General Information ..........1-6 Speed Control Switch ........3-3 Zero X Technical Specifications ....1-6 Main Power Indicator ........3-4 Zero MX Technical Specifications ....1-7 Energy Gauge ..........3-4 Vehicle Range ..........1-9 Torque Control Switch ........3-4 Optimizing Your Range By Adapting Handlebar Controls ..........
Page 3
Maintaining Your Motorcycle ........5-1 Customer Assistance ........... 7-1 Owner’s Responsibilities ........5-1 Warranty Information ..........7-2 Bolt Torque Table ..........5-2 Zero Motorcycles Limited Warranties.....7-3 Power Pack ............5-5 Standard Warranty ......... 7-3 General Maintenance ........... 5-6 Extended Warranty ........7-4 Motor ..............
Congratulations and thank you for purchasing the motorcycle is in the index in the back of the manual. 2010 Zero X/MX electric motorcycle; we welcome you The terms “right” or “left” refer to the rider’s right or to the community of Zero Motorcycle riders. This left, when sitting on the motorcycle.
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.
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...
Production Identification Number (PIN) PIN Location PIN Break Down The PIN is a 17-digit number stamped on the head tube of the frame. Do not alter or remove this as it is the legal identifier for your motorcycle. A. PIN Label (Canadian version only) See Location Of Important Labels on page 2-3.
Page 8
Motorcycle Type Dirt 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 9 = 2009...
General Information Zero X Technical Specifications MOTOR DRIVETRAIN Type Brushed permanent magnetic electric Transmission Clutchless one speed • Sport-Mars • Sport-12T/71T, 420 Chain Motor Drive System • Extreme-Perm • Extreme-15T/71T, 420 Chain • Torque 67.7 N m (50 lb ft) CHASSIS/SUSPENSION/BRAKES Peak Front Suspension...
Zero MX Technical Specifications DIMENSIONS MOTOR Wheel Base 137.2 cm (54 in) Type Brushed permanent magnetic electric • Sport-Mars Seat Height 88.3 cm (34.8 in) Motor • Extreme-Perm Rake 23 degrees • Torque 67.7 N m (50 lb ft) Peak...
Page 11
DRIVETRAIN DIMENSIONS Transmission Clutchless one speed Wheel Base 138.4 cm (54.5 in) • Sport-12T/71T, 420 Chain Seat Height 87.1 cm (34.3 in) Drive System • Extreme-15T/71T, 420 Chain Rake 24 degrees CHASSIS/SUSPENSION/BRAKES Front Suspension • Sport-203.2 mm (8 in) WEIGHT •...
The more conservative you ride • Hard acceleration will cause a voltage drop, the better range you can expect from your Zero X/MX thereby making the energy gauge drop Motorcycle. significantly; the gauge should recover when you roll off the throttle.
Emissions Information Transporting The Zero X/MX electric motorcycle is a zero emissions (MX model only) vehicle under California (CARB), U.S. Federal (EPA), When the front fork is compressed, the built up and European Union standards. It uses no gasoline pressure must be released to help prevent fork seal or other liquid fuel.
Page 14
It is recommended that the motorcycle be tied-down Use two ratchet straps in the front and two in the using ratchet straps and a fork support (A) to prevent rear. The tie down straps should be at a 45° angle fork damage.
Safety Information General Safety Precautions 5. Never permit a guest to ride your electric motorcycle without proper instruction. These are 1. This is a performance motorcycle and should performance motorcycles and should be treated be treated with extreme caution. with extreme caution. 6.
10. Modifications of the motorcycle may render the 4. The Zero X/MX power pack should be plugged in vehicle unsafe and may cause severe personal when storing the motorcycle for extended periods injury. Zero Motorcycles cannot be held liable for of time.
8. Failure to follow battery storage and charging instructions as described in this Zero Motorcycles Owner’s Manual may void the warranty of your Zero motorcycle. These guidelines have been rigorously tested to ensure maximum battery efficiency and service. Location Of Important Labels...
Traveling at high speeds reduces A. Speed Control Switch overall range. Zero Motorcycles speed claims are B. Main Power Indicator based upon Zero Motorcycles test riders and an C. Energy Gauge overall average of our high speed testing. These may D. Torque Control Switch...
• Main Power Indicator Amber indicates that the state of charge of the power pack is getting low. The green LED is solidly lit when the motorcycle is • Red indicates that the state of charge of the ready to ride. When the green power LED is on, do power pack is very low and that the power pack not twist the throttle unless you are ready to ride.
Left Handlebar Control Right Handlebar Control Throttle Control Kill Switch Twist the throttle in a counter-clockwise rotation (A) to When the button (A) is accelerate the motor and start the motorcycle in a pressed, it will kill forward direction. Release the throttle and it will return power to the motor to the neutral position (B), decelerating the motor.
Starting And Operating First Time Set-Up 6. Inspect the hydraulic brake system. Follow the hydraulic lines 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.
Uncrating Your Motorcycle The X/MX 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.
Page 32
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.
With the key switch in the OFF position, twist the Pre-Ride Inspection throttle and release to verify that the throttle is smooth and returns correctly. Before operating the Zero X/MX motorcycle, check the • Tires following to make sure the motorcycle is secure and Check both tires for condition and tread depth.
• WARNING: Opening of the power pack is for trained Zero Motorcycles technicians. Please be aware that The key should be removed from the motorcycle incorrect handling of a Zero battery can be when parked, to prevent theft.
Page 35
Power Pack Swapping The X and MX motorcycles feature a quick change power pack. This allows the rider to charge one power pack while using another. To change the power...
Page 36
Battery Management System (BMS) Every power pack contains a Battery Management System (BMS) which monitors the condition of the cells and optimizes the charging process to provide the highest-performance, longest-range, and longest- life for the power pack. The BMS also monitors the battery for a host of predefined conditions, and then takes actions according to these conditions.
Page 37
• • High Or Low Temperature Safety Interlocks Action: If the BMS senses that the power pack is The BMS can disable the motorcycle’s throttle- too hot, above 71°C (160°F), or too cold, below - control if the power pack is fully discharged, or in 7°C (20°F), it sends a signal to disable the motor case of other errors.
Page 38
Beeps The BMS will beep only under two circumstances: The BMS includes an electronic beeper sealed inside • When the motorcycle key switch is turned from the power pack. The beeper is located on the left “OFF” to “ON.” When the motorcycle is turned ON, front of the power pack behind the opening (A).
Page 39
• Battery Charger If the power pack terminates the charge before the charger reaches the state previously Keep your power pack connected to the charger when mentioned, then the charger will continue to cycle your motorcycle is sitting in storage or if it will be and will top off the power pack until the power sitting unused for more than 7 days.
Page 40
Charger LED Indicators Note: The charger must be plugged in for the charger’s indicators to illuminate. See Battery Charger on page 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 41
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 42
6. AVOID connecting the Zero charger and another (Not Installed in Motorcycle) device to a single 15A/20A or the circuit may become overloaded. 1. Remove the power pack from the motorcycle. See Power Pack Swapping on page 4-6. 7. Charging a fully discharged power pack takes about 2 hours.
Page 43
4. AVOID connecting the Zero charger and another device to a single 15A/20A circuit or the circuit may become overloaded. 5. Charging a fully discharged Zero X/MX power pack takes about 2 hours. 6. Your power pack is equipped with an “Emergency Energy Reserve Beep.”...
Operating Your Motorcycle The front and rear brake should be applied together, with a slight amount more of braking on the front. Starting CAUTION: If you apply the front or rear brake hard enough, it is possible to lock the wheels. This could 1.
Brake Adjustment Lever Reach Master Cylinder/Lever Angle Adjust the brake lever reach by turning the 1. Loosen, but do not remove, the handlebar clamp reach adjustment knob screws (A). (A). Turning the knob 2. Position the master cylinder/lever on the counter-clockwise will handlebar in your desired position.
Page 46
MX Sport and Extreme Models: 1. Bleed Screw - The small Allen screw (A) at the top of the fork leg is the “bleed” screw. The bleed screw serves two purposes: • Transporting your motorcycle. See Transporting on page 1-10.
Page 47
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 (C) securing the screw (D). The adjuster has 12 stages of adjustment.
Page 48
X Sport and Extreme Models: 2. Pre-load - Adding or removing air from the fork leg changes pre-load. This is done by 1. Spring Tuning - Spring tuning is accomplished by unscrewing the dust cap from the top of the left changing the air pressure within the fork.
Page 49
set too fast will cause the fork to top out 2. By adding or removing air pressure (or nitrogen) harshly. If the fork is topping out and you have from the Schrader valve (A) on the bottom of the the correct spring for your weight, turn the right fork leg.
Page 50
More compression damping will feel stiff over small Record this measurement, this will be bumps but will be more resistant to bottoming out. measurement M1. Never run less than 345 kpa (50 psi) in the canister. Rear Shock Adjustment Spring Adjustment: Obtaining the correct rear spring rate is critical for proper handling.
Page 51
Have a second assistant take a Example: measurement using the same locations as in step 2. 600 mm (24 in) Record this measurement, this will be measurement M2. 500 mm (28 in) 100 mm (4 in) If the total is between 90 to 100 mm (3.5 to 4.0 in) the sag is correct.
Page 52
• • Spring Pre-load Adjustment Rebound Adjustment - The rebound adjuster knob (C) is at the bottom of the shock. It has 8 stages Clean any dirt or debris from the of adjustment. Printed on the knob is S-F, threads of the shock. meaning Slow and Fast.
Maintaining Your Motorcycle Owner’s Responsibilities 4. The operator is responsible for learning and obeying all country, federal, state, and local laws 1. This owner’s manual should be considered a governing the operations of an electric motorcycle. permanent part of this motorcycle and should remain with it even if the motorcycle is 5.
Bolt Torque Table LOCATION ITEM TORQUE NOTES • Front axle pinch bolts 11-13 N m (8-10 lb ft) ® ® Use LOCTITE • Front axle end bolts 18-20 N m (13-15 lb ft) • ® ® Front caliper mount bolts 11-13 N m (8-10 lb ft) Use LOCTITE...
See Bolt Torque Table on page 5-2. Zero recommends you plug in your Zero motorcycle 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.
General Maintenance If the brake pads (A) are worn, replace both brake pad immediately. Motor CAUTION: Wear safety glasses when using compressed air to avoid eye injuries. The motor does not require much maintenance, but dust can collect inside the motor and can cause premature brush wear.
Wheels And Tires Rear CAUTION: The shock absorber assembly contains Inspect both wheels for the following: highly pressurized gas. • • Bent, loose, or missing spokes Do not attempt to tamper with or open the cylinder or shock. • Bent or cracked wheels •...
Tire Inflation Chain Cleaning The Drive Chain CAUTION: Under-inflation is the most common cause of tire failure and may result in severe tire cracking, CAUTION: tread separation, “blowout,” or unexpected loss of • Wear safety glasses when cleaning the chain to motorcycle control causing personal injury and prevent eye injuries.
Page 62
• Never have the motor spinning the wheel. Turn 1. Remove the key from the key switch. the wheel only by hand. Failure to do so could result in serious personal injury. 2. Set the motorcycle on a stand or lift so the rear •...
Page 63
Drive Chain Adjustment Procedure Checking The Drive Chain 1. Remove the key from the key switch. 1. Remove the key from the key switch. 2. Loosen both front motor mount Allen bolts (B). 2. Using a ruler, grasp the chain halfway between the front and rear sprockets.
Cleaning To prolong the life of your motorcycle it should be washed periodically. Regular cleaning, using correct methods, is an important factor in maintaining the value of your Zero motorcycle. It also ensures that safety-relevant parts remain in full working order. CAUTION: After cleaning and before starting on your journey, always test the brakes.
For more information on the power pack and the 1. It is required to always leave the power pack electrical system see Battery Management System plugged in when the Zero X/MX is not in use. The (BMS) on page 4-7. Zero X/MX charger is designed to maintain a...
Maintenance Schedule The scheduled maintenance must be performed in accordance with this chart to keep the Zero X/MX motorcycle in top running condition. The initial maintenance is vitally important and must not be neglected. ITEM ROUTINE EVERY INITIAL TIME INTERVALS...
Page 67
ITEM ROUTINE EVERY INITIAL TIME INTERVALS RIDE 1 month 6 months 12 months 18 months 24 months 30 months Wheel • Check bearings for smooth operation. Bearings Replace if necessary. • Check bearing assemblies for looseness. Swingarm • Moderately repack with lithium grease. Pivot •...
Page 68
ITEM ROUTINE EVERY INITIAL TIME INTERVALS RIDE 1 month 6 months 12 months 18 months 24 months 30 months • Check operation and for oil leakage. • Service/Rebuild if necessary. Refer Front Fork to the service manual for more information. Rear Shock •...
If the fuse melts repeatedly, have the electrical system inspected by your CSC. There is one 4 amp ATM-4 fuse on the X/MX. The fuse controls the coil side of the motor controller solenoid and the key switch. 5-16...
Page 70
Follow the maintenance schedules on pages 5-13 through 5-15. After a scheduled service or routine is performed, record the information on the chart below. DATE ITEM SERVICE/ROUTINE DESCRIPTION 5-17...
If you are unable to solve an issue with your Zero X/MX 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.
Page 73
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.
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 75
Power Pack Empty Power Pack Unbalanced If the power pack is completely empty, an error-beep The power pack contains many individual cells. The will sound and the BMS will disable the throttle. You BMS continuously monitors the cells and tries to keep cannot ride the motorcycle until you recharge the them all “in balance”...
Page 76
The Low-Power Pack warning beep will sound BMS Appendix continuously until either (1) the motorcycle is turned There are other beeps that 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.
It is possible to encounter the sanity check result error- Safety Interlocks beeps from a badly-malfunctioning or damaged power If the BMS detects a serious internal fault, it can take pack. If so, you should contact your CSC. Your power either or both of two actions to prevent damage to the pack may need to be repaired or replaced.
Page 78
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 79
Instrument Panel Power Pack Full (High 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 80
NUMBER OF GREEN CAUSE SOLUTION FLASHES Kill switch is in the OFF position. Press the Motorcycle disabled due to kill switch kill switch ON button. Board failed its power-on self test. Try power System startup failure cycling the key switch. Throttle is ON or throttle/connection is bad.
Page 81
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.
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.
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...
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.
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...
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.
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,...
Perform routine care and maintenance of your Zero Motorcycles Inc. electric motorcycle and power pack Zero Motorcycles as detailed in the Owner’s Manual. 1 Victor Square Scotts Valley, CA 95066...
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 94
INDEX Accessories ............5-16 Chain ................5-8 Add On Electrical Equipment ........4-6 Checking The Drive Chain ........ 5-10 An Important Message To You From Zero ....1-1 Cleaning The Drive Chain ........5-8 Drive Chain Adjustment Procedure ....5-10 Lubricating The Drive Chain .......
Page 95
General Troubleshooting ......... 6-11 Front Fork Adjustment ..........4-16 Fuses ..............5-16 Handlebar Controls ............ 3-5 Left Handlebar Control ........3-6 General Information ............ 1-6 Right Handlebar Control ........3-6 Zero MX Technical Specifications ......1-7 Zero X Technical Specifications ......1-6 INDEX-2...
Page 96
Maintaining Your Motorcycle ........5-1 Accessories ............5-16 Instrument Panel ..........3-3, 6-8 Bolt Torque Table ..........5-2 Energy Gauge ............3-4 Fuses ..............5-16 Main Power Indicator ........... 3-4 General Maintenance ........... 5-6 Speed Control Switch .......... 3-3 Owner’s Responsibilities ........5-1 Torque Control Switch ..........
Page 97
Optimizing Your Range By Adapting Your Public Charging Stations ........... 1-9 Riding Style ..............1-9 Purchaser’s Responsibilities ........7-7 Owner Information ............1-3 Owner’s Responsibilities ........... 5-1 Rear Brake Lever ............3-6 Rear Shock Adjustment ........... 4-21 Parking And Long Term Storage ......5-12 Right Handlebar Control ..........
Page 98
Starting ............... 4-15 Starting And Operating ..........4-1 Uncrating Your Motorcycle .......... 4-2 First Time Set-Up ..........4-1 Understanding Beep Sequences ......6-3 General Operation ..........4-4 Operating Your Motorcycle ......... 4-15 Stopping ..............4-15 Vehicle Range ............. 1-9 Suspension ..............5-6 Front ..............
Need help?
Do you have a question about the MX and is the answer not in the manual?
Questions and answers