Zero Motorcycles ZERO SR Owner's Manual
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Zero Motorcycles ZERO SR Owner's Manual

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ZERO S
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ZERO DS
2015 OWNER'S MANUAL

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Summary of Contents for Zero Motorcycles ZERO SR

  • Page 1 ™ ZERO S ZERO SR ™ ™ ZERO DS 2015 OWNER’S MANUAL...

  • Page 3: Table Of Contents

    Table Of Contents Introduction ............ 1.1 Location of Important Labels ........2.3 Location of Important Labels ........2.3 Introduction..............1.1 An Important Message To You From Zero Controls and Components ......3.1 Motorcycles ............... 1.1 Controls and Components.......... 3.1 About This Manual ............ 1.1 Motorcycle Controls ..........
  • Page 4 How Do You Obtain Service Under This Limited Cleaning..............5.21 Warranty? ..............7.6 Parking and Long Term Storage......5.22 Transfer Of Ownership And Warranty....... 7.7 Zero Motorcycles Accessories .........5.22 Fuses ...............5.22 Customer Information ..........7.8 Service Record ............5.26 Customer Assistance ..........7.8 Reporting Safety Defects ..........

  • Page 5: Introduction

    Congratulations and thank you for purchasing the 2015 charger, and regenerative braking): Zero S, Zero SR, or Zero DS (S/SR/DS) electric • Zero S: Street motorcycle; we welcome you to the community of Zero Motorcycles riders.

  • Page 6: Useful Information For Safe Riding

    Introduction Useful Information For Safe Riding Plug in Your Z-Force Power Pack™ ® This manual contains the word WARNING to indicate CAUTION: Proper care of the motorcycle’s power pack is something that could hurt you or others. It also contains essential! When not in use, the power pack should be left the word CAUTION to indicate things that could damage on the charger even if fully charged.

  • Page 7: Identification Numbers

    Identification Numbers Owner Information Identification Numbers Record information pertaining to your motorcycle here. When contacting your dealer, you may need to provide this information.

  • Page 8: Power Pack Serial Number

    Identification Numbers Power Pack Serial Number Vehicle Identification Number (VIN) The Power Pack serial number is located on the upper The VIN is a 17-digit number stamped on the head tube of front left of the power pack. the frame. Do not alter or remove this number as it is the legal identifier for your motorcycle.
  • Page 9 Identification Numbers VIN Break Down The following breakdown of the VIN will help you understand the significance of each digit or character in case you need to reference it when contacting Zero or ordering parts.

  • Page 10: General Information

    General Information Technical Specifications General Information • ZF9.4: 3.9 hours (100% charged) / Supplemental Charger Quick Charge Time (with 3.4 hours (95% charged) Zero S one accessory charger) • ZF12.5: 5.0 hours (100% charged) / The Zero S specifications below apply to both the S ZF9.4 4.5 hours (95% charged) and ZF12.5 models (unless otherwise specified).
  • Page 11 General Information DRIVETRAIN DIMENSION Transmission Clutchless Direct Drive Wheel Base 57.0 in (1,448 mm) Final Drive 132T/28T, Poly Chain® GT® Carbon™ belt Seat Height 31.8 in (807 mm) CHASSIS/SUSPENSION/BRAKES Rake 24.7 degrees Front Suspension Travel 6.25 in (159 mm) Trail 3.2 in (80 mm) Rear Suspension Travel 6.35 in (161 mm)
  • Page 12 General Information Zero SR RANGE • ZF12.5: 151 miles (243 km) City (EPA UDDS) MOTOR Type Z-Force® 75-7 passively air-cooled, • ZF12.5: 94 miles (151 km) Highway, 55 mph high-efficiency, radial flux permanent hi-temp (88 km/h) magnet, brushless motor • ZF12.5: 115 miles (185 km) >Combined...
  • Page 13 General Information DRIVETRAIN DIMENSION Transmission Clutchless Direct Drive Wheel Base 56.8 in (1,443 mm) Final Drive 132T/30T, Poly Chain® GT® Carbon™ belt Seat Height 31.8 in (807 mm) CHASSIS/SUSPENSION/BRAKES Rake 24.7 degrees Front Suspension Travel 6.25 in (159 mm) Trail 3.2 in (80 mm) Rear Suspension Travel 6.35 in (161 mm)
  • Page 14 General Information Zero DS • ZF9.4: 1.9 hours (100% charged) / Supplemental Charger Quick Charge Time (with 1.4 hours (95% charged) MOTOR max accessory chargers) • ZF12.5: 2.4 hours (100% charged) / Type Z-Force® 75-7 passively air-cooled, 1.9 hours (95% charged) high-efficiency, radial flux permanent Input Universal 100 - 240 V AC...
  • Page 15 General Information CHASSIS/SUSPENSION/BRAKES WEIGHT Front Suspension Travel 7 in (178 mm) Frame 23 lbs (10.4 kg) • ZF9.4: 381 lb (173 kg) Rear Suspension Travel 7.03 in (179 mm) Curb Weight • ZF12.5: 413 lb (187 kg) Front Brakes Bosch Gen 9 ABS, J-Juan asymmetric dual piston floating caliper, 320 mm OD x 5 mm •...

  • Page 16: Vehicle Range

    General Information Vehicle Range Reported motorcycle range values are measured using two different types of industry standard test procedures: The range of an electric vehicle is defined as the distance 1. “City (EPA UDDS)”: This test procedure uses a duty the vehicle travels on a single full charge of the power cycle known as the “Universal Dynamometer Driving pack.

  • Page 17: Public Charging Stations

    General Information Public Charging Stations Maximizing Your Range There are more public charging stations coming online Range varies in electric motorcycles similarly to how it every day and there may be some in your area. You can varies in gas motorcycles. However, the big difference charge from a Level 1 public charging station with your between electric and gas is that energy consumption is supplied charge cord or from a Level 2 charging station...
  • Page 18 General Information 1.14...
  • Page 19 General Information 1.15...

  • Page 20: Emissions Information

    General Information Emissions Information The Zero S/SR/DS electric motorcycle is a true freeway capable zero emissions vehicle under California Air Resources Board (CARB), U.S. Federal (EPA), and European Union standards. It uses no gasoline or other liquid fuel. It has no tailpipe and therefore no tailpipe emissions.

  • Page 21: Transporting

    General Information Transporting It is recommended that the motorcycle be tied-down using ratchet straps while it is being transported. Place the ratchet straps around a frame contact point. Soft straps must be used to prevent scratches or other damage. Use two ratchet straps in the front and two in the rear. The tie down straps should be at a 45°...
  • Page 22 Notes 1.18...

  • Page 23: General Safety Precautions

    General Safety Precautions • Prior to each use the rider must check everything in the Safety Information General Safety Precautions General Safety Precautions “every ride” column of the maintenance schedule on • This is a performance motorcycle and should be page 5.2, and the charge level of the power pack as treated with extreme caution.

  • Page 24: Important Operating Information

    • Failure to follow power pack storage and charging • Turn the motor stop switch OFF when backing up or instructions as described in this Zero Motorcycles pushing the motorcycle while dismounted. Owner’s Manual may void the warranty of your Zero •...

  • Page 25: Location Of Important Labels

    Location of Important Labels Location of Important Labels Location of Important Labels The vehicle could contain the following information for both North American and European models: A. VECI (Vehicle Emission Control Information) label C. VIN label (North America) - certification label shown B.
  • Page 26 Location of Important Labels High Voltage Warning Label Affixed to battery...

  • Page 27: Controls And Components

    Controls and Components Controls and Components Controls and Components THIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 28: Motorcycle Controls

    Controls and Components Motorcycle Controls...
  • Page 29 Controls and Components A. Mirrors G. Front Brake Lever This motorcycle is equipped with convex mirrors. A For description and operation see “Handlebar convex mirror has a curved surface. Convex mirrors Controls”, on page 3-16. offer a greater field of view than a similar flat mirror. H.

  • Page 30: Left Side View

    Controls and Components Left Side View...
  • Page 31 Controls and Components A. Headlight F. Kickstand The kickstand swings out from the side and supports • For headlight operation, see “Handlebar Controls”, on the motorcycle when parked. The key switch should page 3-16. be in the OFF position when parked. •...

  • Page 32: Right Side View

    Controls and Components Right Side View...
  • Page 33 Controls and Components A. Rear Break Fluid Reservoir See “Rear Brake Fluid Reservoir”, on page 5-10. B. Auxiliary Power Pack Charging Connection For description and operation see “Quick Charging (Off Board Accessory Charger)”, on page 4-10. The auxiliary connector is located above the motor. C.

  • Page 34: Dash Overview

    Controls and Components Dash Overview...
  • Page 35 Controls and Components A. Adjust Button (ADJ) the rider using the performance level mode button located on the right handlebar control assembly. See See “Dash Settings”, on page 3-12. “Performance Level Mode Button”, on page 3-19. B. Select Button (SEL) I.

  • Page 36: Warning Indicator Lights

    Controls and Components Warning Indicator Lights 3.10...
  • Page 37 Controls and Components A. Left Indicator Turn Signal E. ABS (Anti-Lock Brake System) Indicator An arrow on the lower dash flashes green The indicator illuminates when the key is in the same direction as selected by the in the ON position. The light will extinguish turn signal switch.

  • Page 38: Dash Settings

    Controls and Components Dash Settings Displays A&B Display A The displays on the dash can be customized to your To select Display A with the dash in its normal operating personal preferences by using the ADJ (Adjust) and SEL mode, momentarily press the SEL button once. Press the (Select) buttons.
  • Page 39 Controls and Components Display B Setting the Clock To select Display B with the dash in its normal operating mode, momentarily press the SEL button twice. Press the ADJ button to toggle through the following fields: • Trip 2 Odometer - Displays individual trip mileage and is reset by pressing and holding the ADJ button for 2 seconds.
  • Page 40 Controls and Components Unit Display - Speed Unit Display - Temperature To change the units that speed is shown in: To change the units that the temperature display is shown: 1. With the dash in its normal operating mode press and 1.

  • Page 41: Smartphone Application

    Controls and Components Smartphone Application Bluetooth Pairing ® You can download a smartphone application that lets you The following steps must be taken to properly pair a perform the following tasks related to your motorcycle: Bluetooth®-equipped smartphone with your motorcycle. •...

  • Page 42: Handlebar Controls

    Controls and Components Handlebar Controls 3.16...
  • Page 43 Controls and Components A. Headlight High/Low Beam Switch back to the closed position (B), de-energizing the motor, and regenerative braking begins. When the switch is pushed, the headlight changes from low beam to high beam. It When the motorcycle is moving and the throttle stays in the selected position until it is control is in the fully closed position, the regenerative switched back.
  • Page 44 Controls and Components F. Motor Stop Switch I. Turn Signal Switch When the top of the switch (A) is pressed, it cuts off When the turn signal switch is pushed in power to the motor controller. The motor controller the left or right position, the corresponding remains in this state until the bottom portion of the front and rear turn signals flash.

  • Page 45: Performance Level Mode Button

    Controls and Components Performance Level Mode Button The SPORT selection causes the motorcycle to accelerate at a significantly faster rate. This position is recommended for advanced riders. The CUSTOM selection has customizable performance settings by using the smartphone application (refer to “Smartphone Application”, on page 3-15).

  • Page 46: Front Brake Lever Adjuster

    Controls and Components Front Brake Lever Adjuster The position of the front brake lever can be adjusted by turning the adjustment knob (A) located on the master cylinder assembly. Turning the knob clockwise or counter-clockwise will adjust the distance between the lever and the throttle control.

  • Page 47: Tank Bag

    Controls and Components Tank Bag Power Tank (if equipped) Depending on specification, your Zero motorcycle may be Your Zero motorcycle may be equipped with a dealer- equipped with a tank bag for additional storage. You can installed optional equipment Power Tank in place of the remove the tank bag by pulling upwards on its sides.
  • Page 48 Notes 3.22...

  • Page 49: Starting And Operating

    Starting and Operating Starting and Operating Starting and Operating First Time Set-Up If your motorcycle was direct-shipped you will need to perform the following: 1. Remove the motorcycle from its shipping crate. See “Unpacking Your Zero Motorcycle”, on page 4.2. 2.

  • Page 50: Unpacking Your Zero Motorcycle

    Recycling crate base. Your Zero Motorcycles shipping crate and packaging materials were designed to be completely recycled. Please Outer Box Cover cut down and recycle all cardboard, plastic, and wood •...

  • Page 51: General Operation

    General Operation • Tires. Check both tires for condition and tread depth. General Operation General Operation Check cold tire pressure frequently. Check for damage This section describes several items you should examine and alignment. Maintain correct tire pressure as before operation. specified on page 5.13.

  • Page 52: Key Switch/Steering Lock Positions

    General Operation Key Switch/Steering Lock Positions Steering Lock Using the steering lock when parked prevents unauthorized use and helps prevent theft. To operate the steering lock: 1. Turn the handlebar all the way to the left. 2. Push the key down from the OFF position and turn the key counter-clockwise while still pushing it in.

  • Page 53: Power Pack

    General Operation OFF Position Power Pack This position is used to turn the motorcycle OFF, disabling The battery is located within the power pack and requires the electrical system. no special break in period. The Zero S/SR/DS power pack leverages proven battery ON Position cell chemistry, configuration, and enhanced reliability.
  • Page 54 General Operation The power pack must be charged within 24 hours if fully Add On Electrical Equipment discharged, and charged within 90 days if stored fully WARNING! Do not add electrical components to your charged. Zero recommends you plug in your Zero motorcycle unless approved by an authorized Zero motorcycle after 90 days, even if fully charged.
  • Page 55 General Operation When charging the motorcycle’s power pack, the charger can be left ON, even after the power pack is fully charged. There are two possible cases that can occur: • When connected to the charger, the power pack will receive a full charge.
  • Page 56 General Operation Charging the Power Pack To charge using the standard charger: WARNING! Charge the Zero power pack with the Zero 1. Plug the supplied power cord (A) into the onboard charger. charger connector. Always keep the power cord with the motorcycle.
  • Page 57 General Operation Note: AVOID connecting the Zero charger and another device to a single 120 V AC 15A/20A circuit, as it may become overloaded. Zero chargers draw as much as 12 amps from the 120 V AC circuit when charging. 3.
  • Page 58 General Operation Quick Charging (Off Board Accessory Charger) The “scalable” quick charging feature allows up to three supplemental accessory chargers (in addition to the existing integrated charger) to be connected to the motorcycle. Use of supplemental accessory chargers can reduce the charging time by up to 70%. Note: The time for charging the motorcycle using quick charging will vary with the number of chargers used.
  • Page 59 General Operation To charge using the Quick Charger 120 V AC or 240 V AC current. The voltage does not change the amount of time that the motorcycle takes to 1. Ensure that the key switch is in the OFF position. charge.
  • Page 60 General Operation • The charger and BMS are balancing. Quick Charger LED Indicators • The BMS is cutting off the charge because one or more cells have reached maximum voltage. C. 100% Charge The 100% Charge LED is a green indicator. If it is on solid, the charging is complete and the charger will enter maintenance mode.

  • Page 61: Operating Your Motorcycle

    General Operation Operating Your Motorcycle without locking the wheels. Your Zero motorcycle is a light- weight performance product and therefore practice is This section describes how to safely operate your strongly recommended to perfect safe emergency stops. motorcycle. Stopping Your Motorcycle Starting To stop your motorcycle: 1.
  • Page 62 Temperature Indicator strategy. To avoid encountering an enforced power reduction, you can choose to slow down a bit until the Zero Motorcycles has developed the most advanced indicator stops flashing. passively air-cooled electric powertrain for your Zero • Stage 2, if temperature continues to build, the indicator...

  • Page 63: Abs (Anti-Lock Brake System)

    General Operation ABS (Anti-lock Brake System) When the motorcycle is stationary and the key is turned to the ON position, it is normal for the ABS warning indicator WARNING! ABS prevents the wheels from locking, (A) on the dash to illuminate. The indicator will remain on therefore maximizing the effectiveness of the braking until the system detects the motorcycle’s speed exceeds system in emergencies and when riding on slippery...
  • Page 64 ABS system repaired. If 2. Wait for the dash display to turn off completely. there are no dealers in you area, call Zero Motorcycles 3. Turn the ignition key to the ON position. Customer Service.

  • Page 65: Front Suspension Adjustment

    General Operation Front Suspension Adjustment 3. Record this measurement (this is the measurement referred to as M1). A shock has two main actions: compression when the shock gets loaded, and rebound when the shock returns back to full length. Compression damping is the adjustment that determines how fast or slow the fork compresses.
  • Page 66 General Operation 9. Record this measurement (this is the measurement Example: referred to as M2). Measurement Operator Value 4.13 in (105 mm) 2.36 in (60 mm) 1.77 in (45 mm) The total sag is 1.77 in (45 mm). Refer to the chart below for the correct sag.
  • Page 67 General Operation Spring Preload Adjustment The spring preload is adjusted by turning the 19 mm anodized hex nut (B) located on top of the fork spring. Note: When adjusting preload, always start from the minimum setting and adjust each fork leg evenly. •...
  • Page 68 General Operation Compression Damping too slow will pack-up (feel harsh over consecutive bumps) while compression that is set too fast will cause the fork to The compression damping is adjusted by turning a screw bottom out harshly. If the fork is bottoming out, turn the on the bottom of each fork leg.

  • Page 69: Rear Shock Adjustment

    General Operation Rear Shock Adjustment Measuring Preload Obtaining the correct rear spring preload (sag) is critical for proper handling. The spring preload must be set to match the weight of the rider. The spring is preloaded for an 180 lb (82 kg) rider. This puts the rear tire 1/3 of the way through its vertical travel.
  • Page 70 General Operation Example: Measurement Operator Value 23.62 in (600 mm) 21.65 in (550 mm) 1.97 in (50 mm) The total sag is 1.97 in (50 mm). Refer to the chart below for the correct sag. If the sag is not correct, the spring preload should be adjusted.
  • Page 71 General Operation Spring Preload Adjustment Rebound Adjustment The rebound adjuster knob (A) is at the bottom of the 1. Clean any dirt or debris from the slots of the shock shock. It has 8 stages of adjustment. Printed on the knob is adjusting collar (A).
  • Page 72 General Operation Compression Adjustment The compression adjustment knob is at the top of the shock. It has 18 stages of adjustment. Printed on the knob is “H” meaning Hard (slower compression) and “S” meaning Soft (faster compression). Turn the adjuster clockwise for a harder ride (slower compression).
  • Page 73 General Operation Factory Supplied Rear Suspension Settings The following information will allow you to adjust the rear suspension back to the factory settings the motorcycle was originally supplied with. S & SR Models ADJUSTMENT SETTING Rear Shock Compression 12 clicks out from fully closed Rear Shock Rebound 8 clicks out from fully closed Rear Shock Spring Preload...
  • Page 74 Notes 4.26...

  • Page 75: Maintaining Your Motorcycle

    Turn Signal Light Bulb (amber) RY10W (10 watt) motorcycle as detailed in this owner’s manual. Brake/Tail Light Bulb LED (replace the entire unit) • Use only Zero approved parts and Zero Motorcycles Front Running Light Bulb W3W (3 watt) accessories. Brake Fluid DOT 4 •...

  • Page 76: Maintenance Schedule

    Maintaining Your Motorcycle Maintenance Schedule The scheduled maintenance must be performed in accordance with this chart to keep the Zero S/SR/DS motorcycle in top running condition. The initial maintenance is vitally important and must not be neglected. Where time and mileage are listed, follow the interval that occurs first.
  • Page 77 Maintaining Your Motorcycle ITEM ROUTINE EVERY INITIAL INITIAL ODOMETER MILEAGE READING RIDE 600 mi 4K mi 8K mi 12K mi 16K mi 20K mi (1K km) (7K km) (13K km) (19K km) (25K km) (31K km) 1 month 6 months 12 months 18 months 24 months...
  • Page 78 Maintaining Your Motorcycle ITEM ROUTINE EVERY INITIAL INITIAL ODOMETER MILEAGE READING RIDE 600 mi 4K mi 8K mi 12K mi 16K mi 20K mi (1K km) (7K km) (13K km) (19K km) (25K km) (31K km) 1 month 6 months 12 months 18 months 24 months...

  • Page 79: Component Fasteners

    Maintaining Your Motorcycle Component Fasteners Periodically check and tighten the following fasteners on your motorcycle. Torque Table LOCATION ITEM TORQUE NOTES Headlight bolts 8 lb ft (11 Nm) Use LOCTITE® 242® (or equivalent) Handlebar clamp mount bolts 19 lb ft (26 Nm) Rear shock mount bolts 40 lb ft (54 Nm) Seat retaining bolts...
  • Page 80 Maintaining Your Motorcycle Left Side of Motorcycle Refer to Torque table on page 5.5.
  • Page 81 Maintaining Your Motorcycle Right Side of Motorcycle Refer to Torque table on page 5.5.

  • Page 82: Power Pack

    Power Pack Power Pack Power Pack CAUTION: You must leave your motorcycle on the charger if you expect it to sit in storage or unused for over 90 days. The power pack must be charged within 24 hours if fully discharged, and charged within 90 days if stored fully charged.

  • Page 83: General Maintenance

    General Maintenance Brakes Front Brake Fluid Reservoir General Maintenance Inspect the level of the front This section describes how to maintain the brake system brake fluid, visible through the of your Zero S/SR/DS motorcycle. It covers the ABS reservoir (C). If the fluid level (Anti-lock Brake System), brake pad examples (specific is visibly below the MIN level brake pads for front and rear are shown), and maintaining...
  • Page 84 General Maintenance Rear Brake Fluid Reservoir Clean any dirt or debris from the cap and reservoir opening (A) before opening the reservoir. The reservoir is located inboard on the frame behind the heel guard. Note: The motorcycle should be in an upright position prior to checking fluid level.
  • Page 85 General Maintenance Brake Pad Inspection Replace the brake pads if either pad’s thickness is 0.053 in (1.35 mm) or less. If the brake pads (A) are worn, replace The brake pads must be inspected when specified in the both brake pads immediately. maintenance schedule, see page 5.2.

  • Page 86: Suspension

    General Maintenance Brake Pad Replacement Suspension Bedding in new brake pads and/or new brake discs is Front recommended to ensure proper brake performance and • For maintenance, see Maintenance Schedule on maximize brake life. Proper bedding improves brake page 5.2. pedal/lever feel and reduces or eliminates brake squeal.

  • Page 87: Wheels And Tires

    General Maintenance Wheels And Tires Tire Inflation Inspect both wheels for the following: WARNING! Under-inflation is a common cause of tire failure and may result in severe tire cracking, tread • Bent or cracked rims separation, “blowout,” or unexpected loss of motorcycle •...

  • Page 88: Drive Belt

    General Maintenance Drive Belt Checking Drive Belt Tension Proper belt tension is essential for optimum operation of The drive belt provides low maintenance and quiet the drive system. operation with minimal stretch. Keep dirt, grease, oil, and Lack of belt tension can lead to “ratcheting.” The teeth of debris off the belt and sprockets.The drive belt tension the belt slide over the teeth of the rear sprocket.
  • Page 89 General Maintenance Drive Belt Adjustment Procedure Note: Adjust both sides (left and right) equally. 1. Remove key from the key switch. 2. Loosen the rear axle nut (A). 3. Loosen the (left and right) 13 mm jam nuts (C). 4. Turn the (left and right) 13 mm adjustment bolts (B) 1/4 turn at a time until the belt adjustment is within specification.

  • Page 90: Headlight Alignment

    General Maintenance Headlight Alignment The headlight should be checked for correct alignment periodically. It must be aligned any time the suspension sag is adjusted because this affects the headlight alignment. Before the headlight can be aligned, the suspension sag and tire pressure must be correctly adjusted.
  • Page 91 General Maintenance Headlight Bulb Replacement To replace the bulb: WARNING! Halogen bulbs contain gas under pressure. 1. Working from behind the headlight, disconnect the Handling a bulb improperly could cause it to shatter into headlight bulb connector (A) and rubber cover (B). flying glass fragments, which could result in serious injury.
  • Page 92 General Maintenance 2. Remove the headlight bulb retainer (A) by turning it 4. Install the headlight bulb into the lens. counter-clockwise. 5. Install the headlight bulb retainer and turn it clockwise until it locks into position. 6. Install the headlight bulb rubber cover. 7.

  • Page 93: Turn Signal Light Bulb Replacement

    General Maintenance Turn Signal Light Bulb Replacement Brake/Tail LED Replacement 1. Remove the turn signal lens screw (A) and remove the The brake/tail LED (A) is not serviceable. Please contact lens. your Zero Motorcycle dealer for replacement. 2. Push in on the bulb, turn the bulb counterclockwise, and then pull the bulb out.

  • Page 94: Running Light Bulb Replacement

    General Maintenance Running Light Bulb Replacement 1. Working from behind the headlight, remove the bulb socket (A) from the headlight by squeezing the metal clip. 2. Pull the old bulb straight out from the socket. 3. Push the new bulb into the socket, and push the socket into the headlight.

  • Page 95: Cleaning

    General Maintenance Cleaning 1. Gently wash your motorcycle with a sponge or a clean soft cloth, mild detergent, and plenty of water. CAUTION: Improper cleaning can damage electrical 2. Use care when cleaning the plastic parts (dash, components, cowlings, panels, and other plastic parts. Do fenders, and side panels), which can scratch easier not use high pressure water or steam cleaners;...

  • Page 96: Parking And Long Term Storage

    A full line of parts, accessories, and apparel can be found checked every 72 hours to ensure that the cells are on the Zero Motorcycles website. balanced and that the power pack is full. • To prolong the life of your power pack you should store Fuses your motorcycle in a cool area.
  • Page 97 General Maintenance 12 Volt Fuse Center 3. Squeeze the tabs (A) on the fuse center to remove the cover. The 12 volt fuse center is located underneath the seat. 4. Replace the fuse(s). The 12-volt fuse values are listed below: The fuse center (see arrow) has a protective cover that FUSE RATING...
  • Page 98 General Maintenance ABS 12 Volt Fuse 3. Gently pull the tab (A) away from the red cap to release the fuse holder and pull upwards. The ABS 12 volt fuse is located underneath the seat. 4. Replace the fuse. The 12-volt fuse value is listed below: The ABS fuse holder (see arrow) is plugged into a FUSE RATING...
  • Page 99 DC/DC Converter 100A Charge Fuse (inline) Note: If the charge fuse (4) needs replacement, contact your Zero Motorcycles dealer. To access the high voltage fuses: 1. Remove the two bolts securing the seat to the motorcycle frame. 2. Pull the seat rearward to gain access to the fuses.

  • Page 100: Service Record

    Service Record Follow the maintenance schedules on page 5.2. After a scheduled service or routine is performed, record the information Service Record on the chart below. DATE ITEM SERVICE/ROUTINE DESCRIPTION 5.26...
  • Page 101 Service Record DATE ITEM SERVICE/ROUTINE DESCRIPTION 5.27...
  • Page 102 Notes 5.28...

  • Page 103: Troubleshooting

    If the motorcycle is involved in an accident do not an authorized dealer at your convenience. If there is no touch any high voltage wiring connectors or the components dealer in your area call Zero Motorcycles Customer connected to the wiring. If a motorcycle fire occurs, extinguish Service.

  • Page 104: System Warning Indicator

    Troubleshooting System Warning Indicator If a fault has been detected, count the number of times the red indicator light (A) flashes (flashing sequence does repeat). Refer to the table starting on the next page for possible causes and solutions to the issue.
  • Page 105 Troubleshooting NUMBER OF RED FLASHES CAUSE SOLUTION Motor stop switch is in the OFF position. Press the Motor Stop Switch Disabled or Kickstand motor stop switch ON button. Kickstand is down. Switch Disabled Raise kickstand. Self-Test Failed Contact Zero or your dealer. Charger Connected Unplug charger.
  • Page 106 Troubleshooting NUMBER OF RED FLASHES CAUSE SOLUTION Motorcycle needs service. Contact Zero or your Motor Controller Error dealer. Loopback Error Needs second module, or blanking plug inserted. Battery Management System (BMS) Reset BMS with button. If problem persists contact Startup Error Zero or your dealer.

  • Page 107: Dash Error Codes

    Troubleshooting Dash Error Codes If an error code has been recorded, it can be retrieved from the dash Display A. To retrieve the error code, see Display A on the “Displays A&B”, on page 3.12 Refer to the table starting on the next page to identify the error associated with the Error Code number.
  • Page 108 Troubleshooting CODE ERROR DESCRIPTION CODE ERROR DESCRIPTION No Error Post Error High Throttle Startup Error Motor Temperature Warning Stage 1 Contactor Open Warning Motor Temperature Warning Stage 2 Contactor Welded Error Controller Temperature Warning Stage 1 Precharge Error Controller Temperature Warning Stage 2 BMS Isolation Fault BMS Throttle Enable Wire Error BMS Isolation Danger...
  • Page 109 Troubleshooting CODE ERROR DESCRIPTION BMS Charger Connected Disable MBB Charger Connected Disable SEVCON Startup Disable Contactor Open Disable BMS Self Test Error BMS Self Test Warning Reserve Partition Disable BMS Internal Disable Internal Disable Error Internal Fault Error Monolith Not Connected...

  • Page 110: General Troubleshooting

    Troubleshooting General Troubleshooting SYMPTOM POTENTIAL CAUSE POTENTIAL SOLUTION Motorcycle does not turn on Power Pack not charged. Key not properly engaged. Charge Power Pack. Recheck key in ignition, turn OFF/ON Motor stop switch turned OFF. Fault code set. again. Press the motor stop Switch ON button. See Charge Fault Code chart on page 6.10 or see Understanding BMS Flash Code Patterns starting on page 6.10.

  • Page 111: Battery Management System

    Troubleshooting Battery Management System The Battery Management System (BMS) is located inside the power pack and is fitted with a window (A) to provide visual notification about the status of the power pack. There are four LED lamps that will flash: one red and three green lamps.
  • Page 112 Troubleshooting Understanding BMS Flash Code Patterns (Idle Mode) In this mode the key is OFF and the power pack is not being charged (the BMS is only monitoring the battery). 1 RED 2 GREEN 3 GREEN 4 GREEN MEANING SOLUTION √...
  • Page 113 Troubleshooting Understanding BMS Flash Code Patterns (Charge Mode) This mode is with the charging cord plugged into the AC power, and the key in the OFF position. During the Charging process, first all lights will flash. Next, lights 1 through 4 will flash depending on the power pack’s state of charge. 1 RED 2 GREEN 3 GREEN...
  • Page 114 Troubleshooting Understanding BMS Flash Code Patterns (Run Mode) In this mode, the key is in the ON position. 1 RED 2 GREEN 3 GREEN 4 GREEN MEANING SOLUTION √ 5 sec 1 sec 25% of Power Remaining Charge Soon √ √...
  • Page 115 Troubleshooting Power Pack Empty Power Pack Too Hot If the power pack is completely empty, the BMS disables The power pack contains internal temperature sensors. If the throttle. You cannot ride the motorcycle until you the BMS measures excessive internal temperatures, it recharge the power pack.
  • Page 116 Troubleshooting Other Error-Flash Patterns If the BMS in your power pack produces an error code which is not described in Understanding BMS Flash Code Patterns, then the power pack has encountered a serious internal hardware problem and must be repaired or replaced by a dealer.

  • Page 117: Cold And Hot Weather Considerations

    Troubleshooting Cold and Hot Weather Considerations Storage of the motorcycle for the winter in a non-heated garage is acceptable, as long as: Cold Weather 1. the coldest temperature in the garage does not fall Cold weather operation of the motorcycle has no below -31°F (-35°C) permanent impact on its power pack/cells;...

  • Page 118: Safety Interlocks

    Troubleshooting Hot Weather Operation Safety Interlocks Operation of the motorcycle in hot temperatures should not If the BMS detects a serious internal fault, it can take either result in any noticeable performance changes. However, or both of two actions to prevent damage to the power the BMS will not allow motorcycle operation and its pack: associated battery discharge above 140°F (60°C), as...
  • Page 119 Troubleshooting Throttle Disable Interlock Charger-Disable Interlock The BMS communicates with the main motorcycle control When the charger is attached and plugged in to AC power, module. The BMS can send a signal to the main the BMS communicates with the charger. The BMS can motorcycle controller requesting that the throttle control on send a signal to the charger requesting that charging the motorcycle be disabled.
  • Page 120 Notes 6.18...

  • Page 121: Limited Warranty Information

    Limited Warranty Information What Does This Limited Warranty Cover? What Is The Coverage Period Of This Limited Zero Motorcycles Inc. ("Zero") warrants that all factory Warranty? manufactured 2015 Zero S/DS/SR motorcycles are free The duration of this Limited Warranty for 2015 Zero...

  • Page 122: Who Does This Limited Warranty Cover

    Limited Warranty Information Who Does This Limited Warranty Cover? are operated according to “proper use” and “under normal operating conditions.” For purposes of this exclusion, the This Limited Warranty applies to all original owners who following definitions apply: submit the warranty registration card within the required •...
  • Page 123 • Damage, malfunctions, or performance problems requirements described in this Owner's Manual. caused by continued operation of the motorcycle after a • Zero motorcycles and Power Packs used for racing or warning light, gauge reading, or other warning indicates other competitive events;...

  • Page 124: What Other Limitations Or Disclaimers Apply To This Limited Warranty

    The following additional limitations and disclaimers apply to state.) to this Limited Warranty: • Zero Motorcycles reserves the right to change or • This Limited Warranty is the only express warranty improve the design of any Zero motorcycle, Power made in connection with the sale of this Zero Pack, or any other Zero parts (collectively, “Zero...

  • Page 125: What Are Your Responsibilities As A Customer

    Limited Warranty Information What Are Your Responsibilities As A What Will Zero Do Under This Limited Customer? Warranty? As the owner of a product covered by this Limited During the duration of this Limited Warranty, an authorized Warranty, it is your responsibility to read and understand Zero dealer will repair or replace (at Zero’s discretion), this Owner's Manual, this Limited Warranty, and all product without charge, any 2015 Zero S/DS/SR motorcycle,...

  • Page 126: How Do You Obtain Service Under This Limited Warranty

    (www.zeromotorcycles.com/locator) for your nearest location. In the event that a dealer is not in your state, province, or country, you can contact Zero Motorcycles Inc. directly at +1 (888) 786-9376 (Monday-Friday, 8am to 5pm Pacific Time) or via e-mail at support@zeromotorcycles.com.

  • Page 127: Transfer Of Ownership And Warranty

    Transfer Of Ownership And Warranty When it comes time to sell your Zero Motorcycle, please visit the Zero Motorcycles website and access the Owner Resources section to fill out the on-line transfer of ownership 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.

  • Page 128: Customer Information

    • Date of purchase • Motor serial number (if visible) An owner information chart is provided on page 1-3 to record this information. Zero Motorcycles Inc. can be contacted as follows: Zero Motorcycles Inc. 380 El Pueblo Road Scotts Valley, CA 95066...

  • Page 129: Reporting Safety Defects

    Zero dealer. If you are unable to resolve the issue with your Motorcycles Inc. Zero Motorcycles authorized dealer you can contact Zero To contact NHTSA, you may call the Vehicle Safety Hotline Motorcycles Inc. directly on +1-888-786-9376, or through...
  • Page 130 Notes 7.10...
  • Page 131 Index Accessories ..............5.22 First Time Set-Up............4.1 Fuses ................5.22 12 Volt Fuse Center ..........5.23 Brake/Tail Light Bulb Replacement ......5.19 High Voltage Fuse Center ........5.25 Brakes ................5.9 Brake Fluid Level Inspection ........5.9 Brake Pad Inspection ..........5.11 General Operation ............4.3 Braking ............4.13 4.15 Key Switch/Steering Lock Positions......4.4 DOT 4 brake fluid ............5.10...
  • Page 132 Index Location Of Important Labels ........2.3 Quick Charging............4.10 Maintenance Schedule..........5.2 Reporting safety defects..........7.9 Maximizing Range............1.13 Motor Serial Number ............. 1.4 Safe Riding Information ..........1.2 Safety Interlocks ............6.16 Operating Your Motorcycle.......... 4.13 Serial Number Braking............4.13 4.15 Motor .................
  • Page 133 Technical Specifications Warning Lights............. 3.8 3.10 Zero DS Technical Specifications ......1.10 Warranty Zero S Technical Specifications........1.6 Coverage..............7.1 Zero SR Technical Specifications ......1.8 Exclusions ..............7.2 Tire Inflation..............5.13 Transfer Of Ownership And Warranty .......7.7 Transporting ..............1.17 Wheels And Tires ............5.13 Troubleshooting Battery Management System (BMS)......6.9...
  • Page 134 Notes INDEX.4...
  • Page 135 First Responder Information - High Voltage Components Locations First Responder Information - High Voltage Components Locations...
  • Page 136 TAKE CHARGE ™ ZEROMOTORCYCLES.COM...

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