Zero FX Owner's Manual
  1. Manuals
  2. Brands
  3. Zero Manuals
  4. Scooter
  5. 2014 FX
  6. Owner's manual

Zero FX Owner's Manual

Hide thumbs Also See for FX:
Table of Contents

Advertisement

Quick Links

Download this manual

Advertisement

Table of Contents
loading

Related Manuals for Zero FX

Summary of Contents for Zero FX

  • Page 3: Table Of Contents

    Controls and Components ......3.1 Introduction..............1.1 Controls and Components.......... 3.1 An Important Message To You From Zero Motorcycle Controls (FX/MX*/XU Street Legal) ..3.2 Motorcycles ............... 1.1 Side View (MX Dirt) ........... 3.4 About This Manual ............ 1.1 Side View (FX Street Legal) ........3.6 Useful Information For Safe Riding ......
  • Page 4 General Maintenance ..........5.10 Brakes..............5.10 Warranty and Customer Information... 7.1 Suspension ..............5.12 Warranty Information ..........7.1 Wheels And Tires.............5.13 Zero Motorcycles Warranties ........7.1 Tire Inflation .............5.13 Standard Warranty............ 7.1 Drive Belt ..............5.14 Standard Warranty Exclusions........7.1 Drive Chain (Optional) ..........5.16 Disclaimers Applicable to Standard Warranty...

  • Page 5: Introduction

     Zero XU Street Legal When it comes time to sell your Zero, please remember to  Belt Drive hand over this manual; it is, by law, an important part of the ...

  • 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 CAUTION to indicate WARNING! 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 WARNING to indicate things that could damage on the charger even if fully charged.

  • Page 7: Identification Numbers

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

  • Page 8: Power Pack Serial Number

    The Power Pack serial number is located on the upper A Vehicle Identification Number (VIN) is found on the right rear of the power pack. FX/XU Street Legal. Note: A Production Identification Number (PIN) is found on Motor Serial Number the MX Dirt bike.
  • Page 9 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. World Manufacturer Identifier 538 = Zero Motorcycles Inc.

  • Page 10: General Information

    Quick Charge Time hours (95% charged) Zero FX (accessory)  ZF5.7 3.3 hours (100% charged)/2.8 The Zero FX specifications below apply to both the ZF2.8 hours (95% charged) and ZF5.7 models (unless otherwise specified). CHAdeMo Recharge Time 1.0 hour (0 to 95%)
  • Page 11 General Information DRIVETRAIN DIMENSIONS Transmission Clutchless Direct Drive Wheel Base 56.6 in (1,438 mm) Final Drive 132T/25T, Poly Chain® GT® Carbon™ Seat Height 35.4 in (899 mm) (belt) Rake 26.1 degrees CHASSIS/SUSPENSION/BRAKES Trail 4.4 in (112 mm) Front Suspension Travel 3.2 in/240 mm WEIGHT Rear Suspension Travel...
  • Page 12 General Information Zero XU CHAdeMo Recharge Time 1.0 hour (0 to 95%) MOTOR CHAdeMo Recharge Time 1.5 hours Type Z-Force 75-5 passively air-cooled, (0 to 100%) high-efficiency, radial flux, permanent Input Standard 120 V AC or 240 V AC magnet, brushless motor...
  • Page 13 General Information CHASSIS/SUSPENSION/BRAKES WEIGHT Front Suspension Travel 2.0 in (51 mm) Frame 17 lbs (7.7 kg)  ZF2.8 255 lbs (102 kg) Rear Suspension Travel 5.78 in (147 mm) Curb Weight  ZF5.7 267 lbs (121 kg) Front Brakes 221 mm OD rotor, 4.5 mm thick 2 piston floating caliper, 27 mm OD pistons ...
  • Page 14 General Information Zero MX  MX ZF2.8: 2.7 hours (100% Charge Time (standard) charged)/2.2 hours (95% charged) MOTOR  MX ZF5.7: 4.9 hours (100%  ZF2.8: 20-60 minutes MX Track charged)/4.4 hours (95% charged)  ZF5.7: 35-120 minutes  ZF2.8 1.6 hours (100% charged)/1.1 Supplemental Charger ...
  • Page 15 General Information Front Tire 80/100-21 in Rear Tire 110/100-18 in Front Wheel 1.60x21 in Rear Wheel 2.15x18 in Front Suspension 38 mm inverted slider forks with adjustable compression and rebound damping Rear Suspension Remote reservoir shock with adjustable spring preload, compression and rebound damping DIMENSIONS Wheel Base...

  • Page 16: Vehicle Range

    Environmental Protection Agency (EPA) in order to reflection of your riding habits. The more conservative you simulate city-type riding. ride the better range you can expect from your Zero Motorcycle. 2. “Highway”: This test procedure uses two separate constant speeds of 55 mph and 70 mph to simulate Some of the factors which affect range include speed, highway riding.

  • Page 17: Public Charging Stations

    J1772 Zero Motorcycle accessory or a CHAdeMO averaged over a shorter distance on an electric Zero Motorcycle accessory. These stations are often motorcycle.
  • Page 18 General Information RANGE LOW SPEED HIGH SPEED FEWER STOPS STOP & GO FLAT ELEVATION CHANGES SMOOTH PAVEMENT SOFT GRAVEL MODULATED RIDING AGGRESSIVE RIDING STREAMLINED FULLY UPRIGHT REDUCED CARGO HEAVIER ZOM0156 1.14...
  • Page 19 General Information RANGE WARM WEATHER COLD WEATHER NO WINDS HIGH HEAD WINDS DRY ROADS SLIPPERY ROADS INFLATED TIRES UNDERINFLATED TIRES LUBED CHAIN DRY CHAIN ADJUSTED CHAIN STRETCHED CHAIN BALANCED PACK UNBALANCED PACK ZOM0157 1.15...

  • Page 20: Emissions Information

    WARNING! Please use only Zero approved parts and accessories for your Zero Motorcycle. Parts and accessories for your Zero Motorcycle have been checked and tested for safety and suitability. Zero is unable to accept any liability whatsoever for parts and accessories which have not been approved.

  • Page 21: Transporting

    General Information Transporting It is recommended that the motorcycle be tied-down using ratchet straps. Place the ratchet straps around a frame When the front fork is compressed, the built up pressure contact point. Soft straps must be used to prevent must be released to help prevent fork seal leaks.
  • Page 22 Notes 1.18...

  • Page 23: General Safety Precautions

     Modifications to the motorcycle may render the vehicle applies to even short journeys, and to every season of unsafe and may cause severe personal injury. Zero the year. Motorcycles cannot be held liable for non-approved ...

  • Page 24: Important Operating Information

     The power pack should be plugged in when storing the motorcycle for extended periods of time.  Keep your Zero connected to the charger when your motorcycle is sitting in storage or if it will be sitting unused for more than 30 days.

  • Page 25: Location Of Important Labels

    Location of Important Labels Location of Important Labels Location of Important Labels The vehicle could contain the following (example) information for both North American and European models: ZOM0106 A. VIN label (European Union) - certification label C. VIN label (North America) - certification label shown B.
  • Page 26 Location of Important Labels Anti-Tamper Control Label (Europe only) The Anti-Tamper control label (shown below) is located on the left-side of the frame.
  • Page 27 Location of Important Labels High Voltage Warning Labels ZOM0112 ZOM0111 Located on frame for single battery (XU/FU only) Located near the battery (XU/FX only)
  • Page 28 Notes...

  • Page 29: Controls And Components

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

  • Page 30: Motorcycle Controls (Fx/Mx*/Xu Street Legal)

    Controls and Components Motorcycle Controls (FX/MX*/XU Street Legal)
  • Page 31 For description and operation see page 5-10. G. Motor Stop Switch For description and operation see page 3-12. H. Throttle Control For description and operation see page 3-12. * The Zero MX motorcycle does not have a headlight or turn signals.

  • Page 32: Side View (Mx Dirt)

    Controls and Components Side View (MX Dirt)
  • Page 33 Controls and Components A. Drive Belt For description and operation see page 5-14. B. Drive Belt Tension Adjuster For description and operation see page 5-14. C. Power Pack Rail Knob For description and operation see page 5-9. D. Power Pack For description and operation see page 5-9 E.

  • Page 34: Side View (Fx Street Legal)

    Controls and Components Side View (FX Street Legal)
  • Page 35 Controls and Components A. Drive Belt For description and operation see page 5-14. B. Drive Belt Tension Adjuster For description and operation see page 5-16. C. Power Pack Rail Knob For description and operation see page 5-9. D. Power Pack For a description see page 5-9.

  • Page 36: Side View (Xu Street Legal)

    Controls and Components Side View (XU Street Legal)
  • Page 37 Controls and Components A. Drive Belt For a description see page 5-14. B. Drive Belt Tension Adjuster For a description and operation see page 5-14. C. Power Pack Rail Knob For a description see page 5-9. D. Power Pack Rail For a description see page 4-7.

  • Page 38: Instrument Panel (Fx/Mx/Xu Street Legal)

    Controls and Components Instrument Panel (FX/MX/XU Street Legal) 3.10...
  • Page 39 The main power indicator (green) is ON any time the RPM, and Max. Holding it down clears the trip key is in the ON position. If the main power indicator is odometer resetting it back to zero. flashing, the system has detected a fault. For I. Display Area troubleshooting, see section page 6-1.

  • Page 40: Handlebar Controls (Fx/Mx/Xu Street Legal)

    Controls and Components Handlebar Controls (FX/MX/XU Street Legal) 3.12...
  • Page 41 Controls and Components A. Flash-to-pass When the motorcycle is moving and the throttle control is in the fully closed position it will activate the When the headlight is in the low beam position, push regenerative braking feature. Regenerative braking the flash-to-pass switch and the high beam will takes some of the energy from the moving motorcycle illuminate and will stay illuminated until the switch is and turns it back into electrical energy.
  • Page 42 Controls and Components E. Motor Stop Switch G. Horn Button When the switch (A) is pressed, it will stop power to When the key is in the ON position, the horn will the motor controller. The motor controller will remain sound when the button is pressed.

  • Page 43: Performance Level Switch (Fx/Mx/Xu Street Legal)

     Make minor adjustments  Collect and email logs to Zero support staff  Examine the precise State of Charge (SOC) of your motorcycle The performance level switch (A) is a two position switch ...
  • Page 44 Notes 3.16...

  • Page 45: Starting And Operating

    The charge indicator should read fully charged. perform the following: 1. Remove the motorcycle from its shipping crate. See Unpacking Your Zero Motorcycle on page 4-2. 2. You must charge the power pack before riding the motorcycle. Your Zero Motorcycle is shipped fully charged from the factory.

  • Page 46: Unpacking Your Zero Motorcycle

     Remove the tie down straps from crate base (MX only). Unpacking Your Zero Motorcycle  Carefully lift rear portion of the motorcycle over the Although unpacking your Zero Motorcycle can be done by swingarm standoff and off crate base. a single person, it is recommended to have a second ...

  • Page 47: General Operation

    MX Dirt - 3 bars (½ specified on page 5-13. Replace the tires when the charge), or FX/XU Street Legal - 5 bars (½ charge), we tread height is 0.08 inches (2 mm) or less. suggest you recharge before use. Always keep the charger cord with the motorcycle.

  • Page 48: Key Switch/Steering Lock Positions

    General Operation Key Switch/Steering Lock Positions Steering Lock Using the steering lock when parked will prevent unauthorized use and help 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 49: Power Pack

    This position is used for operating the motorcycle. In this motorcycle. The integrated onboard charger minimizes position the following will occur: charge time and can work in parallel with Zero’s quick  Lights turn ON (FX/XU - street legal) charge accessories to cut charge times by as much as ...
  • Page 50 ** When the motorcycle is ridden with average aggressiveness on average trails/tracks. WARNING! Opening of the power pack is for trained Zero Motorcycles technicians. Please be aware that incorrect handling of a Zero power pack can be dangerous. DO...
  • Page 51 General Operation Power Pack Swapping 4. Using a firm grip, slide the power pack out of the frame. DO NOT lift the power pack by the plastic connector The motorcycles feature a quick change power pack. This housing. allows the rider to charge one power pack while using another.

  • Page 52: Power Pack Charger

    90 days if stored fully charged. Zero recommends previously noted. you plug in your Zero Motorcycle after 30 days, even if fully The on-board charger LED indicators (A) are visible on the charged. Please leave your Zero Motorcycle plugged in upper panel.
  • Page 53 General Operation MX Charging LED. FX and XU Charging LED...
  • Page 54 General Operation Charging the Power Pack To charge using the standard charger (FX/XU only): WARNING! Charge the Zero power pack with the Zero 1. Ensure that the key switch is in the OFF position. charger. 2. Plug the supplied power cord into the onboard charger It is possible for lithium ion cells to overheat and fail.
  • Page 55 General Operation change the amount of time that the motorcycle takes to charge. 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 10 amps from the 120 V AC circuit when charging.
  • Page 56 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 57 General Operation  The BMS is cutting off the charge because one or Quick Charger LED Indicators 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 off-board accessory charger will enter maintenance mode.

  • Page 58: Operating Your Motorcycle

    We suggest performance and durability of its powertrain. progressive use of the brakes to bring the Zero Motorcycle to a complete stop without locking the wheels. Your Zero Motorcycle is a light weight performance product and...
  • Page 59 Please note that the lighting of this temperature indicator does not indicate that there’s anything malfunctioning with your Zero motorcycle; it is simply letting you know that the thermal strategy is working. If you do not moderate your speed/power, the bike’s system will reduce your...

  • Page 60: Front Suspension Adjustment

    General Operation Front Suspension Adjustment Rebound Damping The rebound damping is adjusted by turning the slotted A shock has two main actions: compression when the adjuster screw (B) on the top of both fork legs. Next to it shock gets loaded, and rebound when the shock returns will be the writing S-F, meaning Slow and Fast.
  • Page 61 Factory Supplied Front Suspension Settings The following information will allow you to adjust the front suspension back to the factory settings the motorcycle was originally supplied with. FX / MX Models ADJUSTMENT SETTING Front Fork Compression 5 clicks out from fully closed...

  • Page 62: Rear Shock Adjustment

    General Operation 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 180 lb (82 kg) rider. This puts the rear tire 1/3 of the way through its vertical travel.
  • Page 63 If the sag is not correct, the spring pre- load should be adjusted. See “Spring Pre-load Adjustment”, on page 4-20. MODEL FX - Street Legal 2.3 in to 2.9 in (69-76 mm) MX - Dirt 2.3 in to 2.9 in (69-76 mm) XU - Street Legal 1.5 in to 1.9 in (38-49 mm)
  • Page 64 General Operation Spring Pre-load Adjustment 1. Clean any dirt or debris from the threads of the shock near the lock ring (A). 2. Using a lock ring wrench loosen the lock nut (A). 3. For measurements less than the specified value, decrease the pre-load on the spring by turning the spring nut (B) counter-clockwise on the shock.
  • Page 65 Rebound Adjustment The rebound adjuster knob (A) is at the bottom of the shock. The FX and MX models have 13 clicks of rebound adjustment (the XU has 8). The FX and MX motorcycles have a knob at the base of the shock. However, the XU has a distinct red knob (A).
  • Page 66 General Operation Compression Adjustment The compression adjustment knob is at the top of the shock. The FX and MX models have 19 clicks of compression adjustment (XU model has none). The knob has “+” (slower compression) and “-” (faster compression).
  • Page 67 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. FX / MX Models ADJUSTMENT SETTING Rear Shock Compression 14 clicks out from fully closed...
  • Page 68 Notes 4.24...

  • Page 69: Maintaining Your Motorcycle

    Turn Signal Light Bulb (amber) RY10W (10 watt) motorcycle as detailed in this owner’s manual. Brake/Tail Lights Bulb 1157 (5 watt)  Use only Zero approved parts and Zero Motorcycle Front Running Light Bulb W3W (3 watt) accessories. Brake Fluid DOT 4 ...

  • Page 70: Maintenance Schedule

    Maintaining Your Motorcycle Maintenance Schedule The scheduled maintenance must be performed in accordance with this chart to keep the Zero FX/MX/XU 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 71 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 72 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 73: Component Fasteners

    Maintaining Your Motorcycle Component Fasteners Periodically check and tighten the following fasteners on your motorcycle. Torque Table LOCATION ITEM TORQUE NOTES Front axle end bolts 19 lb ft (26 Nm) Use LOCTITE® 242® (or equivalent) Front caliper mount bolts 12 lb ft (20 Nm) Use LOCTITE®...
  • Page 74 Maintaining Your Motorcycle Left Side Of Motorcycle ZOM0085 Refer to Torque table on page 5-5.
  • Page 75 Maintaining Your Motorcycle Right Side Of Motorcycle ZOM0086 Refer to Torque table on page 5-5.
  • Page 76 Maintaining Your Motorcycle Handlebars Refer to Torque table on page 5-5.

  • Page 77: Power Pack

    The power pack must be charged within 24 hours if fully discharged, and charged within 90 days if stored 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 78: General Maintenance

    General Maintenance General Maintenance Brakes Rear Brake Pads An example of the rear brake pads is shown below. This section describes how to inspect the brake fluid level for both the front and rear brakes. Your motorcycle uses Nissin brake pads for stopping power. Both front and rear pad examples are shown below.
  • Page 79 General Maintenance Front Brake Rear Brake Inspect the level of the front Inspect the level of the rear brake fluid through the sight brake fluid by inspecting the glass (B). If the fluid level is level through the reservoir visibly below the low level housing.

  • Page 80: Suspension

    General Maintenance Brake Pad Inspection Suspension The brake pads must be inspected when specified in the Front maintenance schedule. See Maintenance Schedule  For maintenance, see Maintenance Schedule on information on page 5-2. Visually inspect the brakes by page 5-2. looking at the remaining brake pad material through the ...

  • Page 81: Wheels And Tires

    General Maintenance Wheels And Tires Tire Inflation Inspect both wheels for the following: CAUTION: Under-inflation is the most common cause of  Bent, loose, or missing spokes tire failure and may result in severe tire cracking, tread separation, “blowout,” or unexpected loss of motorcycle ...

  • Page 82: 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.
  • Page 83 General Maintenance Drive Belt Adjustment Procedure Note: Please adjust both sides equally. 1. Remove key from the key switch. 2. Loosen the rear axle nut (C). 3. Loosen left and right (A) jam nuts (13mm) in order to make adjustments. 4.

  • Page 84: Drive Chain (Optional)

    General Maintenance Drive Chain (Optional) 3. Using a brush, fill the bristles with spray from the chain cleaner. Begin gently scrubbing the chain on the top of Cleaning The Drive Chain your swingarm using the brush. CAUTION: Wear safety glasses when cleaning the chain 4.
  • Page 85 General Maintenance Follow the manufacturer’s instructions for the chain Checking The Drive Chain lubricant you are using; below are the general guidelines. 1. Remove the key from the key switch. Do not allow any of the lubricant to get on the brake rotor. 2.

  • Page 86: Headlight Alignment

    General Maintenance Adjusting The Drive Chain Headlight Alignment 1. Remove the key from the key switch. The headlight should be checked for correct alignment 2. Loosen the 13 mm jam nut (A) on the chain tensioner. periodically. It must be aligned any time the suspension sag is adjusted because this will affect the headlight Note: Chain tension will increase slightly when motor alignment.
  • Page 87 General Maintenance To replace the bulb: 1. Remove the three screws (A) from the headlight trim ring. 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: ...
  • Page 88 General Maintenance 2. Disconnect the headlight bulb connector (B). 5. Install the headlight bulb into the lens. 6. Install the headlight spring clip. 3. Unhook the headlight bulb spring clip (C) by pushing 7. Connect the headlight connector and install the down and to the side.

  • Page 89: Turn Signal Light Bulb Replacement

    General Maintenance Turn Signal Light Bulb Replacement Brake/Tail Light Bulb Replacement To replace the signal light bulb: To replace the brake/trail light bulb: 1. Remove the turn signal lens screw (A) and remove the 1. Remove the brake/tail light lens screws (A) and remove lens.

  • Page 90: Running Light Bulb Replacement

    General Maintenance Running Light Bulb Replacement 1. Remove the three screws (A) from the headlight trim ring. 3. Install the bulb and pivot the contact back onto the bulb. 4. Install the headlight into the housing, install trim ring with the gasket and install the trim ring screws. 2.

  • Page 91: Cleaning

    General Maintenance Cleaning 1. Gently wash your motorcycle with a sponge or a clean soft cloth, mild detergent, and plenty of water. WARNING! 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 92: Parking And Long Term Storage

     It is recommended to always leave the power pack Zero accessories are designed to complement and plugged in. The Zero charger is designed to maintain a function with other systems on your motorcycle. Your balanced and complete charge at all times without dealer can accessorize the motorcycle using genuine Zero wasting any electricity.
  • Page 93 General Maintenance 12 Volt Fuse Center To access the 12 volt fuse center: The 12 volt fuse center is located behind the front fork 1. Remove the left trim panel by removing 3 hex bolts, 1 under the left trim panel. standard bolt, and (push-in) plastic rivet.
  • Page 94 General Maintenance High Voltage Fuse Center To replace a high voltage fuse:  Unscrew the fuse cover. The high voltage fuse center is located on the left side of the motorcycle (in a cluster of five fuses).  Replace the fuse. ...

  • Page 95: Service Record

    Service Record Service Record Follow the maintenance schedules on page 5-2. After a scheduled service or routine is performed, record the information on the chart below. DATE ITEM SERVICE/ROUTINE DESCRIPTION 5.27...
  • Page 96 Notes 5.28...

  • Page 97: Troubleshooting

    If you are unable to solve an issue with your Zero MX/FX/XU Motorcycle, take it to an Always observe and obey the instructions on labels authorized dealer at your convenience. If there is no dealer attached to components on the motorcycle - they are there in your area call Zero Motorcycles Customer Service.

  • Page 98: 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 99 50 ms 60 sec Pack Low Charge power pack  50 ms 1 sec Number of Cell Packs Not Set Contact Zero or the Dealer  50 ms 1 sec Self-Test Failed Contact Zero or the Dealer  50 ms...
  • Page 100 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 101 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 102 Troubleshooting Power Pack Empty Power Pack Too Hot If the power pack is completely empty, an error-beep The power pack contains internal temperature sensors. If sounds and the BMS disables the throttle. You cannot ride the BMS measures excessive internal temperatures, it the motorcycle until you recharge the power pack.
  • Page 103 BMS Error Beep Pattern It is possible to encounter the power ON self-test result error-beeps from a badly malfunctioning or damaged power pack. If so, the user should return the power pack to Zero for repair or replacement. PATTERN WHEN MEANING...

  • Page 104: 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 Operation 1. the coldest temperature in the garage does not fall Operation of the motorcycle in cold temperatures has no below -31°F (-35°C) permanent impact on its battery pack/cells;...
  • Page 105 Troubleshooting Hot Weather Operation Operation of the motorcycle in hot temperatures should not result in any noticeable performance changes. However, the BMS will not allow motorcycle operation and its associated battery discharge above 140°F (60°C), as measured at the battery. In hot temperatures greater than 110°F (43°C), the charger reduces its charge current to the battery, increasing charge time accordingly;...

  • Page 106: Safety Interlocks

    Troubleshooting Safety Interlocks Throttle Disable Interlock The BMS communicates with the main motorcycle control If the BMS detects a serious internal fault, it can take either module. The BMS can send a signal to the main or both of two actions to prevent damage to the power motorcycle controller requesting that the throttle control on pack: the motorcycle be disabled.
  • Page 107 Troubleshooting Charger-Disable Interlock When the charger is attached and plugged in to AC power, the BMS communicates with the charger. The BMS can send a signal to the charger requesting that charging terminates immediately. When the charger is disabled, the indicator lights on the charger displays that charging has stopped.

  • Page 108: System Warning Indicator

    Troubleshooting System Warning Indicator If a fault has been detected, count the number of times the red LED (A) flashes. Refer to the table on the following pages for a possible cause and solution to the issue. 6.12...
  • Page 109 Motor Stop Switch Disabled or Kickstand motor stop switch ON button. Kickstand is down. Switch Disabled Raise kickstand. Indicator Always ON Contact Zero or your dealer. Self-Test Failed Unplug charger. Throttle is ON or throttle/connection is bad. Verify Charger Connected throttle action and/or check connection.
  • Page 110 Zero or your dealer. Turn the ignition OFF and allow to cool off and then Temperature Protection Error restart. If problem persists contact Zero or your dealer. Turn the ignition OFF and ON. If problem persists Throttle Output Error contact Zero or your dealer.

  • Page 111: 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 Understanding BMS Flash Code Patterns (Charge Mode) on page 6-4.
  • Page 112 Notes 6.16...

  • Page 113: Warranty Information

    Zero Motorcycles Inc. expressly warrants all 2013 Zero This warranty does not apply to tire wear, chain or sprocket manufactured FX and XU models from defects in material condition, brake pads or rotors, fork seals, grips, foot pegs, and workmanship to the original owner, under normal...

  • Page 114: Disclaimers Applicable To Standard Warranty

    Zero Motorcycles Inc. assumes no responsibility for incidental, consequential or other damages including but not limited to: expense of returning the Zero product to a...

  • Page 115: Proper Use

    30 Submit the warranty registration card for your Zero days, or keeping it on the charger when in storage or out of Motorcycle within the required time period as printed on regular use.

  • Page 116: Warranty Procedures

    Zero Motorcycles BV Warranty services may be obtained by contacting your Fluorietweg 12D local Zero Motorcycle dealer; please see the locator on www.zeromotorcycles.com for the nearest location. In the Alkmaar, 1812 RR event that a dealer is not in your state, province, or country, you can contact Zero Motorcycles Inc.

  • Page 117: Transfer Of Ownership And Warranty

    Warranty Information 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 118: Customer Information

    Customer Information Customer Information Customer Assistance Please have the following available when contacting Zero Motorcycles Inc. as they are essential to effectively and efficiently answer your questions or resolve your concerns.  Owner’s name and address  Owner’s telephone number ...

  • Page 119: Reporting Safety Defects

    However, NHTSA cannot become involved in individual problems between you, your dealer, or Zero Motorcycles Inc. To contact NHTSA, you may call the Vehicle Safety Hotline toll-free at: 1-888-327-4236 (TTY: 1-800-424-9153);...
  • Page 120 Notes...

  • Page 121: Index

    Index Drive Chain ..............5.16 Adjustment Procedure..........5.18 Accessories ..............5.24 Cleaning ..............5.16 Lubricating...............5.16 Bolt Torque Specifications..........5.5 Brake/Tail Light Bulb Replacement ......5.21 Emissions Information ..........1.16 Brakes ................. 5.10 Brake Fluid Level Inspection ........5.10 Brake Pad Inspection ..........5.12 First Time Set-Up............4.1 DOT 4 brake fluid ............5.11 Fuses ................5.24 Front Brake .............5.11 High Voltage Fuse Center ........5.26...
  • Page 122 Index Important Operating Information ........2.2 Parts/Maintenance Items..........5.1 Inspection Performance Level Switch........... 3.15 Pre-Ride..............4.3 Eco Position ............3.15 Sport Position............3.15 Power Pack ..............5.9 Keys Plug in Your Z-Force Power Pack......1.2 Replacement Code Number ........1.4 Serial Number ............
  • Page 123 Front (Factory) ............4.17 Location............. 1.4 Rear (Factory) ............4.23 Understanding Your VIN Number ......1.5 Vehicle Range .............1.12 VIN.................1.4 Technical Specifications Zero FX Technical Specifications......1.6 Zero MX Technical Specifications......1.10 Warranty ................7.1 Zero XU Technical Specifications ......1.8 Standard..............7.1 Temperature Indicator Standard Warranty Exclusions......7.1 Power Pack Full (High Power Pack-Voltage)....6.6...
  • Page 124 Notes INDEX.4...

  • Page 125: First Responder Information

    First Responder Information - High Voltage Components Locations WARNING WARNING NEVER cut high voltage components or cabling. Cutting could result in serious injury or death. DO NOT CUT DO NOT CUT COLORED COLORED High voltage cables and components may remain energized for ZONES ZONES up to 10 seconds after disabling.

This manual is also suitable for:

XuMx

Table of Contents