Table of Contents

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Introduction ................................................................. 1-1
Introduction ............................................................ 1-1
Index .............................................................. 1-1
Plug In Your Z-Force Power Pack™ ................... 1-2
Owner Information ................................................ 1-3
Power Pack Serial Number ................................. 1-4
Key Code Number ............................................... 1-4
Motor Serial Number ............................................ 1-4
Motor Identification ................................................ 1-4
Identification Numbers ......................................... 1-5
VIN/PIN Breakdown ...................................... 1-6
General Information ............................................. 1-7
Technical Specifications ............................... 1-7
Technical Specifications ............................... 1-8

Table Of Contents

Vehicle Range .................................................... 1-12
Your Riding Style ................................................ 1-12
Public Charging Stations ................................... 1-12
Emissions Information ....................................... 1-13
Transporting ........................................................ 1-13
Safety Information ..................................................... 2-1
General Safety Precautions ................................. 2-1
Important Operating Information .................. 2-2
Location Of Important Labels ...................... 2-3
Controls And Components ....................................... 3-1
Motorcycle Controls (X/MX Dirt) ........................... 3-1
Right Side View (X/MX Dirt) ................................. 3-3
Instrument Panel (X/MX Dirt) ............................... 3-5
Charge Indicator ........................................... 3-5
Main Power Indicator .................................... 3-5
TOC-1

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Summary of Contents for Zero X Dirt 2011

  • Page 1: Table Of Contents

    Table Of Contents Introduction ..............1-1 Vehicle Range ............ 1-12 An Important Message To You From Zero ..1-1 Optimizing Your Range By Adapting Introduction ............1-1 Your Riding Style ..........1-12 Index .............. 1-1 Public Charging Stations ........1-12 Useful Information For Safe Riding ....
  • Page 2 Starting And Operating ..........4-1 Headlight Bulb Replacement ..... 5-13 First Time Set-Up ..........4-1 Turn Signal Light Bulb Replacement ..5-15 Unpacking Your Zero Motorcycle ....4-2 Brake/Tail Light Bulb Replacement ... 5-16 General Operation ..........4-4 Running Light Bulb Replacement ..... 5-17 Cleaning ............
  • Page 3 Motor Temperature Indicator ...... 6-11 General Troubleshooting ......6-14 Warranty/Customer Assistance ....... 7-1 Customer Assistance ........... 7-1 Warranty Information ..........7-2 Zero Motorcycles Limited Warranties.....7-3 Standard Warranty ......... 7-3 Extended Warranty ........7-4 Disclaimers Applicable to Standard Warranty and Extended Warranty....7-5 Proper Use ............
  • Page 4 NOTES TOC-4...
  • Page 5: Introduction

    This manual covers the following motorcycles: Congratulations and thank you for purchasing the • X Dirt 2011 Zero electric motorcycle; we welcome you to the community of Zero motorcycle riders. This manual is • MX Dirt designed to provide you with a better understanding •...
  • Page 6: Useful Information For Safe Riding

    Useful Information For Safe Riding Plug In Your Z-Force Power Pack™ This manual contains the word CAUTION to tell about WARNING: Proper care of the motorcycle’s power pack something that could hurt you or others. It also is essential! When not in use, the power pack should contains the word WARNING to tell about things that be left on the charger, even if fully charged.
  • Page 7: Owner Information

    Owner Information Record important information pertaining to your motorcycle here. When contacting your Certified Service Center (CSC), you may need to provide this information. CSC Information Motorcycle Information Name VIN (X/MX/XU) Address PIN (X/MX) Model Telephone No. Power Pack Serial Number E-mail Key Code Date of Purchase...
  • Page 8: Power Pack Serial Number

    Power Pack Serial Number Motor Identification The power pack serial number is located on the A. Mars inside edge of the connector housing. • X - Dirt • X/XU - Street Legal Key Code Number B. Agni The key code is a 5 digit number used to create •...
  • Page 9: Identification Numbers

    Identification Numbers The Vehicle Identification Number (VIN) is found on the XU/X/MX Street Legal. The Production Identification Number (PIN) is found on the X/MX Dirt. This is a 17-digit number (A) stamped on the head tube of the frame. Do not alter or remove this as it is the legal identifier for your motorcycle.
  • Page 10: Vin/Pin Breakdown

    VIN/PIN Breakdown 538 = On Road World Manufacturer Identifier A4Z = Off Road Motorcycle Type Z2 = X/MX Platform X1 = 11 MY X E1 = 11 MY MX U1 = 11 MY XU Model Line U2 = 11 MY XU LSM X0 = 11 MY X M0 = 11 MY MX M1 = Electric Motor Type...
  • Page 11: General Information

    Brake Rotor Minimum Thickness 3.85 mm (0.15 in) 2 hours (standard) *Environmental Protection Agency (EPA) Urban Dynamometer Driving Schedule (UDDS) Quick Recharge 1.2 hours (100% charged) Time (optional) 1.0 hours (90+% charged) **Zero chargers typically draw as much as 10 amps.
  • Page 12: Zero Mx Dirt/Mx Street Legal Technical Specifications

    Typical Cost to $0.21 Recharge Rear Wheel 16 x 2.15 in DIMENSIONS Wheel Base 141 cm (55.5 in) Zero MX Dirt/MX Street Legal Seat Height Technical Specifications 84.5 cm (33.3 in) (standard) MOTOR Low Seat Height 79.4 cm (31.3 in)
  • Page 13 141 cm (55.5 in) Sprockets, 420 Chain Seat Height 84.5 cm (33.3 in) (standard) *Environmental Protection Agency (EPA) Urban Dynamometer Driving Schedule (UDDS) Low Seat Height **Zero chargers typically draw as much as 10 amps. 79.4 cm (31.3 in) (option)
  • Page 14: Zero Xu Technical Specifications

    Quick Recharge 1.2 hours (100% charged) Time (optional) 1 hours (90+% charged) Input** Standard 120 V AC or 240 V AC *Environmental Protection Agency (EPA) Urban Dynamometer Driving Schedule (UDDS) **Zero chargers typically draw as much as 10 amps. 1-10...
  • Page 15 CHASSIS/SUSPENSION/BRAKES POWER SYSTEM Front Wheel 19 x 1.85 in Charger Type Integrated Rear Wheel 16 x 2.15 in Estimated Pack 52,000 Km (32,000 miles) Life (to 80%) DIMENSIONS DRIVETRAIN Wheel Base 138 cm (54.3 in) Transmission Clutchless one speed Seat Height 80.6 cm (31.8 in) (standard) Drive System...
  • Page 16: Vehicle Range

    The more conservatively you • Hard acceleration will decrease your range. ride, the better range you can expect from your Zero motorcycle. • Coasting whenever possible makes a significant difference;...
  • Page 17: Emissions Information

    WARNING! Please use only Zero approved parts and accessories for your Zero motorcycle. Parts and products 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 18 It is recommended that the motorcycle be tied-down Use two ratchet straps in the front and two in the using ratchet straps. Place the ratchet straps around rear. The tie down straps should be at a 45° angle a frame contact point. Soft straps must be used to from the motorcycle.
  • Page 19: Safety Information

    Safety Information General Safety Precautions 5. Never permit a guest to ride your electric motorcycle without proper instruction. 1. This is a performance motorcycle and should 6. Never use alcohol or mind-altering drugs before be treated with extreme caution. operating your electric motorcycle. 2.
  • Page 20: Important Operating Information

    10. Modifications to the motorcycle may render the 5. Keep your Zero connected to the charger when vehicle unsafe and may cause severe personal your motorcycle is sitting in storage or if it will be injury. Zero Motorcycles cannot be held liable for sitting unused for more than 7 days.
  • Page 21: Location Of Important Labels

    8. Failure to follow power pack 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 power pack efficiency and service.
  • Page 22: Throttle And Speed Control Label

    Throttle And Speed Control Label There is no engine braking...
  • Page 23: Controls And Components

    Controls And Components Motorcycle Controls (X/MX Dirt) PERFORMANCE LEVEL ZADI A. Motor Stop Switch B. Instrument Panel C. Key Switch/Steering Lock D. Performance Level Switch E. Front Brake/Brake Fluid Reservoir F. Throttle Control...
  • Page 24: Motorcycle Controls (X/Mx/Xu Street Legal)

    Motorcycle Controls (X/MX/XU Street Legal) A. Mirrors B. Left Handlebar Control C. Key Switch/Steering Lock D. Instrument Panel E. Performance Level Switch F. Front Brake/Brake Fluid Reservoir G. Motor Stop Switch H. Throttle Control...
  • Page 25: Right Side View (X/Mx Dirt)

    Right Side View (X/MX Dirt) A. Drive Chain E. Fuse Center (Behind Trim Panel) B. Power Pack Rail Knob F. Front Master Cylinder Reservoir C. Power Pack G. Chain Adjuster D. Power Pack Rail H. Rear Master Cylinder Reservoir (Behind Trim Panel)
  • Page 26: Right Side View (X/Mx/Xu Street Legal)

    Right Side View (X/MX/XU Street Legal) A. Drive Chain F. Front Master Cylinder Reservoir B. Power Pack Rail Bolt (Security Bolt XU) G. Power Pack Charger (XU only) C. Power Pack H. Cooling Fan Inline Fuse (MX only) D. Power Pack Rail Chain Adjuster E.
  • Page 27: Instrument Panel (X/Mx Dirt)

    Instrument Panel (X/MX Dirt) A. Charge Indicator The charge indicator on the motorcycle is used to inform you of the amount of remaining energy in the power pack. The charge indicator is segmented into 3 colors, the colors indicate the following: •...
  • Page 28: Temperature Indicator

    C. Motor Temperature Indicator The “I” position reduces the acceleration of the The motor temperature sensor senses the motorcycle to be less aggressive. It is an ideal temperature of the motor and power pack. This will position to use for times when you want softer trigger the motor temperature indicator, which will acceleration.
  • Page 29: Instrument Panel (X/Mx/Xu Street Legal)

    Instrument Panel (X/MX/XU Street Legal) A. Left Turn Signal Indicator B. High Beam Indicator C. Main Power Indicator D. System Warning Indicator E. Motor Temperature Indicator F. Right Turn Signal Indicator G. Select Button H. Adjust Button Display Area J. Charge Indicator...
  • Page 30: Indicators

    A, trip odometer setting B, RPM and Max. Holding it down C. Main Power Indicator will clear the trip odometer resetting it back to zero. The main power indicator is ON any time the key is in the ON position.
  • Page 31: Performance Level Switch

    Performance Level Switch The performance level is a two position switch that toggles between Eco and Sport. To select either of (XU Street Legal) the switch positions, the motorcycle must be stopped and the key switch in the OFF position. The Eco position reduces the acceleration of the motorcycle to be less aggressive.
  • Page 32: X/Mx Street Legal

    (X/MX Street Legal) The performance level is a two position switch that toggles between “I” and “II”. To select either of the switch positions, the motorcycle must be stopped and the key switch in the OFF position. The “I” position reduces the acceleration of the motorcycle to be less aggressive.
  • Page 33: Handlebar Controls (X/Mx Dirt)

    Handlebar Controls (X/MX Dirt) A. Motor Stop Switch B. Front Brake Lever C. Throttle Control 3-11...
  • Page 34: Left Handlebar Control

    Left Handlebar Control Right Handlebar Control C. Throttle Control A. Motor Stop 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 stop forward direction.
  • Page 35: Handlebar Controls (X/Mx/Xu Street Legal)

    Handlebar Controls (X/MX/XU Street Legal) A. High Beam Flash-to-Pass E. Motor Stop Switch B. Headlight High/Low Beam Switch F. Turn Signal Switch C. Front Brake Lever G. Horn Button D. Throttle Control 3-13...
  • Page 36 D. Throttle Control A. High Beam Flash-to-Pass Twist the throttle in a counter-clockwise rotation (A) to When the headlight is in the low beam position, push energize the motor and start the motorcycle in a the flash-to-pass switch and the high beam will forward direction.
  • Page 37 F. Turn Signal Switch G. Horn Button When the turn signal switch is When the key is in the ON position, the horn will pushed in the left or right sound when the button is pressed. Electric vehicles position, the corresponding front run quietly;...
  • Page 38 NOTES 3-16...
  • Page 39: Starting And Operating

    1. Remove the motorcycle from its shipping crate. to the brake lines. Verify that the brakes function See Unpacking Your New Zero Motorcycle on properly. page 4-2. 7. Make sure the motorcycle key switch is OFF, then 2.
  • Page 40: Unpacking Your Zero Motorcycle

    Unpacking Your Zero Motorcycle Inner Assembly • Carefully remove plastic cover from motorcycle. Although unpacking your Zero motorcycle can be done by a single person, it’s recommended to have • Locate small parts box below motorcycle and put a second person to help lift and remove your to the side.
  • Page 41 • Carefully lift rear portion of the motorcycle over the Recycling swingarm standoff and off crate base. Your Zero Motorcycle’s shipping crate and packaging • Carefully lift front wheel out of crate base materials were designed to be completely recycled.
  • Page 42: General Operation

    Pre-Ride Inspection if it rolls. You should be able to completely lock-up the wheels by applying the brakes. Before operating the Zero motorcycle, check the following to make sure the motorcycle is secure and • Throttle...
  • Page 43 Key Switch/Steering Lock Positions A. Steering Lock Using the steering lock when parked will prevent unauthorized use and help prevent theft. To 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 down.
  • Page 44: Power Pack

    7 days. The power pack must be charged within 24 hours if fully discharged, and charged within 60 days if stored fully charged. Zero recommends you plug in your Zero motorcycle after 7 days, even if fully charged. Please leave your Zero motorcycle plugged in whenever possible.
  • Page 45 WARNING: Opening of the power pack is for trained dramatically reduce the range and/or life expectancy of Zero Motorcycles’ technicians. Please be aware that the power pack. incorrect handling of a Zero power pack can be dangerous. DO NOT OPEN!
  • Page 46 (B) (X/MX/XU - Street Legal). The security bolt requires the supplied tool to remove and install. The security bolt can be replaced with the thumb screw available from Zero Motorcycles Accessories. 5. Using the ejection lever (E) remove the power pack connector.
  • Page 47 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 power pack for a host of predefined conditions, and then takes actions according to these conditions.
  • Page 48 • • 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 49 Beeps The BMS will beep only under two circumstances: The BMS includes an electronic beeper sealed inside • When the motorcycle is turned ON, the BMS the power pack. The beeper is located on the left will perform a self-test. It will always sound a front of the power pack behind the opening (A).
  • Page 50 Zero recommends you plug in your Zero motorcycle after 7 days, even if fully charged. Please leave your Zero motorcycle plugged in whenever possible. WARNING: Charge the Zero power pack with the Zero charger. When charging the motorcycle’s power pack the charger can be left on, even after the power pack is fully charged.
  • Page 51 Charger LED Indicators C. 100% Charge The 100% Charge LED is a green indicator. If it is on A. Ammeter solid, the charging is complete and the charger will The Ammeter LED is enter maintenance mode. If it is flashing, the an amber indicator absorption phase is complete and the charger is in that indicates that...
  • Page 52 30 minutes or less. WARNING: Charge the Zero power pack with the Zero charger. It is possible for lithium ion cells to overheat The max charging temperature cutoff is a power pack and fail.
  • Page 53 (A). 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 54 Power Pack Swapping on page 4-8. Note: AVOID connecting the Zero charger and another 2. Connect the charger to the power pack. device to a single 120 V AC 15A/20A circuit, as it may become overloaded.
  • Page 55 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 Quick Charging (Not Installed in Motorcycle) 1. Remove the power pack from the motorcycle. See Quick charging is an option that contains a Power Pack Swapping on page 4-8. stand-alone charger (A) and dual charger harness (B). It is used in conjunction with the charger 2.
  • Page 57 Note: AVOID connecting the Zero charger and another 3. Connect the stand-alone charger to this connector. device to a single 120 V AC 15A/20A circuit, as it may 4. Plug the supplied power cord (A) into the become overloaded. Zero chargers draw as much as integrated charger connector.
  • Page 58 7. Tuck the intregrated charger connector behind the body panel, to protect it from the elements. 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 59: Operating Your Motorcycle

    We Starting suggest progressive use of the brakes to bring the Zero motorcycle to a complete stop without locking 1. Turn the key switch to the ON position. the wheels. Your Zero motorcycle is a light-weight performance product and therefore practice is 2.
  • Page 60: Suspension Adjustment

    Suspension Adjustment The adjuster has 18 stages of adjustment. This determines how quickly the fork returns to its Front Fork Adjustment extended position after being compressed. Turning the rebound adjuster screw clockwise will A shock has two main actions: compression when slow the rebound speed down making it better for the shock gets compressed, and rebound when the larger, rolling terrain or bumps.
  • Page 61 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 62 Rear Shock Adjustment Spring Adjustment: Obtaining the correct rear spring rate is critical for proper handling. The spring rate must be set to match the weight of the rider. The spring is preloaded for an 82 kg (180 lb) rider. Heavier riders require stiffer spring rates.
  • Page 63 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) The total sag is 100 mm (4.0 in). Refer to the chart below for the correct sag.
  • Page 64 • • 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 near the lock ring (A). meaning Slow and Fast.
  • Page 65 (MX - Dirt and Street Legal) • Compression Adjustment - The compression adjustment knob is under the rear of the seat. It has 21 stages of adjustment. The knob has HARD (slower compression) and SOFT (faster compression). Turn the adjuster clockwise for slower compression.
  • Page 66 (X - Dirt and X/XU - Street Legal) • Compression Adjustment - The compression adjustment knob (D) is at the top of the shock. It has 18 stages of adjustment. The knob has + (slower compression) and - (faster compression). Turn the adjuster clockwise for slower compression.
  • Page 67: Maintaining Your Motorcycle

    2. Perform routine care and maintenance on your electric motorcycle. electric motorcycle as detailed in this owner’s manual. 3. Use only Zero approved parts and Zero Motorcycle Accessories.
  • Page 68: Bolt Torque Table

    Bolt Torque Table LOCATION ITEM TORQUE NOTES • Front axle pinch bolts 18 N m (13 lb ft) Use LOCTITE ® ® • Front axle end bolts 26 N m (19 lb ft) Use LOCTITE ® ® • ® ® Front caliper mount bolts 20 N m (15 lb ft)
  • Page 69 See Bolt Torque Table on page 5-2.
  • Page 70 See Bolt Torque Table on page 5-2.
  • Page 71: Power Pack

    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.
  • Page 72: General Maintenance

    General Maintenance Front Brake Inspect the level of the Motor front brake fluid through the sight glass (B). If CAUTION: Wear safety glasses when using the fluid level is visibly compressed air to avoid eye injuries. LOWER below the low level indicator (C), brake fluid The motor requires little maintenance, but dust can must be added.
  • Page 73 Rear Brake Replace the brake pads if either pad’s thickness is 1.35 mm (0.05 in) or less. If the brake pads (A) are Inspect the level of the worn, replace both brake pads immediately. rear brake fluid by inspecting the level through the reservoir housing.
  • Page 74: Suspension

    Suspension Wheels And Tires Front Inspect both wheels for the following: For maintenance, see Maintenance Schedule on pages 5-20 through 5-25. • Bent, loose, or missing spokes To adjust the fork, see Suspension Adjustment on • Bent or cracked rims page 4-22.
  • Page 75: Tire Inflation

    Tire Inflation Drive 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 76 • 1. Remove the key from the key switch. Never have the motor spinning the wheel. Turn the wheel only by hand. Failure to do so could 2. Set the motorcycle on a stand or lift so the rear result in serious personal injury. wheel is free to spin.
  • Page 77 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 5/16” hex bolts 2. Using a ruler, grasp the chain halfway between (D).
  • Page 78: Headlight Alignment

    the vertical adjustment is off, it will cause the beam to point too closely to or too far ahead of the motorcycle. With the headlight on the low beam position, the motorcycle perpendicular to the ground, and the operator sitting on the motorcycle, verify the beam alignment.
  • Page 79: Headlight Bulb Replacement

    Headlight Bulb Replacement CAUTION: Halogen bulbs contain gas under pressure. Handling a bulb improperly could cause it to shatter into flying glass fragments. To help avoid personal injury: • Turn off the key switch and allow the bulb to cool before changing the bulb. •...
  • Page 80 2. Disconnect the headlight bulb connector (A) and 4. Lift up on the spring clip and remove the remove the cover (B). headlight bulb. 3. Unhook the headlight bulb spring clip (A) by WARNING: Do not touch the glass portion of the (1) pushing down then (2) pushing to the side.
  • Page 81: Turn Signal Light Bulb Replacement

    5. Install the headlight bulb into the lens. Turn Signal Light Bulb Replacement 6. Install the headlight spring clip. 1. Remove the turn signal lens screw (A) and remove the lens. 7. Install the headlight bulb cover. 2. Push in on the bulb, turn the bulb counter- 8.
  • Page 82: Brake/Tail Light Bulb Replacement

    Brake/Tail Light Bulb Replacement 2. Push in on the bulb and turn the bulb counter- clockwise then pull the bulb out. 1. Remove the brake/tail light lens screws (A) and 3. Insert the new bulb into the socket, push in and remove the lens.
  • Page 83: Running Light Bulb Replacement

    Running Light Bulb Replacement 1. Remove the three screws (A) from the headlight trim ring. 4. Insert the new bulb into the socket, push in and turn clockwise until it stops. 2. Pull the bulb socket (A) from the headlight. 5.
  • Page 84: Cleaning

    Do not use any harsh chemical products on plastic value of your Zero motorcycle. It also ensures that parts. Be sure to avoid using cloths or sponges safety-relevant parts remain in full working order.
  • Page 85: Parking And Long Term Storage

    (BMS) on page 4-9. 1. It is required to always leave the power pack plugged in when the Zero is not in use. The Zero WARNING: Opening of the power pack is for trained charger is designed to maintain a balanced and Zero Motorcycles’...
  • Page 86: Maintenance Schedule

    Maintenance Schedule The scheduled maintenance must be performed in accordance with this chart to keep the Zero motorcycle in top running condition. The initial maintenance is vitally important and must not be neglected. X/MX - Dirt ITEM ROUTINE EVERY INITIAL...
  • Page 87 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. Motor Brush • Blow out with a high pressure air hose. ...
  • Page 88 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.       Front Fork • Service/Rebuild if necessary. Rear Shock •...
  • Page 89 X/MX/XU - Street Legal Where time and mileage are listed, follow the interval that occurs first. ITEM ROUTINE EVERY INITIAL ODOMETER MILEAGE READINGS RIDE 1,000 km 7,000 km 13,000 km 19,000 km 25,000 km 31,000 km (600 mi) (4,000 mi) (8,000 mi) (12,000 mi) (16,000 mi)
  • Page 90 ITEM ROUTINE EVERY INITIAL ODOMETER MILEAGE READINGS RIDE 1,000 km 7,000 km 13,000 km 19,000 km 25,000 km 31,000 km (600 mi) (4,000 mi) (8,000 mi) (12,000 mi) (16,000 mi) (20,000 mi) 1 month 6 months 12 months 18 months 24 months 30 months Wheel...
  • Page 91 ITEM ROUTINE EVERY INITIAL ODOMETER MILEAGE READINGS RIDE 1,000 km 7,000 km 13,000 km 19,000 km 25,000 km 31,000 km (600 mi) (4,000 mi) (8,000 mi) (12,000 mi) (16,000 mi) (20,000 mi) 1 month 6 months 12 months 18 months 24 months 30 months •...
  • Page 92: Parts/Maintenance Items

    Zero Motorcycle Accessories the fuses. To remove the cover, squeeze the tabs (A) together and lift off the cover. Zero accessories are designed to complement and function with other systems on your motorcycle. Your FUSE # CIRCUITS...
  • Page 93 MX - Dirt and MX - Street Legal The cooling fan inline fuse (A) is located between the front right lower frame rail, in front of the motor. FUSE # CIRCUITS CONTROLLED Cooling Fan Note: Trim panel removed for clarity Inline Fuse: There are 2 inline 12 volt fuses, one controls the cooling fan and the other controls the instrument...
  • Page 94 X/MX/XU - Street Legal 58 Volt* The instrument panel inline fuse (A) is located behind The 58 volt fuse center is located behind the frame the right trim panel, above the fuse center. fork tube on the left side of the frame. Remove the cover to access the fuse.
  • Page 95 Inline Fuse: If your XU is equipped with the quick charge option, there is a 58 volt 25 amp fuse. This fuse is located under the seat. * Do NOT interchange 12 volt and 58 volt fuses. 5-29...
  • Page 96 Follow the maintenance schedules on pages 5-20 through 5-25. After a scheduled service or routine is performed, record the information on the chart below. DATE ITEM SERVICE/ROUTINE DESCRIPTION 5-30...
  • Page 97: Troubleshooting

    If you are unable to solve an issue with your Zero 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 98 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. ...
  • Page 99: Understanding Beep Sequences

    Understanding Beep Sequences The Battery Management System (BMS) is located inside the power pack and is fitted with a beeper to provide audible notifications about the status of the power pack. Below you will find information on the meaning of the beep sequences.
  • Page 100 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 101 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.
  • Page 102: Safety Interlocks

    It is possible to encounter the power ON self-test result Safety Interlocks error beeps from a badly malfunctioning or damaged If the BMS detects a serious internal fault, it can take power pack. If so, you should contact your CSC. Your either or both of two actions to prevent damage to the power pack may need to be repaired or replaced.
  • Page 103 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 terminate immediately.
  • Page 104 Instrument Panel Power Pack Full (High Pack Voltage) System Warning 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 105 Motorcycle disabled due to motor Press the motor stop switch ON button, or stop switch or kickstand switch kickstand is down. Raise kickstand. Self-Test Failed Contact Zero or CSC. Charger Connected Unplug charger. Throttle is ON or throttle/connection is bad High Throttle Disable Verify throttle action and/or check connection.
  • Page 106 Problem sensing temperature of Range board. Contact CSC. Turn the key switch OFF and ON. If High Current Disable the problem persists contact Zero or CSC. Turn the key switch OFF and allow Temperature Protection Error to cool off. Then restart, if problem persists contact Zero or CSC.
  • Page 107: Motor Temperature Indicator

    2 Fast-Pause-2 Fast High Power Pack Temperature The Zero is equipped with a motor temperature sensor that senses the temperature of the motor and power pack. This indicator will blink in the unlikely event that you exceed the motorcycle’s performance capabilities;...
  • Page 108 • X/MX/XU You can continue to ride without performance interruptions. • You should reduce speed - this will lower power output and the motor temperature to eliminate the blinking warning indicator. Stage 2 If the motor continues to heat up: •...
  • Page 109 Stage 3 Motor Temperature Disabled If the critical temperature threshold of the motor This warning indicator is on solid. This is an is reached: indication that the motor temperature sensor is not detected. Check the connections to the temperature You will not reach this stage without knowingly sensor.
  • Page 110: General Troubleshooting

    Incorrect tire pressure Inflate to correct tire pressure. See page 5-9. Replace/balance front tire with the same tire supplied Deformed front tire from Zero. Handlebars wobbly (shimmy) Replace/balance tire with the same tire supplied from Bald tire (excess wear) Zero.
  • Page 111: Warranty/Customer Assistance

    Warranty/Customer Assistance Customer Assistance Zero Motorcycles Inc. can be contacted via the contact Zero Motorcycles methods listed below. Please have available the 170 Technology Circle following, as they are essential to effectively and Scotts Valley, California 95066 efficiently answer your questions or resolve your concerns.
  • Page 112: Warranty Information

    Warranty Information LIMITED WARRANTY COVERAGE STANDARD EXTENDED MOTORCYCLE (Replaces 2nd Year of the Second Year PARTS COVERED Standard Warranty) First Year (Excluding Shipping and Labor)    Motor    Controller    Power Pack   ...
  • Page 113: Zero Motorcycles Limited Warranties

    This warranty does not apply to tire wear, chain or sprocket condition, brake pads or rotors, fork seals, Zero Motorcycles Inc. expressly warrants all Zero grips, foot pegs, the seat, or any other parts subject manufactured products from defects in material and to normal wear and tear.
  • Page 114: Extended Warranty

    Under this limited warranty and liability agreement, This extended warranty excludes aftermarket Zero Motorcycles Inc. shall have no obligation and the accessory kits which may be subject to their own purchaser shall have no remedy against Zero warranties. Motorcycles Inc. and its officers and/or agents for any...
  • Page 115: Disclaimers Applicable To Standard Warranty And Extended Warranty

    The purchaser acknowledges that there is an inherent during the time the warranty service is being risk in the operation of Zero motorcycles and all other performed, travel, loss or damage to personal Zero Motorcycles Inc. products, and herewith...
  • Page 116: Proper Use

    Zero Motorcycles Inc. electric motorcycle. Serious injury or Service may also be available from a local Zero death may result from improper operation or failure to Motorcycles Certified Service Center please see the observe warnings and safety instructions on any locator on www.zeromotorcycles.com for the nearest...
  • Page 117: Transfer Of Ownership And Warranty

    A service technician will When it comes time to sell your Zero motorcycle, contact you with specific instructions to ensure that please visit the Zero Motorcycles website and access you receive the best service for your motorcycle.
  • Page 118 Zero Motorcycles from your Zero Motorcycles dealer. Further information 170 Technology Circle can be obtained from your authorized Zero dealer or Scotts Valley, CA 95066. Zeromotorcycles.com. All illustrations and specifications contained in this ©2011 Zero Motorcycles Inc.
  • Page 119 ............5-26 Brake Pad Inspection ..........5-7 Add On Electrical Equipment ........4-7 Braking ................4-21 An Important Message To You From Zero ....1-1 Chain ................5-9 Battery Management System (BMS) ......4-9 Checking The Drive Chain ........ 5-11 Beep-Signals ............4-10 Cleaning The Drive Chain ........
  • Page 120 Right Side View ..........3-3, 3-4 Zero MX Dirt Technical Specifications ....1-8 Customer Assistance ..........7-1 Zero MX Street Legal Technical Specifications .. 1-8 Zero X Dirt Technical Specifications ....1-7 Zero X Street Legal Technical Specifications ..1-7 Zero XU Technical Specifications ......
  • Page 121 Owner’s Responsibilities ........5-1 Identification Numbers ..........1-5 Power Pack ............5-5 VIN/PIN Breakdown ..........1-6 Zero Motorcycle Accessories ......5-26 Instrument Panel (X/MX Dirt) ........3-5 Maintenance Schedule ..........5-20 Instrument Panel (X/MX/XU Street Legal) ....3-7 Motor ................5-6 Indicators ...............
  • Page 122 Power Pack Empty ............. 6-4 Power Pack Full (High Pack Voltage) ....... 6-8 Operating Information ..........2-2 Power Pack Swapping ..........4-8 Operating Your Motorcycle ........4-21 Pre-Ride Inspection ............ 4-4 Braking ..............4-21 Brakes ..............4-4 Starting ..............4-21 Drive Chain ............
  • Page 123 Suspension Adjustment ........... 4-22 Front Fork Adjustment ........4-22 Safe Riding ..............1-2 Rear Shock Adjustment ........4-24 Safety Information ............2-1 Safety Interlocks ..........4-10, 6-6 Instrument Panel ..........6-8 Power Pack Full (High Pack Voltage) ....6-8 Tail Light Bulb Replacement ........5-16 The Charger Disable Interlock ......
  • Page 124 Warranty/Customer Assistance ........7-1 Warranty Information ........... 7-2 Unpacking Your Zero Motorcycle ....... 4-2 Warranty Procedures ..........7-6 Understanding Beep Sequences ......6-3 Wheels And Tires ............5-8 Low Power Pack Warning ........6-4 Other Error-Beep Patterns ........6-5 Power Pack Empty ..........6-4 Power Pack Unbalanced ........

This manual is also suitable for:

Mx dirt 2011X street legal x dirt 2011

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