Zero Motorcycles S 2010 Owner's Manual
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Zero Motorcycles S 2010 Owner's Manual

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  • Page 2: Table Of Contents

    Table Of Contents Introduction ..............1-1 Safety Information ............. 2-1 An Important Message To You From Zero ..1-1 General Safety Precautions ......... 2-1 Introduction ............1-1 Important Operating Information ....2-2 Index .............. 1-1 Location Of Important Labels ...... 2-3 Useful Information For Safe Riding ....
  • Page 3 Right Side View ............ 3-5 Suspension ........... 5-8 Instrument Panel ..........3-7 Wheels And Tires ......... 5-8 Indicators ............3-8 Tire Inflation ..........5-9 Handlebar Controls ..........3-9 Chain ..............5-10 Headlamp Alignment ........5-13 Starting And Operating ..........4-1 First Time Set-Up ..........4-1 Headlamp Bulb Replacement .....5-14 Uncrating Your Motorcycle ......
  • Page 4 Warranty/Customer Assistance ....... 7-1 Customer Assistance ........... 7-1 Warranty Information ..........7-2 Zero Motorcycles 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 ............
  • Page 5 NOTES TOC-4...

  • Page 6: Introduction

    Introduction An Important Message To You Introduction Index From Zero Congratulations and thank you for purchasing the A good place to locate information about the 2010 Zero S/DS electric motorcycle; we welcome you motorcycle is in the index in the back of the manual. to the community of Zero Motorcycle riders.

  • Page 7: Useful Information For Safe Riding

    Useful Information For Safe Riding This manual contains the word CAUTION to tell about something that could hurt you or others. It also contains the word WARNING to tell about things that could damage your motorcycle. CAUTION: Please read this manual carefully and completely before operating this motorcycle.

  • Page 8: Owner Information

    Owner Information Record important information here pertaining to your motorcycle. When contacting your Certified Service Center (CSC) you may need to provide this information. CSC Information Motorcycle Information Address Model Telephone No. Battery Serial Number E-mail Date of Purchase...

  • Page 9: Vehicle Identification Number (Vin)

    Vehicle Identification Number (VIN) 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 See Location Of Important Labels on page 2-3.
  • Page 10 S = Street Motorcycle Type C = Commuter 2 = 168 Cell 3 = 2nd Generation Model Line 4 = 336 Cell M = Mars P = Perm Motor Type Z = Z Motor Force A = Agni 05 = 0 - 50 HP 51 = 50 - 100 HP Net Brake Horse Power 10 = 100 + HP...

  • Page 11: General Information

    General Information Zero S Technical Specifications MOTOR CHASSIS/SUSPENSION/BRAKES Front Suspension Type Brushed permanent magnetic electric 203.2 mm (8 in) Travel Est. Top Speed 108 km/h (67 mph) Rear Suspension 203.2 mm (8 in) Travel POWER SYSTEM 2 Piston Hydraulic, Stainless Rotor, Front Brakes Hand Actuated Type...

  • Page 12: Zero Ds Technical Specifications

    DIMENSIONS Zero DS Technical Specifications Wheel Base 144.3 cm (56.8 in) Seat Height MOTOR 86.4 cm (34 in) (Standard) Low Seat Height Type Brushed permanent magnetic electric 81.3 cm (32 in) (Option) Est. Top Speed 108 km/h (67 mph) Rake 22 degrees Steering Angle +35 degrees, -35 degrees...
  • Page 13 DRIVETRAIN DIMENSIONS Transmission Clutchless one speed Wheel Base 146.8 cm (56.75 in) Drive System 16T/53T Sprockets, 420 Chain Seat Height 88.9 cm (35 in) (Standard) CHASSIS/SUSPENSION/BRAKES Low Seat Height 83.8 cm (33 in) Front Suspension (Optional) 228.6 mm (9 in) Travel Rake 24 degrees...

  • Page 14: Vehicle Range

    Vehicle Range 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 The range of an electric vehicle is defined as the miles) of steady riding at 40 km/h (25 mph).

  • Page 15: Public Charging Stations

    Public Charging Stations Emissions The Zero S and DS do not require any gasoline and, There are more public charging stations coming on- as a result, do not get ‘miles per gallon.’ For the line every day and there may be some in your area. sake of emissions comparisons, the EPA estimates These stations are often available at a variety of there to be about 33.705 kilowatt hours in one gallon...

  • Page 16: Transporting

    Transporting It is recommended that the motorcycle be tied-down using ratchet straps and a fork support (A) to prevent When the front fork is compressed, the built up fork damage. Place the ratchet straps around the pressure must be released to help prevent fork seal frame or a solidly mounted part.
  • Page 17 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. 1-12...
  • Page 18 NOTES 1-13...
  • Page 19 NOTES 1-14...

  • Page 20: Safety Information

    Safety Information General Safety Precautions 6. Do not ride on wet, frozen, oily or pitted surfaces. Avoid potholes, surface cracks, and other 1. This is a performance motorcycle and should obstacles. be treated with extreme caution. 7. Never use alcohol or mind-altering drugs before operating an electric motorcycle.

  • Page 21: Important Operating Information

    2. Switch the power OFF when backing up or vehicle unsafe and may cause severe personal pushing the motorcycle while dismounted. It is injury. Zero Motorcycles cannot be held liable for possible to unintentionally twist the throttle, non-approved modifications. resulting in unexpected acceleration.

  • Page 22: Location Of Important Labels

    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.

  • Page 23: Power Pack Information Label

    Power Pack Information Label...

  • Page 24: Throttle And Speed Control Label

    Throttle And Speed Control Label Power Pack Labels There is no engine braking A. Power Pack (Battery) Fuse Label B. Main Power Cut-Off Label...

  • Page 25: Power Pack (Battery) Fuse Label

    Power Pack (Battery) Fuse Label Main Power Cut-Off Label MAIN POWER CUT-OFF SLIDE UP SLIDE DOWN...

  • Page 26: Performance Specifications/Operation Guidelines

    Performance Specifications/ Z-Force Air Induction System Operation Guidelines 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 The Zero S/DS motorcycle is designed to provide fender.

  • Page 27: System Error Indicator

    System Error Indicator Stage 1 The brush carrier begins to reach an undesirable The Zero S/DS is equipped with a motor brush temperature: carrier temperature error indicator. In the unlikely event that you exceed the motorcycle’s • A slow blink is clearly seen on the dash-mounted performance capabilities, it will provide you with warning indicator.
  • Page 28 • • The brush carrier should take no longer than At this point it is strongly recommended that you about 10 minutes to cool. reduce your speed and consider finding a safe area to exit the road. • When the warning indicator turns off you can •...
  • Page 29 NOTES 2-10...

  • Page 30: Controls And Components

    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 Right Handlebar Control...
  • Page 31 A. Mirrors F. Front Brake Lever This motorcycle is equipped with convex mirrors. A The front brake lever controls the front brake when convex mirror has a curved surface. Convex the lever is squeezed. When braking, the throttle mirrors offer a greater field of view than a similar should be in the neutral/returned position.

  • Page 32: Left Side View

    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 Kickstand...
  • Page 33 A. Headlamp F. AC Charger Power Connection For description and operation, see Charging The • For headlamp operation, see Handlebar Power Pack on page 4-12. Controls on page 3-10. G. On-Board Battery Charger • For headlamp bulb replacement, see For description and operation, see Battery Charger Headlamp Bulb Replacement on page 5-14.

  • Page 34: Right Side View

    Right Side View A. Rear Brake Fluid Reservoir B. Drive Chain Adjuster C. Rear Brake Pedal D. Power Pack...
  • Page 35 A. Rear Brake Fluid Reservoir See Rear Brake on page 5-7. B. Drive Chain Adjuster See Drive Chain Adjustment 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.

  • Page 36: Instrument Panel

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

  • Page 37: Indicators

    Indicators E. Energy Gauge This bar graph displays the amount of energy remaining in the power pack, similar to the fuel A and F. Turn Signals gauge on a gasoline powered vehicle. An arrow on the instrument panel will flash green in the G.

  • Page 38: Handlebar Controls

    Handlebar Controls A. High Beam Flash-to-Pass B. Headlamp High/Low Beam Switch F. Turn Signal Switch C. Front Brake Lever G. Kill Switch D. High Beam Indicator H. Throttle E. Horn Switch...
  • Page 39 D. High Beam Indicator A. Flash-to-Pass When the headlamp is in high beam position or When the headlamp is in the low beam position, the flash-to-pass switch is pressed this indicator push the flash-to-pass switch and the high beam will will illuminate.
  • Page 40 G. Kill Switch When the switch (A) is pressed, it will kill power to the motor controller. The motor controller will remain in this state until the ON (B) button is pressed. The switch does not turn off all electrical circuits, just the operation of the motor.
  • Page 41 NOTES 3-12...

  • Page 42: Starting And Operating

    Starting And Operating First Time Set-Up 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 If your motorcycle was direct shipped you will need to the brake lines.

  • Page 43: Uncrating Your Motorcycle

    Uncrating Your Motorcycle The S/DS motorcycle arrives almost entirely assembled. It is recommended that you have an assistant to help with the uncrating procedure. We advise wearing protective gloves and protective eyewear when uncrating the Zero motorcycle. It is possible during shipping that sharp edges or points may occur, please use caution.
  • Page 44 3. With the assistant holding the motorcycle upright, 5. Remove the fork support (A), located between the remove the ratchet straps (B). wheel and front fender. 4. Fold down the ramp (A) and lower the protective plastic. 6. Carefully roll the motorcycle off of the crate base. 7.

  • Page 45: General Operation

    • General Operation Throttle With the key switch in the OFF position, apply the Pre-Ride Inspection throttle and release to verify that the throttle is smooth and returns correctly. Before operating the Zero S/DS motorcycle, check the following to make sure the motorcycle is secure and •...

  • Page 46: Key Switch Positions

    Key Switch Positions There is a red dot (A) indicating the ON position. 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.

  • Page 47: Main Power Cut-Off

    To Unlock This switch must be in the OFF position when transporting or shipping the motorcycle. 1. Install the key and turn counter-clockwise. 2. Remove the key. Never ride with the key in the fork lock. MAIN POWER CUT-OFF SLIDE UP SLIDE DOWN Main Power Cut-Off The main power cut-off switch (A) is located on the...

  • Page 48: Power Pack

    Power Pack The 6 digit serial number for the battery is located on a label on the top of the power pack. The battery is located within the power pack and Add On Electrical Equipment requires no special break in period. Under normal use and correct power pack maintenance, the power WARNING: Do not add anything electrical to your pack should maintain most of its capacity for...
  • Page 49 • Battery Management System (BMS) High or Low Temperature Action: If the BMS senses that the power pack is Every power pack contains a Battery Management too hot, above 71°C (160°F), or too cold, below - System (BMS) which monitors the condition of the 7°C (20°F), it sends a signal to disable the motor cells and optimizes the charging process to provide controller and the motorcycle will not run until the...
  • Page 50 • Safety Interlocks Battery Charger The BMS can disable the motorcycle’s throttle- When charging the motorcycle’s power pack (battery) control if the power pack is fully discharged, or in the charger (A) can be left ON, even after the battery case of other errors.
  • Page 51 • When left on the charger the power pack will receive a full charge. Once fully charged, the charger will check the status of the power pack once every 72 hours to ensure that it maintains a full charge. When fully charged a green light will illuminate on the charger.
  • Page 52 Charger LED Indicators Note: The charger must be plugged in for the charger’s indicators to illuminate. See Battery Charger on pages 4-9 and 4-10 for location. Ammeter Solid: Displays approximate scale of current output during bulk phase. High (Amber) internal charge temperature. Current output reduced. Flashing: Also displays algorithm #1-6 for 11 seconds if no power pack is connected.
  • Page 53 Charging The Power Pack WARNING: Charge the Zero power pack with the Zero charger. It is possible for lithium ion cells to overheat and burst. It is recommended to charge in a location that is away from combustible materials and in a well ventilated area.
  • Page 54 5. AVOID connecting the Zero motorcycle charger and another device to a single 15A/20A or the circuit may become overloaded. 6. Charging a fully discharged power pack takes about 4 hours. 7. Your power pack is equipped with an “Emergency Energy Reserve Beep.”...

  • Page 55: Operating Your Motorcycle

    Operating Your Motorcycle The front and rear brake should be applied together, with a slight amount more of the braking on the front. Starting CAUTION: If you apply the front or rear brake hard enough, it is possible lock the wheels. This could 1.

  • Page 56: 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 57 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 screw and a jam nut (A) securing the screw (B). The adjuster has 12 stages of adjustment.
  • Page 58 Rear Shock Adjustment Spring Adjustment: Obtaining the correct rear spring rate is critical for proper handling. The spring rate must be set to match the weight of the rider. Heavier riders require stiffer spring rates. A good approximation of your rear spring requirements can be found by measuring the rear suspension’s sag.
  • Page 59 Have a second assistant take a Example: measurement using the same locations as in step 2. 600 mm (23.6 Record this measurement, this will be measurement M2. 500 mm (19.6 100 mm (4 in) If the total is between 90 to 100 mm (3.5 to 4.0 in), the sag is correct.
  • Page 60 • 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. Using a spanner wrench loosen the lock nut (A). For measurements less than 90 mm (3.5 in), decrease the pre-load on the spring by turning the spring nut (B) counter-clockwise on the shock.
  • Page 61 NOTES 4-20...

  • Page 62: Maintaining Your Motorcycle

    Maintaining Your Motorcycle Owner’s Responsibilities 4. The operator is responsible for learning and obeying all country, federal, state, and local laws governing the operations of an electric motorcycle. 1. This owner’s manual should be considered a permanent part of this motorcycle and should 5.

  • Page 63: Bolt Torque Table

    Bolt Torque Table LOCATION ITEM TORQUE NOTES Handlebar clamp mount bolts 13-15 N•m (10-11 lb ft) Use LOCTITE ® ® Shock mount bolts 13-15 N•m (10-11 lb ft) Use anti-sieze lubricant ® ® Rear caliper mount bolts 11-13 N•m (8-10 lb ft) Use LOCTITE ®...
  • Page 64 See Bolt Torque Table on page 5-2.
  • Page 65 See Bolt Torque Table on page 5-2.

  • Page 66: 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. While it does require charging, it does not require maintenance.

  • Page 67: General Maintenance

    General Maintenance Front Brake Inspect the level of the Motor front brake fluid through the sight glass (B). If CAUTION: Wear safety glasses when using the fluid level is visibly compressed air to avoid eye injury. below the low level indicator (C), brake fluid The motor does not require much maintenance, but must be added.
  • Page 68 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 5-20 through 5-22. 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 69: Suspension

    Suspension For maintenance, see Maintenance Schedule on pages 5-20 through 5-22. Front To adjust the shock, see Rear Shock Adjustment on For maintenance, see Maintenance Schedule on page 4-17. pages 5-20 through 5-22. Wheels And Tires To adjust the fork, see Suspension Adjustment on page 4-15.

  • Page 70: 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, missing tread lugs, or accurate gauge when the tires are cold. This means bruises in the tread or sidewall area that the tires have not been ridden on for 3 hours.

  • Page 71: Chain

    Chain Follow the manufacturer’s instructions for the chain cleaner you are using; below are the general guide- Cleaning The Drive Chain lines. CAUTION: 1. Remove the key from the key switch. • Wear safety glasses when cleaning the chain to prevent eye injuries.
  • Page 72 3. Let the motorcycle stand for 30 minutes to allow Lubricating The Drive Chain the lubricant to penetrate the link rollers. CAUTION: • Wear safety glasses when lubricating the chain to Checking The Drive Chain prevent eye injuries. 1. Remove the key from the key switch. •...
  • Page 73 Drive Chain Adjustment Procedure 6. Tighten all motor mount Allen bolts. See Bolt Torque Table on page 5-2. 1. Remove the key from the key switch. 7. Tighten the 13 mm jam nut on the chain 2. Loosen both rear motor mount Allen bolts (A). tensioner.

  • Page 74: Headlamp Alignment

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

  • Page 75: Headlamp Bulb Replacement

    Headlamp Bulb Replacement 1. Remove the two screws (A) from the headlamp housing. 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 off the key switch and allow the bulb to cool before changing the bulb.
  • Page 76 3. Working with the headlamp on a bench, WARNING: Do not touch the glass portion of the disconnect the headlamp bulb connector and headlamp bulb. Keep the headlamp bulb free of cover. contaminants. Oil from your fingers or contaminates will shorten the life of the bulb. Thoroughly clean any 4.

  • Page 77: Turn Signal Bulb Replacement

    6. Install the headlamp bulb into the lens. 7. Install the headlamp spring clip. 8. Install the headlamp bulb cover; ensure that the arrow is pointing up. 9. Connect both connectors and install the headlamp screws. Turn Signal Bulb Replacement 1.

  • Page 78: Running Lamp Bulb Replacement

    Running Lamp Bulb Replacement 1. Remove the two screws (A) from the headlamp housing. 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.

  • Page 79: Cleaning

    3. Pull the old bulb out of the socket. Cleaning 4. Push the new bulb into the socket and push the To prolong the life of your motorcycle it should be socket (A) into the headlamp. washed periodically. Regular cleaning, using correct methods, is an important factor in maintaining the 5.

  • Page 80: Parking And Long Term Storage

    WARNING: Opening of the power packs is for trained charge at all times without wasting any electricity. Zero Motorcycles technicians. Please be aware that incorrect handling of a Zero battery can be dangerous. DO NOT OPEN!

  • 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. ITEM ROUTINE EVERY...
  • 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 •...

  • Page 84: Parts/Maintenance Items

    CSC can accessorize the motorcycle using genuine Zero accessories. PART NUMBER A full line of Parts, Accessories, and Apparel can be Headlamp Bulb-55 watt found on the Zero Motorcycles website. Turn Signal Bulb 1156 Fuses Stop/Tail Lamp Bulb 1157 Whenever there is an excessive amount of current...
  • Page 85 Z-Force Power Pack Battery Fuses Fuse Center Location The Z-Force power pack (A) has four MDA slow blow The 12-volt fuse center is located behind the front fuses. The fuses are located on the back of the fork. The fuse center has a protective cover that must power pack in front of the rear wheel.
  • Page 86 FUSE # CIRCUITS CONTROLLED Headlamp, Flash-to-Pass Not Used Turn Signals, Horn Instrument Panel, Tail/Stop Lamp 5-25...
  • Page 87 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. ODOMETER DATE MILEAGE ITEM SERVICE/ROUTINE DESCRIPTION READING 5-26...
  • Page 88 NOTES 5-27...
  • Page 89 NOTES 5-28...

  • Page 90: Troubleshooting

    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...
  • Page 91 NUMBER OF RED FLASHES CAUSE SOLUTION Reset charger (interrupt AC power for 15 Power Pack High Voltage seconds). Reset charger (interrupt AC power for 15 Power Pack Low Voltage seconds). Charge Timeout caused by power Check connections. pack not reaching required voltage. Operate charger at a lower ambient Charger output was reduced due to temperature.

  • Page 92: Understanding Beep Sequences

    Understanding Beep Sequences The Battery Management System (BMS) is located inside the power pack and is fitted with a beeper to provide audible notifications about the status of the power pack. Below you will find information on the meaning of the beep sequences.
  • Page 93 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 94 The Low-Power Pack warning beep will sound BMS Appendix continuously until either (1) the motorcycle is turned There are other beeps which may occur under two OFF, or (2) the throttle control is disabled for any circumstances that operators will normally never see. reason, which includes the power pack being Unlike many electronic systems, the BMS essentially completely empty.

  • Page 95: Safety Interlocks

    It is possible to encounter the sanity check result error- Safety Interlocks beeps from a badly-malfunctioning or damaged power pack. If so, the user should return the power pack to If the BMS detects a serious internal fault, it can take Zero for repair or replacement.
  • Page 96 If the throttle is disabled while riding, the motorcycle The Charger-Disable Interlock will cease to provide power, and the operator must When the charger is attached and plugged-in to AC pull over to a safe location. power, the BMS communicates with the charger. The BMS can send a signal to the charger requesting that All conditions which would cause the BMS to disable charging terminates immediately.
  • Page 97 Instrument Panel Power Pack Full (High Power Pack-Voltage) Main Power Indicator If the BMS detects that the power pack is already full, it will disable further charging to prevent damage to If a fault has been detected, count the number of the power pack.
  • Page 98 c t i t i s l i k c t i l i k c t i c t i e l i s t i f l e . t s u l i n i l c t i e l t e l t e l t...
  • Page 99 NUMBER OF GREEN CAUSE SOLUTION FLASHES Could not pre-charge motor controller. Precharge failure Contact CSC. Problem with current sensor or connection. Current sensor error Contact CSC. Problem sensing temperature of board. Board temperature sensor error Contact CSC. Unknown system error Contact Zero or CSC.

  • Page 100: General Troubleshooting

    General Troubleshooting SYMPTOM POTENTIAL CAUSE POTENTIAL SOLUTION Power Pack not charged Charge Power Pack. Motorcycle does not turn Key not properly engaged Recheck key in ignition, turn OFF/ON again. Main power cut-off not engaged Move the main power cut-off to the UP/ON position. Kill Switch turned off Press the Kill Switch "ON"...
  • Page 101 NOTES 6-12...

  • Page 102: Warranty/Customer Assistance

    Warranty/Customer Assistance Customer Assistance Phone: (888) 786-9376 Zero Motorcycles Inc. can be contacted via the contact Monday-Friday methods listed below. Please have available the 8am to 5pm Pacific Time following, as it is essential to effectively and efficiently answer your questions or resolve your concerns.

  • Page 103: Warranty Information

    Warranty Information LIMITED WARRANTY COVERAGE STANDARD EXTENDED NO FAULT MOTORCYCLE (Replaces 2nd Year (Replacement Parts Second Year PARTS COVERED of the Standard are 50% of Retail First Year (Excluding Shipping Warranty) Cost Unless Noted) and Labor) Motor (35% Discount) Controller Power Pack (20% Discount) Fork...

  • Page 104: Zero Motorcycles Limited Warranties

    This warranty does not apply to tire wear, chain or sprocket condition, brake pads or rotors, fork seals, Zero Motorcycles Inc. expressly warrants all Zero grips, foot pegs, the seat, or any other parts subject manufactured products from defects in material and to normal wear and tear.

  • Page 105: Extended Warranty

    Under this limited warranty and liability agreement, This extended warranty excludes aftermarket Zero Motorcycles Inc. shall have no obligation and the accessory kits which may be subject to their own purchaser shall have no remedy against Zero warranties. Motorcycles Inc. and its officers and/or agents for any...

  • Page 106: No Fault Warranty

    The purchaser acknowledges that there is an inherent No Fault Warranty Exclusions: risk in the operation of Zero motorcycles and all other Zero Motorcycles Inc. products, and herewith Accessory kits include their own warranties and are assumes liability for any injury arising from all not included in this no fault coverage.

  • Page 107: Proper Use

    Zero exclusion may not apply to you. Motorcycle warranty registration form will indemnify and hold Zero Motorcycles Inc. harmless and take full Zero Motorcycles Inc. reserves the right to change or responsibility for conveying all safety warnings,...

  • Page 108: Purchaser's Responsibilities

    Motorcycle within the required time period as printed you receive the best service for your motorcycle. on the registration card. Perform routine care and maintenance of your Zero Zero Motorcycles Motorcycles Inc. electric motorcycle and power pack 1 Victor Square Scotts Valley, CA 95066 as detailed in the Owner’s Manual.

  • Page 109: Transfer Of Ownership And Warranty

    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 110 NOTES...
  • Page 111 NOTES 7-10...
  • Page 112 INDEX Brake Pad Inspection ..........5-7 Accessories ............... 5-23 Brakes ..............4-4, 5-6 Add On Electrical Equipment ........4-7 Brake Fluid Level Inspection ....... 5-6 An Important Message To You From Zero ....1-1 Brake Pad Inspection .......... 5-7 Front Brake ............5-6 Rear Brake ............
  • Page 113 Controls And Components ........3-1 Fuse Center Location ..........5-24 Customer Assistance ..........7-1 Fuses ................. 5-23 General Information ............ 1-6 Dangerously Low Voltage .......... 4-8 General Maintenance ..........5-6 Disclaimers Applicable to Standard Brakes ..............5-6 Warranty, Extended Warranty and Chain ..............
  • Page 114 Brakes ..............4-4 Drive Chain ............4-4 Left Side View ............. 3-3 Electrical System ..........4-4 Limited Warranties ............. 7-3 Power Pack ............4-4 Location Of Important Labels ........2-3 Throttle ..............4-4 Main Power Cut-Off Label ........2-6 Tires ..............4-4 Power Pack (Battery) Fuse Label .......
  • Page 115 Too Hot ..............6-4 Power Pack Empty ............. 6-4 Operating Information ..........2-2 Power Pack Full (High Power Pack-Voltage) ... 6-8 Operating Your Motorcycle ........4-14 Power Pack Information Label ........2-4 Braking ..............4-14 Pre-Ride Inspection ............ 4-4 Starting ..............4-14 Power Pack ............
  • Page 116 Starting And Operating ..........4-1 Stop/Tail Lamp Bulb Replacement ......5-16 Uncrating Your Motorcycle .......... 4-2 Stopping ..............4-14 Understanding Beep Sequences ......6-3 Suspension ..............5-8 Front ..............5-8 Rear ............... 5-8 Vehicle Identification Number(VIN) ......1-4 Suspension Adjustment ........... 4-15 VIN Break Down ...........
  • Page 117 Z-Force Air Induction System ........2-7 Z-Force Power Pack Battery Fuses ......5-24 Zero Motorcycles Limited Warranties ......7-3 INDEX-6...

This manual is also suitable for:

Ds 2010

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