throttle toward you counter clockwise to increase speed When the throttle is twisted away...

Страница 56: ...ng 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 top of both fork legs Next to it will be the writing S F meaning Slow and Fast The adjuster has 18 stages of adjustment This determines how quickly the fork returns to its extended position after bei...

Страница 57: ...on 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 that is set too slow will pack up feel harsh over consecutive bumps while compression that is set too fast will cause the fork to bottom out harshly If the fork is bottoming out turn the adjuster on...

Страница 58: ...rrect 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 wheel off the ground 2 Measure vertically from the rear axle to the rear fender Mark this spot as it will be used for other measurements 3 Record this measurement this will be measurement M1 M1 4 Remove...

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 step 2 9 Record this measurement this will be measurement M2 10 Subtract the second measurement M2 from the first measurement M1 ...

Страница 60: ...g 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 adjustment Printed on the knob is S F meaning Slow and Fast The rebound adjuster knob controls how slow or fast the shock returns to its extended position after being compressed Turning the knob cloc...

Страница 61: ...4 20 NOTES ...

Страница 62: ...are 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 country federal state and local laws governing the operations of an electric motorcycle 5 Always wear a DOT approved helmet goggles appropriate boots and all other appropriate safety equipment when opera...

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 swingarm 105 110 N m 77 81 lb ft Use LOCTITE 270TM I Rear axle pinch bolts 11 13 N m 8 10 lb ft Use LOCTITE 242 J Rear axle end bolts 18 20 N m 13 15 lb ft Use LOCTITE 242 K Triple tree pinch bolts 13 ...

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: ...ve 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 access to and troubleshoot the power pack 4 Dispose of the power pack according to your state and local laws It is encouraged that the power pack be recycled rather than disposed of in landfills Locate ...

Страница 67: ...s 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 sealed container Front Brake A B C Inspect the level of the front brake fluid through the sight glass B If the fluid level is visibly below the low level indicator C brake fluid must be added Clean ...

Страница 68: ...ew 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 schedule See Maintenance Schedule on pages 5 20 through 5 22 Visually inspect the brakes by looking at the remaining brake pad material through the sides of the brake caliper Replace the brake pads if...

Страница 69: ...k 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 cracked wheels Impact marks on the wheels Suspension Front For maintenance see Maintenance Schedule on pages 5 20 through 5 22 To adjust the fork see Suspension Adjustment on page 4 15 For maintenance se...

Страница 70: ...ions 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 loss of motorcycle control causing personal injury and possible death Tire pressure should be checked and adjusted before each ride Tire pressure is checked using an accurate gauge when the tires ar...

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 stand or lift so the rear wheel is free to spin While turning the wheel by HAND spray the inside of your entire chain with a good coating of chain cleaner and let it sit for a few minutes 3 Using a br...

Страница 72: ...nd 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 from the key switch 2 Using a ruler grasp the chain halfway between the front and rear sprockets 3 The chain should move 16 mm 63 in in either direction so 32 mm 1 25 in of total free play 4 If the cha...

Страница 73: ...nt 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 adjuster bolt D a 1 4 turn at a time until the chain free play is within specification 6 Tighten all motor mount Allen bolts See Bolt Torque Table on page 5 2 3 Loosen both front motor mount Allen bolts B ...

Страница 74: ...will 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 motorcycle perpendicular to the ground and the operator sitting on the motorcycle verify the beam alignment To adjust the headlamp horizontally turn screw B until the correct beam alignment is achieved To...

Страница 75: ...p 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 halogen bulb Handle the bulb only by its base Avoid touching the glass A 2 Disconnect the main headlamp connector A 1 Remove the two screws A from the headlamp housing ...

Страница 76: ...shing 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 fingers or contaminates will shorten the life of the bulb Thoroughly clean any fingerprints or contaminates from the bulb using a clean cloth moistened with alcohol ...

Страница 77: ...eplacement 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 turn clockwise until it stops 4 Install the lens and screw tighten the screw Do not over tighten the screw otherwise the lens may break A Stop Tail Lamp Bulb Replacement 1 Remove the stop tail lamp le...

Страница 78: ...p 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 it stops 4 Install the stop tail lamp lens and screws tighten the screws Do not over tighten the screws otherwise the lens may break A ...

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 dirt do not leave the cleaner on the affected area any longer than instructed Also thoroughly rinse the area off with water immediately dry it and then apply a corrosion protection spray WARNING Impro...

Страница 80: ...ging 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 in a cool area Storing your motorcycle in a hot area will cause your power pack s life to be shortened 4 If for some reason your motorcycle was not plugged in for several days you should always char...

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 Replace brake pads if necessary 9 9 9 9 9 9 9 2 Rear Brake Check operation and for fluid leakage Replace brake pads if necessary 9 9 9 9 9 9 9 3 Brake Hoses Check for cracks or damage Replace if necessary...

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 Replace worn chain 9 Every 1 000 km 600 mi and after washing the motorcycle or riding in the rain 9 Steering Bearings Check bearing assembly for looseness Moderately repack with lithium grease every...

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 and for oil leakage Replace if necessary 9 9 9 9 9 9 14 Throttle Grip Check operation and free play 9 9 9 9 9 9 15 Rear Brake Pedal Pivot Shaft Apply lithium grease all purpose grease lightly 9 9 9 9 9...

Страница 84: ...otorcycle 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 cir...

Страница 85: ...ity 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 label B see Power Pack Labels on page 2 5 Fuse Center Location The 12 volt fuse center is located behind the front fork The fuse center has a protective cover that must first be removed to gain access ...

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 5 2 t r o P e g r a h C 4 5 2 t u p t u O r e t r e v n o C C D ...

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 chart below ...

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 call Zero Motorcycles Customer Service Power Pack And Charger If a fault occurs during charging count the number of times the red light A flashes on the charger in between pauses See the table on pa...

Страница 91: ...arger output was reduced due to high temperatures Check connections Operate charger at a lower ambient temperature 4 ÆÆÆÆ Power pack could not be trickle charged up to minimum voltage Contact CSC 5 ÆÆÆÆÆ Over Temperature Charger shut down due to high internal temperature Ensure sufficient cooling air flow and reset charger interrupt AC power for 15 seconds 6 ÆÆÆÆÆÆ Charger Internal Fault Reset cha...

Страница 92: ...ion 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 Key on Power Pack Empty Charge power pack before riding 4 Long Key on Too Hot Let power pack cool down 5 Long Key on Power Pack Unbalanced Leave on charger for 72 hours 4 Short 1 Long Riding Low Powe...

Страница 93: ...dividual 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 Unbalanced error beep and disable the throttle You cannot ride the motorcycle until the problem is resolved The solution to the problem is to plug in the charger and allow the power pack to charge for...

Страница 94: ...e 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 never power cycles A typical BMS is powered on only once in the factory when it is connected to the wiring harness inside the power pack It may quite possibly operate continuously for years without ever ...

Страница 95: ...power 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 certain serious internal problems even if the power pack is connected to a charger and plugged in to AC power The power pack cannot be charged until the problem is resolved The Throttle Disable Interlo...

Страница 96: ...ger 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 can send a signal to the charger requesting that charging terminates immediately When the charger is disabled the indicator lights on the charger will show that charging has stopped There are two cond...

Страница 97: ...s 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 of the power pack If the charger fails to terminate a charging cycle when the power pack is full the BMS will terminate charging itself to prevent damage Instrument Panel Main Power Indicator If a f...

Страница 98: ... 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 Æ Æ Æ Æ Æ 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 r u t a r e p m e t r o t o m d a B r o s n e s e r u t a r e p m e t e c a l p e R s n o i t c e n n o c s n o i t c e n n o c k c e h c r o d n a 6 Æ Æ Æ Æ Æ Æ d e t c e t e d e g a t l o v w o L s n o i...

Страница 99: ...t pre charge motor controller Contact CSC 10 ÆÆÆÆÆ ÆÆÆÆÆ Current sensor error Problem with current sensor or connection Contact CSC 11 ÆÆÆÆÆ ÆÆÆÆÆÆ Board temperature sensor error Problem sensing temperature of board Contact CSC 12 ÆÆÆÆÆÆ ÆÆÆÆÆÆ Unknown system error Contact Zero or CSC ...

Страница 100: ...he 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 to the UP ON position Handlebars wobbly shimmy Incorrect tire pressure Inflate to correct tire pressure See page 5 9 Deformed front tire Replace balance front tire with the same tire supplied from the...

Страница 101: ...6 12 NOTES ...

Страница 102: ...answer 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 provided on page 1 3 to record this information Zero Motorcycles 1 Victor Square Scotts Valley California 95066 USA Phone 888 786 9376 Monday Friday 8am to 5pm Pacific Time E mail support zeromotorcyc...

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 Discount Controller Power Pack 20 Discount Fork Rear Shock Frame Swingarm Brake Assemblies Electrical Wheels ...

Страница 104: ...of 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 rotors fork seals grips foot pegs the seat or any other parts subject to normal wear and tear Wheels are excluded from this standard warranty on off road bikes once they have been ridden This standard wa...

Страница 105: ...cluded 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 warranty excludes parts and components damaged by use or operation under abnormal circumstances or contrary to the requirements described in the owner s manual or damaged by improper use or accidents Ra...

Страница 106: ...n 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 this no fault coverage Zero Motorcycles Inc assumes no liability for any misuse or improper operation of Zero motorcycles Under this limited warranty and liability agreement Zero Motorcycles Inc shall...

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 allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you Zero Motorcycles Inc reserves the right to change or improve the desi...

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 other appropriate safety equipment when operating a motorcycle Warranty Procedures Warranty services may be obtained by contacting Zero Motorcycles Inc at 888 786 9376 or via e mail at support zerom...

Страница 109: ...p 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 contact the Zero Motorcycles Customer Service department for assistance Phone 888 786 9376 Monday Friday 8am to 5pm Pacific Time E mail support zeromotorcycles com 24 hours http www zeromotorcycles com ow...

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 Rear Brake 5 7 Braking 4 14 C Chain 5 10 Checking The Drive Chain 5 11 Cleaning The Drive Chain 5 10 Drive Chain Adjustment Procedure 5 12 Lubricating The Drive Chain 5 11 Charger LED Indicators 4 11...

Страница 113: ...7 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 Headlamp Alignment 5 13 Headlamp Bulb Replacement 5 14 Maintenance Schedule 5 20 Motor 5 6 Parking And Long Term Storage 5 19 Running Lamp Bulb Replacement 5 17 Stop Tail Lamp Bulb Replacement 5 16 Suspensi...

Страница 114: ...1 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 Power Pack Labels 2 5 Throttle And Speed Control Label 2 5 Low Power Pack Warning 6 4 Lubricating The Drive Chain 5 11 M Main Power Cut Off 4 6 Main Power Cut Off Label 2 6 Maintaining Your Motorcyc...

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 Power Pack Full High Power Pack Voltage 6 8 Power Pack Information Label 2 4 Pre Ride Inspection 4 4 Power Pack 4 4 Proper Use 7 6 Public Charging Stations 1 10 Purchaser s Responsibilities 7 7 R Rea...

Страница 116: ...ontrol 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 Motorcycle 4 2 Understanding Beep Sequences 6 3 V Vehicle Identification Number VIN 1 4 VIN Break Down 1 4 VIN Location 1 4 Vehicle Range 1 9 W Warranty 7 3 Disclaimers 7 5 No Fault Warranty 7 5 Standard W...

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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