Zero FX 2018 Owner's Manual
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Zero FX 2018 Owner's Manual

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2018 OWNER'S MANUAL

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Summary of Contents for Zero FX 2018

  • Page 1 ™ ZERO FX ZERO FXS ™ 2018 OWNER’S MANUAL...

  • Page 3: Table Of Contents

    Introduction ............ 1.1 Controls and Components ......3.1 Introduction..............1.1 Controls and Components.......... 3.1 An Important Message From Zero ......1.1 Motorcycle Controls ..........3.2 About This Manual ............ 1.1 Left Side View ............3.4 Useful Information For Safe Riding ......1.2 Right Side View............
  • Page 4 Power Pack Swapping (if equipped) ......5.3 Cleaning..............6.28 On-Board Power Pack Charger .........5.4 Parking and Long Term Storage......6.29 Charging the Power Pack ..........5.5 Zero Motorcycles Accessories ........ 6.29 Quick Charging (Off-Board Accessory Charger)..5.7 Fuses ..............6.30 Public Charging Stations..........5.11 Add On Electrical Equipment ........5.11 Troubleshooting ..........
  • Page 5 What Other Limitations Or Disclaimers Apply To This Limited Warranty ..........9.5 What Are Your Responsibilities As A Customer? ..9.6 What Will Zero Do Under This Limited Warranty? ..9.7 How Does This Limited Warranty Relate To State Law? ................. 9.7 How Do You Obtain Service Under This Limited Warranty? ..............

  • Page 7: Introduction

    About This Manual Congratulations and thank you for purchasing the 2018 This manual covers the following motorcycles (standard Zero FX or Zero FXS electric motorcycle; we welcome you features and equipment include Integrated Z-Force® to the community of Zero Motorcycles riders. This manual...

  • Page 8: Useful Information For Safe Riding

    Introduction Useful Information For Safe Riding Unplug Your Z-Force Power Pack™ ® This manual contains the word WARNING to indicate CAUTION: Proper care of the motorcycle’s power pack is something that could hurt you or others. It also contains essential! Once your motorcycle is charged, disconnect the word CAUTION to indicate things that could damage the power pack from AC power.

  • Page 9: Identification Numbers

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

  • Page 10: Power Pack Serial Number

    Identification Numbers Power Pack Serial Number Vehicle Identification Number (VIN) The Power Pack serial number is located on the upper The VIN is a 17-digit number stamped on the head tube of front left of the power pack. the frame (A). Do not alter or remove this number as it is the legal identifier for your motorcycle.
  • Page 11 Identification Numbers VIN Breakdown The following breakdown of the VIN will help you understand the significance of each digit or character in case you need to reference it when contacting Zero or ordering parts.

  • Page 12: General Information

    It has no tailpipe and therefore no tailpipe reflection of your riding habits. The more conservatively emissions. It also has no exhaust or evaporative you ride, the better range you can expect from your Zero emissions. Because the Zero FX/FXS runs solely on FX/FXS motorcycle.

  • Page 13: Maximizing Your Range

    Range varies in electric motorcycles similarly to how it 134/2014 Annex VII. varies in gas motorcycles. However, the big difference For Zero motorcycles sold in all other countries, range is between electric and gas is that energy consumption is calculated using the following types of industry standard...
  • Page 14 General Information...
  • Page 15 General Information...

  • Page 16: Transporting

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

  • Page 17: General Safety Precautions

    • Modifications to the motorcycle may render the vehicle recommended to ride without the correct protective unsafe and may cause severe personal injury. Zero clothing; this applies to even short journeys and to cannot be held liable for non-approved modifications.

  • Page 18: Important Operating Information

    General Safety Precautions Important Operating Information CAUTION: Only charge the Zero power pack with the motorcycle’s on-board charger or the approved Zero Several operating considerations are listed below: accessory charger. • Always turn the key switch and motor stop switch to the •...

  • Page 19: Location Of Important Labels

    Location of Important Labels Location of Important Labels Location of Important Labels The motorcycle could contain the following information for both North American and European models: A. VECI (Vehicle Emission Control Information) label C. VIN label (European Union) - certification label B.
  • Page 20 Location of Important Labels High Voltage Warning Labels Located near the motor...

  • Page 21: Controls And Components

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

  • Page 22: Motorcycle Controls

    Controls and Components Motorcycle Controls...
  • Page 23 Controls and Components A. Mirrors G. Throttle Control This motorcycle is equipped with convex mirrors. A For description and operation, see“Handlebar convex mirror has a curved surface. Convex mirrors Controls”, on page 3.17. offer a greater field of view than a similar flat mirror. H.

  • Page 24: Left Side View

    Controls and Components Left Side View...
  • Page 25 Controls and Components A. Headlight E. Drive Belt Tension Adjuster • For headlight operation, see “Handlebar Controls”, on For the drive belt adjustment procedure, see “Drive page 3.17. Belt Adjustment Procedure”, on page 6.19. • For headlight bulb replacement, see “Headlight Bulb F.

  • Page 26: Right Side View

    Controls and Components Right Side View...
  • Page 27 Controls and Components A. Drive Belt For description and operation, see “Drive Belt”, on page 6.16. B. Drive Belt Tension Adjuster For the drive belt adjustment procedure, see “Drive Belt Adjustment Procedure”, on page 6.19. C. Power Pack Rail Latch For description and operation, see “Power Pack Swapping (if equipped)”, on page 5.3.

  • Page 28: Dash Overview

    Controls and Components Dash Overview...
  • Page 29 Controls and Components A. Adjust Button (ADJ) the rider using the performance level mode button located on the right handlebar control assembly. See See “Dash Settings”, on page 3.13. “Performance Level Mode Button”, on page 3.20. B. Select Button (SEL) I.

  • Page 30: Warning Indicator Lights

    Controls and Components Warning Indicator Lights 3.10...
  • Page 31 Controls and Components Left Turn Signal Indicator Flashes green when a left turn is selected by the turn signal switch. This arrow remains flashing until the turn signal request has been canceled. System Warning Indicator Indicates a system fault has been detected. See “System Warning Indicator”, on page 7.2 for more information.
  • Page 32 Controls and Components ABS (Anti-Lock Brake System) The indicator illuminates when the key is in the ON position. Indicator The light will extinguish when the motorcycle exceeds 3 mph (5 km/h). Unless there is a fault, the indicator will stay off until the key is cycled off and back to the ON position again.

  • Page 33: Dash Settings

    Controls and Components Dash Settings Displays A&B Display A The displays on the dash can be customized to your personal preferences by using the ADJ (Adjust) and SEL To select Display A with the dash in its normal operating (Select) buttons. mode, momentarily press the SEL button once.
  • Page 34 Controls and Components Display B Setting the Clock To select Display B with the dash in its normal operating mode, momentarily press the SEL button twice. Press the ADJ button to toggle through the following fields: • Trip 2 Odometer - Displays individual trip mileage and is reset by pressing and holding the ADJ button for 2 seconds.
  • Page 35 Controls and Components Unit Display - Speed Unit Display - Temperature To change the units that speed is shown in: To change the units that the temperature display is shown: 1. With the dash in its normal operating mode press and 1.

  • Page 36: Smartphone Application

    • Adjust the CUSTOM mode for performance gains 1. Ensure that the motorcycle is not Armed. The • Collect and email logs to Zero support staff motorcycle must be keyed ON, the kickstand must be in the down position, and the run switch must be in the •...

  • Page 37: Handlebar Controls

    Controls and Components Handlebar Controls 3.17...
  • Page 38 Controls and Components A. Headlight High/Low Beam Switch D. Throttle Control When the switch is pushed, the headlight Twist the throttle in a counter-clockwise rotation (A) to changes from low beam to high beam. It energize the motor and start the motorcycle in a stays in the selected position until it is forward direction.

  • Page 39: Performance Level Mode Button

    Controls and Components E. Motor Stop Switch H. Turn Signal Switch When the top of the switch (A) is pressed, it cuts off When the turn signal switch is pushed in power to the motor controller. The motor controller the left or right position, the corresponding remains in this state until the bottom portion of the front and rear turn signals flash.
  • Page 40 Controls and Components Performance Level Mode Button The SPORT selection causes the motorcycle to accelerate at a significantly faster rate but decreases the amount of regeneration when the throttle is released. This position is recommended for advanced riders. The CUSTOM selection has customizable performance settings by using the smartphone application (refer to “Smartphone Application”, on page 3.16).

  • Page 41: Front Brake Lever Adjuster (Fxs Only)

    Parking Brake Operation (if equipped) The position of the front brake lever can be adjusted by Your Zero Motorcycle may be equipped with a parking turning the adjustment knob (A) located on the master brake system. When applied, the parking brake will cylinder assembly.
  • Page 42 Notes 3.22...

  • Page 43: General Operation

    0.08 in (2 mm) or less. Pre-Ride Inspection WARNING! Under-inflation is a common cause of tire Before operating your Zero Motorcycle, check the failure and may result in severe tire cracking, tread following to make sure the motorcycle is secure and intact: separation, “blowout,”...

  • Page 44: Key Switch/Steering Lock Positions

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

  • Page 45: Motorcycle Tip-Over Sensor

    General Operation OFF Position Motorcycle Tip-Over Sensor This position is used to turn the motorcycle OFF, disabling Your motorcycle has a tip-over sensor that will disable the the electrical system. motorcycle’s drive mode in the event it is activated. If your motorcycle’s tip-over sensor is activated: ON Position •...

  • Page 46: Operating Your Motorcycle

    This could cause you to lose control of the motorcycle and could lead to serious injury or death. Progressive use of the brakes should bring the motorcycle to a complete stop without locking the wheels. Your Zero...
  • Page 47 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 speed/power until your Zero can maintain its maximum allowable thermal state;...

  • Page 48: Abs (Anti-Lock Braking System)

    General Operation ABS (Anti-lock Braking System) WARNING! ABS prevents the wheels from locking, therefore maximizing the effectiveness of the braking system in emergencies and when riding on slippery surfaces. The potentially shorter braking distances ABS allows under certain conditions are not a substitute for good riding practices.
  • Page 49 ABS 1. Disconnect external charge cables. system repaired. If there are no dealers in you area, call Zero Motorcycles Customer Service. See “Customer 2. Wait for the dash display to turn off completely. Assistance”, on page 9.10...
  • Page 50 General Operation WARNING! The ABS computer compares the relative speed of the front and rear wheels. Using tires other than those specified by Zero Motorcycles can adversely affect the ABS functionality and stopping distance of your motorcycle. WARNING! If the ABS warning indicator is illuminated when traveling at speeds exceeding 3 mph (5 km/h), the ABS is not functioning.

  • Page 51: Front Suspension Adjustment

    General Operation Front Suspension Adjustment 3. Record this measurement (this is the measurement referred to as M1). A shock has two main actions: compression when the shock gets loaded, and rebound when the shock returns back to full length. Compression damping is the adjustment that determines how fast or slow the shock compresses.
  • Page 52 General Operation 9. Record this measurement (this is the measurement Example: referred to as M2). MEASUREMENT OPERATOR VALUE 6.49 in (165 mm) 3.62 in (92 mm) 2.87 in (73 mm) The total sag is 2.87 in (73 mm). Refer to the chart below for the correct sag.
  • Page 53 General Operation Spring Preload Adjustment The spring preload is adjusted by turning the 19 mm anodized hex nut (B) located on top of the fork spring. Note: When adjusting preload, always start from the minimum setting and adjust each fork leg evenly. •...
  • Page 54 General Operation Compression Damping Start with a middle setting and fine tune the compression from there. Proper compression allows the tire to track the The compression damping is adjusted by turning a screw ground over consecutive bumps. Compression that is set on the bottom of each fork leg.
  • Page 55 General Operation 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 Model ADJUSTMENT SETTING Front Fork Compression 5 clicks counter-clockwise from maximum (H) position.

  • Page 56: Rear Shock Adjustment

    General Operation Rear Shock Adjustment Measuring Preload Obtaining the correct rear spring preload (sag) is critical for proper handling. The spring preload must be set to match the weight of the rider. The spring is preloaded for a 180 lb (82 kg) rider.
  • Page 57 General Operation Example: MEASUREMENT OPERATOR VALUE 24.02 in (610 mm) 20.79 in (528 mm) 3.22 in (82 mm) The total sag is 1.97 in (50 mm). Refer to the chart below for the correct sag. If the sag is not correct, the spring preload should be adjusted.
  • Page 58 General Operation Spring Preload Adjustment Rebound Adjustment The rebound adjuster knob (A) is at the bottom of the 1. Clean any dirt or debris from the slots of the shock shock. Printed on the knob is “H” meaning Hard (MAX, adjusting collar (A).
  • Page 59 General Operation Compression Adjustment The compression adjustment knob is at the top of the shock. Printed on the knob is “H” meaning Hard (MAX, which is for slower compression) and “S” meaning Soft (MIN, which is for faster compression). Turn the adjuster clockwise for a harder ride (slower compression).
  • Page 60 General Operation Factory Supplied Rear Suspension Settings The following information will allow you to adjust the rear suspension back to the factory settings the motorcycle was originally supplied with. FX & FXS Models ADJUSTMENT SETTING Rear Shock Compression 9 clicks counter-clockwise from maximum (H) position.

  • Page 61: Power Pack And Charging

    The integrated on-board charger ride. minimizes charge time and can work in parallel with Zero’s The power pack must be charged within 24 hours if fully quick charge accessories to cut charge times by as much discharged.
  • Page 62 Power Pack and Charging 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.

  • Page 63: Power Pack Swapping (If Equipped)

    3. Push the key lock upward to secure the rail. 4. (Optional) Use the key to lock the rail. 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 4.

  • Page 64: On-Board Power Pack Charger

    The on-board charger indicator (A) is visible on the dash CAUTION: Only charge the Zero power pack with the Zero panel. The charging indicator icon flashes while charging charger or approved Zero accessory chargers.

  • Page 65: Charging The Power Pack

    Note: Frequent top off charging is good for the power pack’s life span, so do not hesitate to charge frequently. WARNING! Always charge the Zero power pack in a To charge using the standard on-board charging location that is well-ventilated and away from combustible equipment: materials.
  • Page 66 Power Pack and Charging 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 14 amps from the 120 V AC circuit when charging.

  • Page 67: Quick Charging (Off-Board Accessory Charger)

    Damage, malfunctions, or performance problems caused by the installation or use of any charger not sold or C. Power Pack Charger approved by Zero will void the warranty of your Zero D. Charger LED Indicators Motorcycle. E. Connector (to motorcycle)
  • Page 68 Power Pack and Charging Using the Quick Charger 5. Connect the Quick charger to the power pack connector (A). You should hear the contactors close To charge using a Quick Charger: and the current State of Charge (SOC) should display Note: If you connect the on-board charger (see “Charging on the dash.
  • Page 69 Power Pack and Charging 9. When the green charge LED becomes solid or the SOC reads 100%, the battery system is fully charged, disconnect the charger. When the power pack is fully charged, disconnect the chargers and reinstall the protective cover. Note: If Quick Charger will be used again, cut access flap (see dashed line (B)) in flexible protective cover before re-installation.
  • Page 70 Power Pack and Charging • The charger and BMS are balancing. Quick Charger LED Indicators • The BMS is cutting off the charge because one or more cells have reached maximum voltage. C. 100% Charge The 100% Charge LED is a green indicator. If it is on solid, the charging is complete and the charger will enter maintenance mode.

  • Page 71: Public Charging Stations

    WARNING! Do not add electrical components to your every day and there may be some in your area. You can motorcycle unless they have been approved by Zero. charge from a Level 1 public charging station with your Some add-on electrical components can damage your...
  • Page 72 Notes 5.12...

  • Page 73: Maintaining Your Motorcycle

    • Perform routine care and maintenance of your electric motorcycle as detailed in this Owner’s Manual. • Use only Zero approved parts and Zero Motorcycles accessories. • The operator is responsible for learning and obeying all country, federal, state, and local laws governing the operations of an electric motorcycle.

  • Page 74: Parts/Maintenance Items

    It is Service History recommended that you have your Zero Motorcycle serviced every 12 months by a Zero Dealer regardless of Follow the maintenance schedules on page 6.2. After each the distance ridden.
  • Page 75 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 76 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 77 Maintaining Your Motorcycle ITEM ROUTINE EVERY INITIAL INITIAL ODOMETER MILEAGE READING RIDE 600 mi 4K mi 8K mi 12K mi 16K mi 20K mi (1K km) (7K km) (13K km) (19K km) (25K km) (31K km) 1 month 6 months 12 months 18 months 24 months...

  • Page 78: 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 40 lb·ft (54 Nm) Use LOCTITE® 242® (or equivalent) Handlebar clamp mount bolts 18 lb·ft (24 Nm) Main pivot bolt/nut (swingarm) 75 lb·ft (102 Nm) Use LOCTITE®...
  • Page 79 Maintaining Your Motorcycle Left Side Of Motorcycle Refer to Torque table on page 6.6.
  • Page 80 Maintaining Your Motorcycle Right Side Of Motorcycle Refer to Torque table on page 6.6.

  • Page 81: Power Pack

    30%. Leaving the power pack discharged below 30% 5. Please contact Zero at support@zeromotorcycles.com for a long period of time could damage the power pack and or locate a recycling center in your area.

  • Page 82: General Maintenance

    Inspect the level of the front This section describes how to maintain the brake system brake fluid through the sight of your Zero FX/FXS motorcycle. It covers the ABS glass (A). If the fluid level is (Anti-lock Brake System), brake pad examples (specific...
  • Page 83 General Maintenance Rear Brake Fluid Reservoir Brake Pad Inspection The brake pads must be inspected when specified in the maintenance schedule, see page 6.2. Visually inspect the brakes by looking at the remaining brake pad material through the sides of the brake caliper. Inspect the level of the rear brake fluid by inspecting the level through the reservoir housing.
  • Page 84 General Maintenance Brake Pad Replacement Bedding in new brake pads and/or new brake discs is recommended to ensure proper brake performance and maximize brake life. Proper bedding improves brake pedal/lever feel and reduces or eliminates brake squeal. Bedding in the brakes is a process of depositing an even layer of pad material on the surface of the brake disc.

  • Page 85: Parking Brake

    General Maintenance Parking Brake 3. Insert a screwdriver into the slot on the end of the cable (A) to prevent it from rotating. If your motorcycle is equipped with a parking brake, it 4. Gradually tighten adjustment nut (B) while rotating the should prevent the rear wheel from rolling when the lever wheel until you can feel drag on the brake rotor.

  • Page 86: Suspension

    General Maintenance Suspension Wheels And Tires Front Inspect both wheels for the following: • For maintenance, see Maintenance Schedule on • Bent, loose, or missing spokes. page 6.2. • Bent or cracked rims. • To adjust the fork, see Suspension Adjustment on •...

  • Page 87: Tire Inflation

    General Maintenance Tire Inflation WARNING! Under-inflation is a common cause of tire failure and may result in severe tire cracking, tread separation, “blowout,” or unexpected loss of motorcycle control, causing serious injury or death. Tire pressure should be checked and adjusted to the proper inflation levels before each ride.

  • Page 88: Drive Belt

    General Maintenance Drive Belt Checking Drive Belt Tension Proper belt tension is essential for optimum operation of The drive belt provides low maintenance and quiet the drive system. operation with minimal stretch. Keep dirt, grease, oil, and Lack of belt tension can lead to “ratcheting.” The teeth of debris off the belt and sprockets.The drive belt tension the belt slide over the teeth of the rear sprocket.
  • Page 89 General Maintenance Drive Belt Tension Tester 1. Remove the key from the ignition switch. The Tension Tester has a plastic measurement arm, 2. Press the Tension Tester steadily to the non-cogged located in a slot. Along this slot there is a measuring scale. side of the belt, half of the distance between the The point of intersection of the measurement arm and the motor-driven sprocket and rear wheel drive sprocket.
  • Page 90 General Maintenance Gates® Carbon Drive™ Smartphone Application 1. Remove the key from the ignition switch. The drive belt tension can be checked by 2. From the application, click the Tension icon and using the Gates® Carbon Drive™ Smartphone Measure. application, which measures belt tension 3.
  • Page 91 General Maintenance Drive Belt Adjustment Procedure Note: Adjust both sides (left and right) equally. 1. Remove key from the key switch. 2. Loosen the rear axle nut (C) on right side of motorcycle. 3. Loosen the (left and right) 13 mm jam nuts (A). 4.

  • Page 92: 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. WARNING! Always wear safety glasses when cleaning the 4.
  • Page 93 General Maintenance Lubricating The Drive Chain Checking The Drive Chain WARNING! Wear safety glasses when lubricating the 1. Remove the key from the key switch. chain to prevent eye injuries. 2. Using a ruler, grasp the chain halfway between the front and rear sprockets.
  • Page 94 General Maintenance Adjusting The Drive Chain Note: Adjust both sides equally. 1. Remove key from the key switch. 2. Loosen the rear axle nut (C) on right side of motorcycle. 3. Loosen the (left and right) 13 mm jam nuts (A). 4.

  • Page 95: Headlight Alignment

    General Maintenance Headlight Alignment The headlight should be checked for correct alignment periodically. It must be aligned any time the suspension sag is adjusted because this will affect the headlight alignment. Before the headlight can be aligned, the suspension sag and tire pressure must be correctly adjusted.
  • Page 96 General Maintenance To replace the bulb: 5. Disconnect the headlight bulb connector (C). 6. Release the headlight bulb sealing boot (D). 1. Remove the two bolts (A) securing the trim cover above headlight assembly to the motorcycle. 2. Release and remove the trim cover. 3.

  • Page 97: Turn Signal Light Bulb Replacement

    General Maintenance 7. Unhook the headlight bulb spring clip (E) by pushing Turn Signal Light Bulb Replacement down and to the side. 1. Remove the turn signal lens screw (A) and remove the lens. 2. Push in on the bulb, turn the bulb counterclockwise, and then pull the bulb out.

  • Page 98: Brake/Tail Light Bulb Replacement

    General Maintenance Brake/Tail Light Bulb Replacement Running Light Bulb Replacement To replace the brake/trail light bulb: 1. Remove the two bolts (A) securing the trim cover above headlight assembly to the motorcycle. 1. Remove the brake/tail light lens screws (A) and remove 2.
  • Page 99 General Maintenance 5. Release the running light bulb retainer from headlight (C). 6. Remove the running light bulb from retainer. 7. Install the replacement running light bulb into retainer. 8. Installation is the reverse of the removal procedure. 6.27...

  • Page 100: Cleaning

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

  • Page 101: Parking And Long Term Storage

    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 NOT OPEN! 6.29...

  • Page 102: Fuses

    General Maintenance Fuses Removing the RH front body panel 1. Remove seat. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one-time protection device and must be replaced each time the circuit is overloaded.
  • Page 103 General Maintenance 12 Volt Fuse Center The 12 volt fuse center is located on the frame under the RH front body panel. The 12 volt fuse values are listed below: FUSE RATING CIRCUITS CONTROLLED ABS 4, Key ABS 9, Valve Headlight Accessory Port Flash Lights, Turn Signals, Horn, Brake/Tail Light...
  • Page 104 General Maintenance ABS Fuse To replace the ABS fuse: The ABS fuse is located on the frame under the RH front 1. Remove the RH front body panel. See “Removing the body panel. RH front body panel”, on page 6-30. 2.
  • Page 105 General Maintenance High Voltage Fuse Locations The high voltage fuses are located behind the side inspection panels. To access the high voltage fuses (left side): 1. Ensure that the key switch is in the OFF position. 4. Pull back sheathing to access fuse holders (if necessary).
  • Page 106 Main Bike Board/Controller 3. Remove the flexible protective cover to gain access to ABC4A DC/DC Converter the fuse. JLLN100 ACCY Charge Fuse (in-line) ABC10A Charge Fuse (on-board) Note: If the charge fuse (3) needs replacement, contact your Zero Motorcycles dealer. 6.34...
  • Page 107 General Maintenance Low Power B+ Fuse (ZF7.2) To access the fuse: 1. Remove bolt (A) securing the fuse cover. 2. Remove cover (B) to gain access to the fuse. 3. Unscrew the fuse cap (C) and withdraw the fuse from the battery.
  • Page 108 Notes 6.36...

  • Page 109: Troubleshooting

    If you are unable to solve an flame has extinguished, douse with a water-based fire issue with your Zero FX/FXS electric motorcycle, take it to extinguisher. an authorized dealer at your convenience. If there is no WARNING! Your motorcycle uses high voltage.

  • Page 110: System Warning Indicator

    Troubleshooting System Warning Indicator If a fault has been detected, count the number of times the red indicator light (A) flashes (flashing sequence does repeat). Refer to the table starting on the next page for possible causes and solutions to the issue.
  • Page 111 Contact Zero or your dealer. Throttle is ON or throttle/connection is bad. Verify High Throttle Disable throttle action and/or check connection. Could not pre-charge motor controller. Contact Zero Precharge Fail or your dealer. Low Power Pack Disable Charge Power Pack Before Riding.
  • Page 112 Zero or your dealer. Cycle Ignition Key OFF and then ON again, or reset Battery Management System (BMS) BMS with button. If problem persists contact Zero or Internal Disable your dealer. Cycle Ignition Key OFF and then ON again, or reset Battery Management System (BMS) BMS with button.

  • Page 113: Dash Error Codes

    Troubleshooting Dash Error Codes If an error code has been recorded, it can be retrieved from the dash Display A. To retrieve the error code, see Display A on the “Displays A&B”, on page 3.13. Refer to the table starting on the next page to identify the error associated with the Error Code number.
  • Page 114 Troubleshooting CODE ERROR DESCRIPTION CODE ERROR DESCRIPTION No Error Post Error High Throttle Startup Error Motor Temperature Warning Stage 1 Contactor Open Warning Motor Temperature Warning Stage 2 Contactor Welded Error Controller Temperature Warning Stage 1 Precharge Error Controller Temperature Warning Stage 2 BMS Isolation Fault BMS Throttle Enable Wire Error BMS Isolation Danger...
  • Page 115 Troubleshooting CODE ERROR DESCRIPTION BMS Charger Connected Disable MBB Charger Connected Disable SEVCON Startup Disable Contactor Open Disable BMS Self-Test Error BMS Self-Test Warning Reserve Partition Disable BMS Internal Disable Internal Disable Error Internal Fault Error Monolith Not Connected Module Did Not Connect BMS Sensor Warning BMS System Warning Bike Configuration...

  • Page 116: General Troubleshooting

    Troubleshooting General Troubleshooting SYMPTOM POTENTIAL CAUSE POTENTIAL SOLUTION Motorcycle does not turn on Power Pack not charged. Key not properly engaged. Charge Power Pack. Recheck key in ignition, turn OFF/ON Motor stop switch turned OFF. Fault code set. again. Press the motor stop Switch ON button. See Charge Fault Code chart on page 7.11 or see Understanding BMS Flash Code Patterns starting on page 7.12.

  • Page 117: 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 118 50 ms 5 sec Healthy BMS OK √ √ 50 ms 5 ms Isolation Fault Contact Zero or the Dealer √ 50 ms 60 sec Pack Low Charge power pack √ 50 ms 1 sec Number of Cell Packs Not Set Contact Zero or the Dealer √...
  • Page 119 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 120 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 121 Troubleshooting Power Pack Empty Power Pack Too Hot If the power pack is completely empty, the BMS disables The power pack contains internal temperature sensors. If the throttle. You cannot ride the motorcycle until you the BMS measures excessive internal temperatures, it recharge the power pack.
  • Page 122 Troubleshooting Other Error-Flash Patterns If the BMS in your power pack produces an error code, which is not described in Understanding BMS Flash Code Patterns, then the power pack has encountered a serious internal hardware problem and must be repaired or replaced by a dealer.

  • Page 123: Cold And Hot Weather Considerations

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

  • Page 124: Safety Interlocks

    Troubleshooting Hot Weather Operation Safety Interlocks Operation of the motorcycle in hot temperatures should not If the BMS detects a serious internal fault, it can take either result in any noticeable performance changes. However, or both of two actions to prevent damage to the power the BMS will not allow motorcycle operation and its pack: associated battery discharge above 140°F (60°C), as...
  • Page 125 Troubleshooting Throttle Disable Interlock Charger-Disable Interlock The BMS communicates with the main motorcycle control When the charger is attached and plugged in to AC power, module. The BMS can send a signal to the main the BMS communicates with the charger. The BMS can motorcycle controller requesting that the throttle control on send a signal to the charger requesting that charging the motorcycle be disabled.
  • Page 126 Notes 7.18...

  • Page 127: Specifications (Europe)

    Specifications (Europe) Zero FX Technical Specifications Input Standard 110 V AC or 220 V AC MOTOR Charger Type 650 W Integrated Type Z-Force 75-5 passively air-cooled, high efficiency magnet, brushless motor Estimated Power Pack 123,000 miles (198,000 km) Life to 80% (city)
  • Page 128 Specifications (Europe) Front Suspension Showa 41 mm inverted cartridge forks, with adjustable spring preload, compression, and rebound damping Rear Suspension Showa 40 mm piston, piggy-back reservoir shock with adjustable spring preload, compression, and rebound damping DIMENSIONS Wheelbase 1,438 mm Seat Height 881 mm Rake 25.4 degrees...

  • Page 129: Zero Fxs

    Specifications (Europe) Zero FXS Charger Type 650 W Integrated MOTOR Estimated Power Pack Life 135,000 miles (217,000 km) Type Z-Force® 75-5 passively air-cooled, to 80% (city) high-efficiency magnet, brushless motor RANGE Magnet Configuration Radial flux interior permanent According to 66 miles (106 km)
  • Page 130 Specifications (Europe) Front Suspension Showa 41 mm inverted cartridge forks, with adjustable spring preload, compression, and rebound damping Rear Suspension Showa 40 mm piston, piggy-back reservoir shock with adjustable spring preload, compression, and rebound damping DIMENSIONS Wheelbase 1,422 mm Seat Height 836 mm Rake 24.4 degrees...

  • Page 131: Specifications (Rest Of The World)

    Specifications (Rest Of The World) Zero FX Specifications (Rest Of The World) Input Standard 110 V AC or 220 V AC MOTOR Charger Type 650 W Integrated Type Z-Force 75-5 passively air-cooled, high efficiency magnet, brushless motor • ZF3.6: 61,000 miles (98,000 km)
  • Page 132 Specifications (Rest Of The World) DRIVETRAIN DIMENSIONS Transmission Clutchless Direct Drive Wheelbase 56.6 in (1,438 mm) Final Drive 90T/18T, Poly Chain® HTD® Carbon™ belt Seat Height 34.7 in (881 mm) CHASSIS/SUSPENSION/BRAKES Rake 25.4 degrees Front Suspension Travel 8.60 in (218 mm) Trail 4.1 in (104 mm) Rear Suspension Travel...

  • Page 133: Zero Fxs

    Specifications (Rest Of The World) Zero FXS Input Standard 110 V AC or 220 V AC MOTOR Charger Type 650 W Integrated Type Z-Force® 75-5 passively air-cooled, high-efficiency magnet, brushless motor • ZF3.6: 67,000 miles (108,000 km) Estimated Power Pack Life to 80% (city) •...
  • Page 134 Specifications (Rest Of The World) DRIVETRAIN DIMENSIONS Transmission Clutchless Direct Drive Wheelbase 56.0 in (1,422 mm) Final Drive 90T/18T, Poly Chain® HTD® Carbon™ belt Seat Height 32.9 in (836 mm) CHASSIS/SUSPENSION/BRAKES Rake 24.4 degrees Front Suspension Travel 7.00 in (178 mm) Trail 2.8 in (71 mm) Rear Suspension Travel...

  • Page 135: Limited Warranty Information

    • ZF3.6 Power Pack Modules on the Zero FX/FXS. card via mail at the time of purchase to ensure timely service. When a covered 2018 Zero Motorcycle is sold to a Should a ZF3.6 Power Pack be purchased to upgrade subsequent owner, the original owner should submit a the capacity of a Zero ZF3.6 after the initial “in service...

  • Page 136: What Is The Coverage Period Of This Limited Warranty

    The duration of this Limited Warranty for Non-Demonstrator The duration of this Limited Warranty depends upon 2018 Motorcycles, not including the Power Packs, is a period whether your 2018 Zero Motorcycle is a demonstrator or a of two (2) years from the original “in service date.” non-demonstrator.

  • Page 137: What Is Not Covered By This Limited Warranty

    Power Packs can yield “shipment date.” over time and usage. Depending on use and storage Note: The “shipment date” is the date that Zero ships the conditions, Power Packs will degrade during the duration Demonstrator Motorcycle to the authorized dealer.
  • Page 138 Zero, the installation and use of any • Parts or components damaged by use or operation parties or accessories that alter the motorcycle’s under abnormal circumstances or contrary to the specifications from those set by Zero, or the use of new...

  • Page 139: What Other Limitations Or Disclaimers Apply To This Limited Warranty

    • Damage, malfunctions, or performance problems apply to you. caused by the failure to follow recommended • Zero does not assume – or authorize any person to maintenance requirements as set forth in this Owner’s assume – any other obligation or liability on its behalf.

  • Page 140: What Are Your Responsibilities As A Customer

    2018 Zero Motorcycle. • Zero reserves the right to change or improve the design Serious injury or death can result from improper operation of any 2018 Zero Motorcycle, Power Pack, or any other or failure to observe warnings and safety instructions on Zero parts (collectively, “Zero products”) at any time,...

  • Page 141: What Will Zero Do Under This Limited Warranty

    These laws vary from State to State. If your state law During the duration of this Limited Warranty, an authorized allows, Zero requires that you first notify us in writing of Zero dealer will repair or replace (at Zero’s discretion),...

  • Page 142: How Do You Obtain Service Under This Limited Warranty

    How Do You Obtain Service Under This Limited Warranty? Warranty services may be obtained by contacting your local Zero Motorcycles dealer. Please refer to the dealer locator on our website (www.zeromotorcycles.com/locator) for your nearest location. In the event that a dealer is not in your state, province, or country, you can contact Zero Motorcycles Inc.

  • Page 143: Transfer Of Ownership And Limited Warranty

    Limited Warranty Information Transfer Of Ownership And Limited Warranty If you sell your 2018 Zero Motorcycle, please visit the Zero website and access the owner resources section to fill out the transfer of ownership and warranty form. This must be performed to allow Zero the ability to contact the new owner in the unlikely event of a safety related issue.

  • Page 144: Customer Information

    380 El Pueblo Road Scotts Valley, CA 95066 Phone: +1 (888) 786-9376 Monday-Friday 8am to 5pm (Pacific Time) E-mail: support@zeromotorcycles.com (24 hours) For updates and additional information about your motorcycle, visit the owner resources section of the Zero website: www.zeromotorcycles.com/owner-resources/ 9.10...

  • Page 145: Reporting Safety Defects

    However, NHTSA cannot become involved in immediately inform your Zero Motorcycles authorized individual problems between you, your dealer, or Zero dealer. If you are unable to resolve the issue with your Motorcycles Inc.
  • Page 146 Notes 9.12...

  • Page 147: Maintenance Record

    Maintenance Record Service History Maintenance Record Maintenance Record 8,000 miles (13,000 km) or 12 months After you have had your Zero motorcycle serviced, please Odometer reading: Date: make sure that the appropriate maintenance record has Notes: been completed. Use the space under “Notes” to record issues you want to remind yourself about or mention at the next service.
  • Page 148 Maintenance Record 20,000 miles (31,000 km) or 30 months 32,000 miles (49,000 km) Odometer reading: Date: Odometer reading: Date: Notes: Notes: Performed by: Performed by: 24,000 miles (37,000 km) or 36 months 36,000 miles (55,000 km) Odometer reading: Date: Odometer reading: Date: Notes: Notes:...
  • Page 149 Maintenance Record 44,000 miles (67,000 km) 56,000 miles (85,000 km) Odometer reading: Date: Odometer reading: Date: Notes: Notes: Performed by: Performed by: 48,000 miles (73,000 km) 60,000 miles (91,000 km) Odometer reading: Date: Odometer reading: Date: Notes: Notes: Performed by: Performed by: 52,000 miles (79,000 km) 64,000 miles (97,000 km)
  • Page 150 Maintenance Record 68,000 miles (103,000 km) 80,000 miles (121,000 km) Odometer reading: Date: Odometer reading: Date: Notes: Notes: Performed by: Performed by: 72,000 miles (109,000 km) 84,000 miles (127,000 km) Odometer reading: Date: Odometer reading: Date: Notes: Notes: Performed by: Performed by: 76,000 miles (115,000 km) 88,000 miles (133,000 km)
  • Page 151 Fuses ................6.30 Squeal ..............6.12 High Voltage Fuse Center ........6.33 Charging the Power Pack..........5.5 General Operation ............4.1 Cleaning Your Motorcycle ...........6.28 Key Switch/Steering Lock Positions......4.2 Contact information Pre-Ride Inspection...........4.1 NHTSA ..............9.11 General Safety Precautions...........2.1 Zero Motorcycles ............9.10 General Troubleshooting ..........7.8 INDEX.1...
  • Page 152 Index Headlight Operating Your Motorcycle..........4.4 Alignment ..............6.23 Braking...............4.4 Bulb Replacement ..........6.23 Stopping..............4.4 Tip-over sensor ............4.3 Owner Information Record ..........1.3 Important Operating Information ........2.2 Owner’s Responsibilities ..........6.1 Inspection Pre-Ride..............4.1 Instrument Panel ..........3.8 3.10 Parking ................
  • Page 153 Transfer Of Ownership And Warranty .......9.9 Technical Specifications Wheels And Tires ............6.14 Zero FX - Europe ............8.1 Zero FX - Rest of the World ........8.5 Zero FXS - Europe ............ 8.3 Zero FXS - Rest of the World........8.7 INDEX.3...
  • Page 154 Notes INDEX.4...
  • Page 155 First Responder Information – High Voltage Component Locations First Responder Information – High Voltage Component Locations...
  • Page 156 TAKE CHARGE ™ ™ ™ ™ ™ ™ ZEROMOTORCYCLES.COM Y Y LES.COM 88-08929.01...

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