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Zero S 2012 Owner's Manual

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2012 Owner's Manual
ZERO S
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ZERO DS
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Summary of Contents for Zero S 2012

  • Page 1 2012 Owner’s Manual ZERO S ™ ZERO DS ™...

  • Page 2: Table Of Contents

    Table Of Contents Introduction ..............1-1 Public Charging Stations ......1-12 An Important Message To You From Zero ..1-1 Emissions Information ......... 1-12 Introduction ............1-1 Transporting ..........1-13 Index .............. 1-1 Safety Information ............. 2-1 Useful Information For Safe Riding ....1-2 General Safety Precautions ........
  • Page 3 Pre-Ride Inspection ........4-3 Maintenance Schedule ........5-24 Key Switch/Steering Lock Positions ..... 4-4 Parts/Maintenance Items ........5-27 Power Pack ........... 4-6 Zero Motorcycle Accessories ......5-27 Operating Your Motorcycle ......4-14 Fuses ..............5-27 Suspension Adjustment ......4-15 Troubleshooting ............6-1 Maintaining Your Motorcycle ........

  • Page 4: Introduction

    - Dual Sport Tires of data in this manual. When it comes time to sell - Belt Drive your Zero S/DS, please remember to hand over this manual; it is, by law, an important part of the vehicle. Index If you have any questions concerning the operation or...

  • Page 5: Useful Information For Safe Riding

    Useful Information For Safe Riding This symbol is located in various locations on the This manual contains the word CAUTION to tell about motorcycle to inform you that something that could hurt you or others. It also exposure to high voltage can contains the word WARNING to tell about things that cause shock, burns and even could damage your motorcycle.

  • Page 6: Owner Information

    Owner Information Record important information pertaining to your motorcycle here. When contacting your dealer, you may need to provide this information. Dealer Information Motorcycle Information Name Address Model Power Pack Serial Number Telephone No. Motor Serial Number E-mail Key Code Date of Purchase...

  • Page 7: Power Pack Serial Number

    Power Pack Serial Number Vehicle Identification Number (VIN) The Power Pack serial number is located on the upper right rear of the power pack. VIN Location Motor Serial Number The motor serial number is stamped on the motor housing. Key Code Number The key code is a 5 digit number used to create duplicate keys.

  • Page 8: Vin Break Down

    VIN Break Down 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. World Manufacturer Identifier 538 = On Road Motorcycle Type Z1 = S/DS Platform M3 = 12 MY S...

  • Page 9: General Information

    • ZF6 6.0 hours (100% charged)/5.3 Charge Time hours (95% charged) *Environmental Protection Agency (EPA) Urban Dynamometer Driving (standard) • ZF9 9.0 hours (100% charged)/8.0 Schedule (UDDS) (95% charged) **Zero chargers typically draw as much as 10 amps at 120 volts.
  • Page 10 CHASSIS/SUSPENSION/BRAKES DRIVETRAIN Direct-link shock with adjustable Transmission Clutchless one speed Rear Suspension spring preload, compression and 28T/132T Sprockets, 8 mm rebound damping pitch, 200 tooth, 14 mm width, Final Drive DIMENSIONS Poly Chain® GT® Carbon™ (belt) Wheel Base 144 cm (56.6 in) CHASSIS/SUSPENSION/BRAKES Seat Height •...

  • Page 11: Zero Ds Technical Specifications

    • ZF6 6.0 hours (100% charged)/5.3 Charge Time hours (95% charged) (standard) • ZF9 9.0 hours (100% charged)/8.0 (95% charged) Zero DS Technical Specifications • ZF6 3.0 hours (100% charged)/2.7 Quick 2X hours (95% charged) Charger Time MOTOR • ZF9 4.9 hours (100% charged)/4.0...
  • Page 12 Front Suspension (optional) • ZF9 85.8 cm (33.8 in) 240 mm (9.4 in) Travel Rake 25.3 degrees Rear Suspension 195 mm (7.69 in) Travel Trail 89 mm 3.5 in **Zero chargers typically draw as much as 10 amps at 120 volts.

  • Page 13: Vehicle Range

    (0.23 gallons/62 miles) Economy (highway) We suggest that you ride conservatively when you first get your Zero S/DS motorcycle, and get to know your motorcycle and your commute. Once you become familiar with the range versus performance of your motorcycle, then you can adjust your riding characteristics if you so desire.

  • Page 14: Optimizing Your Range By Adapting Your Riding Style

    • Average motorcycle range is calculated using an The Zero S/DS has the ability to start, from a standstill, up a steep 13% grade when fully industry standardized formula. The range is separated loaded. It is not recommended that you stop on into two separate specifications: “City (EPA UDDS)”...

  • Page 15: Public Charging Stations

    Zero motorcycle have been line every day and there may be some in your area. checked and tested for safety and suitability. Zero is You can charge from a public charging station with unable to accept any liability whatsoever for parts and the optional J1772 S/DS Zero motorcycle accessory.

  • Page 16: Transporting

    Transporting It is recommended that the motorcycle be tied-down using ratchet straps. Place the ratchet straps around When the front fork is compressed, the built up a frame contact point. Soft straps must be used to pressure must be released to help prevent fork seal prevent scratches or other damage.
  • Page 17 The electrical system must be disconnected when transporting or shipping. Remove the 80 volt fuses (A) from the fuse center. 7.5A 7.5A VOLTS The 80 volt fuse center is located on the back upper right corner of the power pack. See page 5-29 for further information.

  • Page 18: Safety Information

    10. Your safety depends in part on the good which can be found on the Zero Motorcycles mechanical condition of the motorcycle. Be sure website. to follow the maintenance schedule and 5.

  • Page 19: Important Operating Information

    4. The Zero S/DS power pack should be plugged in when storing the motorcycle for extended periods 13. Failure to follow power pack storage and charging of time.

  • Page 20: Location Of Important Labels

    6. The power pack does not require or tolerate deep discharging. To get the most power pack life, recharge the power pack immediately after each ride. Leaving a power pack in a discharged state will cause damage. See Charging The Power Pack on page 4-10.

  • Page 21: Throttle And Speed Control Label

    Throttle And Speed Control Label A. Anti-Tamper Control Label (Europe Only) Located on frame next to the fuse center...
  • Page 22 Anti-Tamper Control Label (Europe Only) TRADE NAME: ZERO MOTORCYCLES BO4 - BATTERY VEHICLE CATEGORY: B MO4 - MOTOR MODEL: S CO4 - CONTROLLER FS-28T - 28T FR. SPROCKET FS-25T - 25T FR. SPROCKET (OPT.) RS132T - 132T RR. SPROCKET TRADE NAME: ZERO MOTORCYCLES...
  • Page 23 NOTES...

  • Page 24: Controls And Components

    Controls And Components Motorcycle Controls A. Mirrors B. Performance Level Switch C. Key Switch/Steering Lock D. Instrument Panel E. Front Brake Fluid Reservoir F. Front Brake Lever G. Throttle Control H. Motor Stop Switch Left Handlebar Control...
  • Page 25 A. Mirrors G. Throttle Control This motorcycle is equipped with convex mirrors. A For description and operation see pages 3-11 convex mirror has a curved surface. Convex and 3-12. mirrors offer a greater field of view than a similar flat mirror. However, the greater field of view H.

  • Page 26: Left Side View

    Left Side View A. Headlight B. Front Turn Signal C. Brake/Tail Light D. AC Charger Power Connection E. Integrated Power Pack Charger F. Kickstand G. Kickstand Switch H. Rear Turn Signal...
  • Page 27 A. Headlight E. Integrated Power Pack Charger For description and operation, see Power Pack • For headlight operation, see Handlebar Charger on page 4-8. Controls on pages 3-11 and 3-12. F. Kickstand • For headlight bulb replacement, see The kickstand swings out from the side and Headlight Bulb Replacement on page 5-18.

  • Page 28: Right Side View

    Right Side View A. Rear Brake Fluid Reservoir B. Auxiliary Power Pack Charging Port C. Power Pack D. Brushless Motor Controller E. Rear Brake Pedal F. Drive Chain/Belt Tension Adjuster...

  • Page 29: For Description And Operation

    A. Rear Brake Fluid Reservoir E. Rear Brake Pedal See Rear Brake on page 5-8. The rear brake pedal controls the rear brake when the pedal is pressed. When braking, the B. Auxiliary Power Pack Charging Connection throttle should be in the closed position. For description and operation see page 4-12.

  • Page 30: Instrument Panel

    Instrument Panel G. Right Turn Signal Indicator A. Left Turn Signal Indicator H. Odometer B. Temperature Indicator Trip Odometer C. High Beam Indicator J. Adjust Button D. Speedometer K. Select Button E. Main Power Indicator L. System Warning Indicator F. Charge Indicator...

  • Page 31: Indicators

    Indicators C. High Beam Indicator When the headlight high beam is on, this indicator will illuminate A. and G. Turn Signals blue, and will remain on until the An arrow on the instrument high beam is turned off. panel will flash green in the same direction as selected by D.
  • Page 32 The trip odometer displays individual trip mileage, and is reset by pressing and holding the adjust button. J. Adjust Button By pressing the adjust button you can toggle between the trip odometer settings. Holding it down will clear the trip odometer resetting it back to zero.

  • Page 33: Performance Level Switch

    Performance Level Switch The performance level is a two position switch that toggles between Eco and Sport. To select either of the switch positions, the motorcycle must be stopped and the key switch in the OFF position. The Eco position reduces the acceleration and top speed of the motorcycle.

  • Page 34: Handlebar Controls

    Handlebar Controls A. High Beam Flash-to-Pass E. Motor Stop Switch B. Headlight High/Low Beam Switch F. Turn Signal Switch C. Front Brake Lever G. Horn Button D. Throttle Control 3-11...
  • Page 35 D. Throttle Control A. High Beam Flash-to-Pass Twist the throttle in a counter-clockwise rotation (A) to When the headlight is in the low beam position, push energize the motor and start the motorcycle in a the flash-to-pass switch and the high beam will forward direction.
  • Page 36 E. Motor Stop Switch G. Horn Button When the switch (A) is When the key is in the ON position, the horn will pressed, it will stop power to sound when the button is pressed. Electric vehicles the motor controller. The motor run quietly;...
  • Page 37 NOTES 3-14...

  • Page 38: Starting And Operating

    1. Remove the motorcycle from its shipping crate. 6. Make sure the motorcycle key switch is OFF, then See Unpacking Your Zero Motorcycle on page 4-2. twist the throttle to make sure it’s rotation is smooth, and it returns correctly.

  • Page 39: Unpacking Your Zero Motorcycle

    Unpacking Your Zero Motorcycle Inner Assembly • Carefully remove plastic cover from motorcycle. Although unpacking your Zero motorcycle can be done by a single person, it is recommended to have • Locate small parts box below motorcycle and put a second person to help lift and remove your to the side.

  • Page 40: General Operation

    Pre-Ride Inspection Your Zero Motorcycles shipping crate and packaging materials were designed to be completely recycled. Before operating the Zero S/DS motorcycle, check the Please cut down and recycle all cardboard, plastic, following to make sure the motorcycle is secure and and metal materials in appropriate receptacles.

  • Page 41: Key Switch/Steering Lock Positions

    • Brakes Key Switch/Steering Lock Positions Squeeze the 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.
  • Page 42 The key should be removed from the motorcycle when parked to prevent theft. The key can be removed in either the OFF or steering lock position. A. Steering Lock Using the steering lock when parked will prevent unauthorized use and help prevent theft. To Lock: 1.

  • Page 43: Power Pack

    495,000 km (308,000 miles) on the Zero S ZF9 requires no special break in period. original power pack. The 2012 Zero S and DS leverage a completely new • Up to 95% higher energy density power packs that battery cell chemistry and configuration. Not only does...
  • Page 44 Zero recommends you plug in your Zero motorcycle after 7 days, even if fully The BMS safeguards the power pack by means of charged. Please leave your Zero motorcycle plugged safety interlocks.
  • Page 45 • Warning: Charge the Zero power pack with the Zero High or Low Temperature charger. Action: If the BMS senses that the power pack is too hot, above 71°C (160°F), or too cold, below The charger is located under the power pack.
  • Page 46 Charger LED Indicators A. Ammeter The Ammeter LED is an amber indicator that indicates the amount of current output and should gradually ramp down from “IIIIII” to “I”. B. 80% Charge The 80% Charge LED is an amber indicator. If it is on solid, the bulk charge phase is complete, 80%...
  • Page 47 C. 100% Charge Charging The Power Pack The 100% Charge LED is a green indicator. If it is on WARNING: Charge the Zero power pack with the Zero solid, the charging is complete and the charger will charger. enter maintenance mode. If it is flashing, the absorption phase is complete and the charger is in It is possible for lithium ion cells to overheat and fail.
  • Page 48 If you experience a power pack that will not take a charge, you should ensure the internal temperature is below 52°C (125°F). If the power pack was recently run and it will not take a charge, the power pack should cool and begin taking a charge in around 30 minutes or less.
  • Page 49 1. Ensure that the key switch is in the OFF position. Note: AVOID connecting the Zero charger and another device to a single 120 V AC 15A/20A circuit, as it may 2. Locate the auxiliary charging connector and become overloaded. Zero chargers draw as much as remove the protective cover.
  • Page 50 4. Always connect the charger to a GROUNDED 5. Connect the integrated charger. See Charging the outlet. When using an extension cord, avoid Power Pack Single Charger (integrated) on excessive voltage drops by using a grounded, page 4-10. 3-wire, 12-AWG cord no longer than 7.6 m (25 ft). The charger can be used on 120 V AC or 240 V 6.

  • Page 51: Operating Your Motorcycle

    1. Turn the key switch to the ON position. Zero motorcycle to a complete stop without locking the wheels. Your Zero motorcycle is a light weight 2. Verify that the charge indicator reads fully charged. performance product and therefore practice is recommended to safely perfect emergency stops.

  • Page 52: Suspension Adjustment

    Suspension Adjustment 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 Front Fork Adjustment will be the writing S-F, meaning Slow and Fast. The adjuster has 18 stages of adjustment.
  • Page 53 3. Compression Damping - The compression damping is adjusted by turning a screw on the bottom of each fork leg. There is a rubber dust cover protecting the jam nut (A) securing the screw (B). The adjuster has 12 stages of adjustment.
  • Page 54 Rear Shock Adjustment Spring Adjustment: Obtaining the correct rear spring preload is critical for proper handling. The spring preload must be set to match the weight of the rider. The spring is preloaded for an 82 kg (180 lb) rider. This puts the rear tire 1/3 of the way through its vertical travel.
  • Page 55 Have a second assistant take a Example: measurement using the same locations as in step 2. 600 mm (23.6 in) Record this measurement, this will be measurement M2. 550 mm (21.7 in) 50 mm (1.97 in) The total sag is 50 mm (1.97 in). Refer to the chart below for the correct sag.
  • Page 56 • Spring Pre-load Adjustment Turning the knob counter-clockwise, or F direction, is good for smaller and more frequent impacts. Clean any dirt or debris from the threads of the shock near the lock ring (A). Using a lock ring wrench loosen the lock nut (A).
  • Page 57 • Compression Adjustment - The compression adjustment knob (D) is at the top of the shock. It has 18 stages of adjustment. The knob has “+” (slower compression) and “-” (faster compression). Turn the adjuster clockwise for slower compression. To speed up compression, turn the adjuster counter-clockwise.

  • Page 58: Maintaining Your Motorcycle

    2. Perform routine care and maintenance of your goggles, appropriate boots, and all other electric motorcycle as detailed in this owner’s appropriate safety equipment when operating an manual. electric motorcycle. 3. Use only Zero approved parts and Zero Motorcycle Accessories.

  • Page 59: Bolt Torque Table

    Bolt Torque Table LOCATION ITEM TORQUE NOTES ® ® Front axle end bolts 26 N•m (19 lb ft) Use LOCTITE Headlight bolts 16 N•m (12 lb ft) Use LOCTITE ® ® ® ® Front caliper mount bolts 20 N•m (15 lb ft) Use LOCTITE Shock mount bolts 52 N•m (38 lb ft)
  • Page 60 Bolt Torque Table, cont’d LOCATION ITEM TORQUE NOTES Triple tree pinch bolts 16 N•m (12 lb ft) Use LOCTITE ® ® ® ® Front axle pinch bolts 18 N•m (13 lb ft) Use LOCTITE ® ® Rear sprocket to cast wheel, 4 bolts (S model) 34 N•m (25 lb ft) Use LOCTITE Rear brake master cylinder to frame bolts...
  • Page 61 See Bolt Torque Table on page 5-2.
  • Page 62 See Bolt Torque Table on page 5-2.

  • Page 63: Power Pack

    Zero recommends you plug in your Zero motorcycle See Bolt Torque Table on page 5-2. after 7 days, even if fully charged. Please leave your Zero motorcycle plugged in whenever possible. 1. The power pack is a lithium ion power system.

  • Page 64: General Maintenance

    General Maintenance Front Brake Inspect the level of the Brakes front brake fluid through Brake Fluid Level Inspection the sight glass (B). If the fluid level is visibly WARNING: Do not spill brake fluid on painted LOWER below the low level surfaces, the finish could be damaged.
  • Page 65 Rear Brake Brake Pad Inspection The brake pads must be inspected when specified in Inspect the level of the the maintenance schedule. See Maintenance rear brake fluid by Schedule on pages 5-24 through 5-26. Visually inspecting the level inspect the brakes by looking at the remaining brake through the reservoir pad material through the sides of the brake caliper.

  • Page 66: Suspension

    Suspension For maintenance, see Maintenance Schedule on pages 5-24 through 5-26. Front To adjust the shock, see Rear Shock Adjustment on For maintenance, see Maintenance Schedule on page 4-17. pages 5-24 through 5-26. Wheels And Tires To adjust the fork, see Suspension Adjustment on page 4-15.

  • Page 67: Tire Inflation

    Inspect both tires for the following: Tire pressure should be checked and adjusted before each ride. Tire pressure is checked using an • Cuts, cracks, splits, or missing tread lugs in the accurate gauge when the tires are cold. This means tread or sidewall area that the tires have not been ridden on for 3 hours.
  • Page 68 Clean the belt with mild soap and water when Checking Drive Belt Tension washing you motorcycle. Towel dry and inspect for the following: Proper belt tension is essential for optimum operation of the drive system. • Cuts or unusual wear patterns. Lack of belt tension can lead to so-called “ratcheting”.
  • Page 69 The Tension Tester has a plastic measurement arm, 1. Remove the key from the key switch. located in a slot. Along this slot there is a measuring scale. The point of intersection of the measurement 2. Press the Tension Tester steadily to the middle of arm and the measuring scale shows the tension the upper side of the belt.
  • Page 70 Drive Belt Adjustment Procedure 4. Turn the adjuster bolt (D) a 1/4 turn at a time until the belt adjustment is within specification. 1. Remove the key from the key switch. 2. Loosen both rear motor mount bolts (A) using a 5 mm Allen/Hex wrench.

  • Page 71: Drive Chain (Optional)

    2. Set the motorcycle on a stand or lift so the rear Drive Chain (Optional) wheel is free to spin. While turning the wheel by HAND, spray the inside of your entire chain with a Cleaning The Drive Chain good coating of chain cleaner and let it sit for a CAUTION: few minutes.
  • Page 72 • Never place your hand between the chain and Checking The Drive Chain sprockets. Work with the chain only in the middle between the two sprockets. Failure to do so 1. Remove the key from the key switch. could result in serious personal injury. 2.
  • Page 73 Drive Chain Adjustment Procedure 5. Turn the adjuster bolt (D) a 1/4 turn at a time until the chain adjustment is within specification. 1. Remove the key from the key switch. 6. Tighten all motor mount hex bolts. See Bolt 2.

  • Page 74: Headlight Alignment

    Headlight Alignment The headlight should be checked for correct alignment periodically. It must be aligned any time the suspension sag is adjusted because this will affect the headlight alignment. Before the headlight can be aligned, the suspension sag and tire pressure must be correctly adjusted.

  • Page 75: Headlight Bulb Replacement

    Headlight Bulb Replacement CAUTION: Halogen bulbs contain gas under pressure. Handling a bulb improperly could cause it to shatter into flying glass fragments. To help avoid personal injury: • Turn the key switch OFF and allow the bulb to cool before changing the bulb. •...
  • Page 76 WARNING: Do not touch the glass portion of the headlight bulb. Keep the headlight bulb free of contaminants. Oil from your fingers or contaminants will shorten the life of the bulb. Thoroughly clean any fingerprints or contaminants from the bulb using a clean cloth moistened with alcohol.

  • Page 77: Turn Signal Light Bulb Replacement

    Turn Signal Light Bulb Replacement 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.

  • Page 78: Running Light Bulb Replacement

    Running Light Bulb Replacement 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. 1. Working from behind the headlight, remove the 4.

  • Page 79: Cleaning

    2. Pull the old bulb straight out from the socket. If tar, bugs, or other similar deposits have accumulated, wash them off as soon as possible. Do 3. Push the new bulb into the socket, and push the not use high pressure or steam cleaners; they can socket into the headlight.

  • Page 80: Parking And Long Term Storage

    WARNING: Opening of the power pack is for trained Parking And Long Term Storage Zero Motorcycles’ technicians. Please be aware that incorrect handling of a Zero power pack can be 1. It is recommended to always leave the power dangerous. DO NOT OPEN! pack plugged in.

  • Page 81: Maintenance Schedule

    Maintenance Schedule The scheduled maintenance must be performed in accordance with this chart to keep the Zero S/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 82 ITEM ROUTINE EVERY INITIAL ODOMETER MILEAGE READINGS RIDE 1,000 km 7,000 km 13,000 km 19,000 km 25,000 km 31,000 km (600 mi) (4,000 mi) (8,000 mi) (12,000 mi) (16,000 mi) (20,000 mi) 1 month 6 months 12 months 18 months 24 months 30 months Wheel...
  • Page 83 ITEM ROUTINE EVERY INITIAL ODOMETER MILEAGE READINGS RIDE 1,000 km 7,000 km 13,000 km 19,000 km 25,000 km 31,000 km (600 mi) (4,000 mi) (8,000 mi) (12,000 mi) (16,000 mi) (20,000 mi) 1 month 6 months 12 months 18 months 24 months 30 months Front Brake Lever...

  • Page 84: Parts/Maintenance Items

    Parts/Maintenance Items Zero Motorcycle Accessories Zero accessories are designed to complement and The proper replacement parts, fluids, and lubricants function with other systems on your motorcycle. Your to use are listed in the chart below. dealer can accessorize the motorcycle using genuine Zero accessories.
  • Page 85 To access the 12 volt fuse center: Fuse Center Locations 12 Volt: • Turn the forks to full lock. The 12 volt fuse center is located behind the front • fork under the top trim panel. Remove the cover from inside the cavity. •...
  • Page 86 80 Volt: FUSE # CIRCUITS The 80 volt fuse center (A) is located on the back CONTROLLED upper right corner of the power pack. Quick Charger Charger DC/DC Converter Main Bike Board/Controller To access the 80 volt fuse center: 7.5A 7.5A •...
  • Page 87 Follow the maintenance schedules on pages 5-24 through 5-26. After a scheduled service or routine is performed, record the information on the chart below. DATE ITEM SERVICE/ROUTINE DESCRIPTION 5-30...

  • Page 88: Troubleshooting

    If you are unable to solve an issue with your Zero S/DS electric motorcycle, take it to an authorized dealer at your convenience. If there is no dealer in your area call Zero Motorcycles Customer Service.
  • Page 89 t n i  a t l t n i   a t l a t l    i r t     i n i a t l c i f n i l o l f ...

  • Page 90: Battery Management System

    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, one red and three green, that will flash.
  • Page 91 5 sec Healthy BMS OK  50 ms 60 sec Pack Low Charge power pack Number of Cell Contact Zero or the  50 ms 1 sec Packs Not Set Dealer Contact Zero or the  50 ms 1 sec...
  • Page 92 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, then 1 through 4 will flash depending on the power pack’s state of charge.
  • Page 93 Charge Mode cont’d MEANING SOLUTION Green Green Green Balancing  500 ms Power Pack Leave on Charger for Unbalanced 72 Hours   500 ms Temperature Disable Let the Power Pack   100 ms 500 ms Too Hot Cool Down...
  • Page 94 Run Mode In this mode, the key is in the ON position. MEANING SOLUTION Green Green Green 25% of Power  5 sec 1 sec Charge Soon Remaining 50% of Power   5 sec 1 sec Charge Soon Remaining 75% of Power ...
  • Page 95 Power Pack Unbalanced Power Pack Empty The power pack contains many individual cells. The If the power pack is completely empty, an error-beep BMS continuously monitors the cells and tries to keep will sound and the BMS will disable the throttle. You them all “in balance”...
  • Page 96 If so, the user should return the power Low Power Pack warning will flash and you can still pack to Zero for repair or replacement. ride the motorcycle, but the remaining range is limited. It means: “Stop at a destination and charge- up.”...

  • Page 97: Safety Interlocks

    Safety Interlocks If the throttle is disabled while riding, the motorcycle will cease to provide power, and the operator must If the BMS detects a serious internal fault, it can take pull over to a safe location. either or both of two actions to prevent damage to the power pack: All conditions which would cause the BMS to disable the throttle are also signaled by a flash code pattern...
  • Page 98 Charger-Disable Interlock Too Hot When the charger is attached and plugged in to AC If the BMS detects high internal power pack power, the BMS communicates with the charger. The temperatures, it will both disable the throttle and BMS can send a signal to the charger requesting that prevent charging.

  • Page 99: Temperature Indicator

    Temperature Indicator The Zero S/DS is equipped with temperature sensors that sense the temperature of the motor, power pack, and brushless motor controller. In the unlikely event PATTERN MEANING that you exceed the motorcycle’s performance capabilities, the temperature indicator will provide you Slow Constant Flash •...
  • Page 100 • You can continue to ride without performance Power Pack Full (High Power Pack-Voltage) interruptions. If the BMS detects that the power pack is already full, it will disable further charging to prevent damage to • You should reduce speed - this will lower power the power pack.
  • Page 101 Instrument Panel System Warning Indicator If a fault has been detected, count the number of times the red LED (A) flashes. Refer to the tables on pages 6-15 and 6-16 for possible cause and solution to the issue. 6-14...
  • Page 102 Motor Stop Switch Disabled or Press the motor stop switch ON button or Kickstand Switch Disabled kickstand is down. Raise kickstand. Self-Test Failed Contact Zero or your dealer. Charger Connected Unplug charger. Throttle is ON or throttle/connection is bad High Throttle Disable Verify throttle action and/or check connection.
  • Page 103 Problem sensing temperature of board. Contact your dealer. Range Turn the ignition OFF and ON. If High Current Disable problem persists contact Zero or your dealer. Turn the ignition OFF and allow to Temperature Protection Error cool off and then restart. If problem persists contact Zero or your dealer.

  • Page 104: General Troubleshooting

    General Troubleshooting SYMPTOM POTENTIAL CAUSE POTENTIAL SOLUTION Charge Power Pack. Power Pack not charged Recheck key in ignition, turn OFF/ON again. Motorcycle does not turn Key not properly engaged Press the motor stop Switch ON button. Motor stop switch turned OFF See Charge Fault Code chart on page 6-2 or see Fault code set Understanding BMS Flash Code Patterns on pages...
  • Page 105 NOTES 6-18...

  • Page 106: Warranty/Customer Assistance

    Warranty/Customer Assistance Customer Assistance Zero Motorcycles Inc. can be contacted via the contact Zero Motorcycles methods listed below. Please have the following 170 Technology Circle available as they are essential to effectively and Scotts Valley, California 95066 efficiently answer your questions or resolve your concerns.

  • Page 107: Warranty Information

    Wheels are excluded from proper use, for 2 years (unlimited miles) from the “In this standard warranty on off-road bikes once they Service Date,” which is the date your Zero Motorcycle have been ridden. dealer performed a Pre-Delivery Inspection (P.D.I) on This standard warranty excludes aftermarket the Zero.

  • Page 108: Disclaimers Applicable To Standard Warranty

    Under this limited warranty and liability agreement, Zero Motorcycles Inc. does not assume or authorize Zero Motorcycles Inc. shall have no obligation and the anyone to assume for them any other obligation. purchaser shall have no remedy against Zero Some states, provinces, or countries do not allow Motorcycles Inc.

  • Page 109: Proper Use

    Submit the warranty registration card for your Zero motorcycle within the required time period as printed on the registration card.

  • Page 110: Warranty Procedures

    Zero Motorcycles Inc. directly at (888) 786-9376 or via e-mail at support@zeromotorcycles.com. Service may also be available from a local Zero Motorcycles Certified Service Center; please see the locator on www.zeromotorcycles.com for the nearest location.

  • Page 111: Transfer Of Ownership And Warranty

    Transfer Of Ownership And Warranty U.S. Manufacture: Zero Motorcycles When it comes time to sell your Zero motorcycle, 170 Technology Circle please visit the Zero Motorcycles website and access Scotts Valley, CA 95066. the Owner Resources section to fill out the on-line transfer of ownership and warranty form.
  • Page 112 This Owner’s Manual shall not be used or relied upon as a substitute for information that is available from your Zero Motorcycles dealer. Further information can be obtained from your authorized Zero dealer or Zeromotorcycles.com. ©2012 Zero Motorcycles Inc. Not to be reproduced wholly or in part without written permission of Zero Motorcycles Inc.
  • Page 113 NOTES...
  • Page 114 Add On Electrical Equipment ........4-7 Brake Pad Inspection .......... 5-8 An Important Message To You From Front Brake ............5-7 Zero Motorcycles ............1-1 Rear Brake ............5-8 Anti-Tamper Control Label (Europe Only) ....2-5 Brake/Tail Light Bulb Replacement ......5-20 Braking ..............
  • Page 115 Dangerously Low Voltage .......... 4-7 Disclaimers Applicable to Standard Warranty ..7-3 General Information ............ 1-6 Drive Belt ..............5-10 Zero DS Technical Specifications ....... 1-8 Checking Drive Belt Tension ......5-11 Zero S Technical Specifications ......1-6 Drive Belt Adjustment Procedure ......5-13 General Maintenance ..........
  • Page 116 Tire Inflation ............5-10 Turn Signal Light Bulb Replacement ....5-20 Key Code Number ............1-4 Wheels And Tires ..........5-9 Key Switch Positions ..........4-4 General Operation ............4-3 Key Switch/Steering Lock Positions ....4-4 Pre-Ride Inspection ..........4-3 Left Side View .............
  • Page 117 Brakes ..............4-4 Drive Belt ............... 4-3 Operating Information ..........2-2 Drive Chain ............4-3 Operating Your Motorcycle ........4-14 Electrical System ..........4-4 Braking ..............4-14 Power Pack ............4-3 Starting ..............4-14 Throttle ..............4-4 Stopping .............. 4-14 Tires ..............
  • Page 118 Turn Signal Light Bulb Replacement ..... 5-20 Front ..............5-9 Rear ............... 5-9 Suspension Adjustment ........... 4-15 Unpacking Your Zero Motorcycle ....... 4-2 Front Fork Adjustment ........4-15 Understanding BMS Flash Code Patterns ....6-4 Rear Shock Adjustment ........4-17 Charge Mode ............
  • Page 119 Vehicle Identification Number (VIN) ......1-4 Warranty ............... 7-2 VIN Break Down ........... 1-5 Disclaimers ............7-3 VIN Location ............1-4 Standard Warranty ..........7-2 Vehicle Range ............1-10 Transfer Of Ownership And Warranty ....7-6 Warranty/Customer Assistance ........7-1 Warranty Information ...........
  • Page 120 TaKe CHarGe ™ www.zerOMOTOrCyCles.com...

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