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Zero FX 2015 Owner's Manual

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ZERO FX
2015 OWNER'S MANUAL

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Summary of Contents for Zero FX 2015

  • Page 1 ™ ZERO FX 2015 OWNER’S MANUAL...

  • Page 3: Table Of Contents

    Table Of Contents Introduction ............ 1.1 Safety Information ......... 2.1 Introduction..............1.1 General Safety Precautions ........2.1 An Important Message To You From Zero General Safety Precautions ........2.1 Motorcycles ............... 1.1 Important Operating Information ....... 2.2 About This Manual ............ 1.1 Location of Important Labels ........
  • Page 4 General Operation .............4.3 Cleaning..............5.24 Key Switch/Steering Lock Positions......4.4 Parking and Long Term Storage......5.25 Power Pack..............4.6 Zero Motorcycles Accessories ........ 5.25 Power Pack Charger..........4.9 Fuses ..............5.26 Operating Your Motorcycle ........4.16 Service Record ............5.31 ABS (Anti-lock Brake System) .........4.18 Front Suspension Adjustment........4.20...
  • Page 5 What Other Limitations Or Disclaimers Apply To This Limited Warranty ..........7.4 What Are Your Responsibilities As A Customer? ..7.5 What Will Zero Do Under This Limited Warranty? ..7.5 How Do You Obtain Service Under This Limited Warranty? ..............7.6 Transfer Of Ownership And Warranty.......

  • Page 7: Introduction

    When it comes time to sell your Zero FX, please ensure that this manual stays with the motorcycle; it is, by law, an important part of the vehicle. If you have any questions...

  • Page 8: Useful Information For Safe Riding

    Introduction Useful Information For Safe Riding Unplug Your Z-Force Power Pack™ ® This manual contains the word CAUTION 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 WARNING 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 right rear of the power pack. the frame (A). Do not alter or remove this as it is the legal identifier for your motorcycle.
  • Page 11 Identification Numbers 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.

  • Page 12: General Information

    (95% charged) Zero FX (accessory) • ZF5.7: 3.4 hours (100% charged) / 2.9 The Zero FX specifications below apply to both the ZF2.8 hours (95% charged) and ZF5.7 models (unless otherwise specified). Input Standard 110 V AC or 220 V AC...
  • Page 13 General Information DRIVETRAIN DIMENSIONS Transmission Clutchless Direct Drive Wheel Base 56.6 in (1,438 mm) Final Drive 132T/25T, Poly Chain® GT® Carbon™ belt Seat Height 34.7 in (881 mm) CHASSIS/SUSPENSION/BRAKES Rake 26.7 degrees Front Suspension Travel 8.60 in (218 mm) Trail 4.1 in (104 mm) Rear Suspension Travel 8.94 in (227 mm)

  • Page 14: Vehicle Range

    J2982 Riding Range Test Procedure for On-Highway reflection of your riding habits. The more conservatively Electric Motorcycles to provide a reasonable and you ride, the better range you can expect from your Zero consistent basis for manufacturers to inform Motorcycle.

  • Page 15: Public Charging Stations

    Level 2 charging station averaged over a shorter distance on an electric with the optional J1772 Zero Motorcycle accessory. These motorcycle. Electric motorcycles are designed for stations are often available at a variety of locations...
  • Page 16 General Information 1.10...
  • Page 17 General Information 1.11...

  • Page 18: Emissions Information

    CAUTION: 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 19: 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 prevent 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 20 Notes 1.14...

  • Page 21: General Safety Precautions

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

  • Page 22: Important Operating Information

    General Safety Precautions Important Operating Information CAUTION: Charge the Zero power pack with the Zero charger. Several operating considerations are listed below: • The power pack does not require nor benefit from deep • Always turn the key switch and motor stop switch to the discharging.

  • Page 23: 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: A. VIN label (European Union) - certification label C. VECI (Vehicle Emission Control Information) label B.
  • Page 24 Location of Important Labels High Voltage Warning Labels Located near the motor Located on frame if only one battery is installed...

  • Page 25: Controls And Components

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

  • Page 26: Motorcycle Controls

    Controls and Components Motorcycle Controls...
  • Page 27 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 3.16. offer a greater field of view than a similar flat mirror. H.

  • Page 28: Left Side View

    Controls and Components Left Side View...
  • Page 29 Controls and Components A. Headlight E. Kickstand Switch This switch is a safety feature that prevents motor • For headlight operation, see “Handlebar Controls”, on operation when the kickstand is down. If the kickstand page 3.16. were down when riding it could contact the ground •...

  • Page 30: Right Side View

    Controls and Components Right Side View...
  • Page 31 Controls and Components A. Drive Belt H. Rear Brake Pedal For description and operation, see “Drive Belt”, on The rear brake pedal controls the rear brake when the page 5.14. pedal is pressed. When braking, the throttle should be in the closed position. B.

  • Page 32: Dash Overview

    Controls and Components Dash Overview...
  • Page 33 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 3.12. “Performance Level Mode Button”, on page 3.19. B. Select Button (SEL) I.

  • Page 34: Warning Indicator Lights

    Controls and Components Warning Indicator Lights 3.10...
  • Page 35 Controls and Components A. Left Indicator Turn Signal E. ABS (Anti-Lock Brake System) Indicator An arrow on the lower dash flashes green The indicator illuminates when the key is in the same direction as selected by the in the ON position. The light will extinguish turn signal switch.

  • Page 36: Dash Settings

    Controls and Components Dash Settings Displays A&B Display A The displays on the dash can be customized to your To select Display A with the dash in its normal operating personal preferences by using the ADJ (Adjust) and SEL mode, momentarily press the SEL button once. Press the (Select) buttons.
  • Page 37 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 38 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 39: 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 40: Handlebar Controls

    Controls and Components Handlebar Controls 3.16...
  • Page 41 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 42: 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 43 Controls and Components Performance Level Mode Button The SPORT selection causes the motorcycle to accelerate at a significantly faster rate. 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 3.15).
  • Page 44 Notes 3.20...

  • 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

    • Carefully lift rear portion of the motorcycle over the Unpacking Your Zero Motorcycle swingarm standoff and off crate base. Although unpacking your Zero Motorcycle can be done by • Carefully lift front wheel out of crate base. a single person, it is recommended to have a second •...

  • Page 47: General Operation

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

  • 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 General Operation OFF Position This position is used to turn the motorcycle OFF, disabling the electrical system. ON Position This position is used for operating the motorcycle. In this position the following will occur: • Lights turn ON • Dash Panel display turns ON...

  • Page 50: Power Pack

    The integrated onboard charger minimizes more), you may want to plug the motorcycle into an AC charge time and can work in parallel with Zero’s quick power source to charge it for a few hours prior to your next charge accessories to cut charge times by as much as ride.
  • Page 51 General Operation 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 safeguards the power pack by means of safety interlocks.
  • Page 52 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 53: Power Pack Charger

    AC power source to charge it for a few hours prior to your next ride. CAUTION: Only charge the Zero power pack with the Zero charger. The charger is located under the power pack.
  • Page 54 General Operation The on-board charger indicator (A) is visible on the dash panel. The charging indicator icon flashes while charging and is continuously lit when fully charged. For examples and information on Quick Charging LEDs see page 4.15. Charging Indicator Icon 4.10...
  • Page 55 It is possible for lithium ion cells to overheat and fail. connector (see inset). Always keep the power cord with the motorcycle. Note: Charge the Zero Power pack in a location that is well-ventilated and away from combustible materials. If charging your Zero Motorcycle outdoors, avoid charging in the rain.
  • Page 56 General Operation 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 12 amps from the 120 V AC circuit when charging.
  • Page 57 General Operation Using the Quick Charger 4. Connect the power pack charger to the power pack connector (A). To charge using the Quick Charger: 5. Connect the Quick charger to the power pack Note: If you connect the on-board charger (see “Charging connector (A).
  • Page 58 General Operation 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 59 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 60: Operating Your Motorcycle

    General Operation Operating Your Motorcycle without locking the wheels. Your Zero motorcycle is a light- weight performance product and therefore practice is This section describes how to safely operate your strongly recommended to perfect safe emergency stops. motorcycle. Stopping Starting 1.
  • Page 61 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 62: Abs (Anti-Lock Brake System)

    General Operation ABS (Anti-lock Brake System) When the motorcycle is stationary and the key is turned to the ON position, it is normal for the ABS warning indicator WARNING! ABS prevents the wheels from locking, (A) on the dash to illuminate. The indicator will remain on therefore maximizing the effectiveness of the braking until the system detects the motorcycle’s speed exceeds system in emergencies and when riding on slippery...
  • Page 63 ABS system repaired. If 2. Wait for the dash display to turn off completely. there are no dealers in you area, call Zero Motorcycles 3. Turn the ignition key to the ON position. Customer Service.

  • Page 64: 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 fork compresses.
  • Page 65 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 66 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 67 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 68: 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 an 180 lb (82 kg) rider. This puts the rear tire 1/3 of the way through its vertical travel.
  • Page 69 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 70 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. It has 8 stages of adjustment. Printed on the knob is adjusting collar (A).
  • Page 71 General Operation Compression Adjustment The compression adjustment knob is at the top of the shock. It has 18 stages of adjustment. Printed on the knob is “H” meaning Hard (slower compression) and “S” meaning Soft (faster compression). Turn the adjuster clockwise for a harder ride (slower compression).
  • Page 72 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. ADJUSTMENT SETTING Rear Shock Compression 9 clicks out from fully closed Rear Shock Rebound 12 clicks out from fully closed Rear Shock Spring Preload...

  • Page 73: 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 74: Maintenance Schedule

    Maintenance Schedule The scheduled maintenance must be performed in accordance with this chart to keep your Zero 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 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: 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 19 lb ft (26 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 78 Maintaining Your Motorcycle Left Side Of Motorcycle Refer to Torque table on page 5.5.
  • Page 79 Maintaining Your Motorcycle Right Side Of Motorcycle Refer to Torque table on page 5.5.

  • Page 80: 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 81: 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 motorcycle. It covers the ABS (Anti-lock glass (C). If the fluid level is Brake System), brake pad examples (specific brake pads...
  • Page 82 General Maintenance Rear Brake Brake Pad Inspection The brake pads must be inspected when specified in the maintenance schedule. See Maintenance Schedule information on page 5.2. Visually inspect the brakes by looking at the remaining brake pad material through the sides of the brake caliper.
  • Page 83 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 84: 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 5.2. • Bent or cracked rims. • To adjust the fork, see Suspension Adjustment on •...

  • Page 85: 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 86: 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 87 General Maintenance Drive Belt Adjustment Procedure Note: Adjust both sides equally. 1. Remove key from the key switch. 2. Loosen the rear axle nut (A). 3. Loosen the (left and right) 13 mm jam nuts (C). 4. Turn the (left and right) 13 mm adjustment bolts (B) 1/4 turn at a time until the belt adjustment is within specification.

  • Page 88: 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 89 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 90 General Maintenance Adjusting The Drive Chain Note: Adjust both sides equally. 1. Remove key from the key switch. 2. Loosen the rear axle nut (A). 3. Loosen the (left and right) 13 mm jam nuts (C). 4. Turn the (left and right) 13 mm adjustment bolts (B) 1/4 turn at a time until the chain adjustment is within specification.

  • Page 91: 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 92 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 93: 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. To replace the signal light bulb: 1. Remove the turn signal lens screw (A) and remove the lens. 8.

  • Page 94: 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 95 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. 5.23...

  • Page 96: 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, cowling's, panels, and other plastic parts. Do fenders, and side panels), which can scratch easier not use high pressure water or steam cleaners;...

  • Page 97: 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! 5.25...

  • Page 98: Fuses

    General Maintenance Fuses 12 Volt Fuse Center The 12 volt fuse center is located on the frame above the Whenever there is an excessive amount of current flowing front power pack. through a circuit the fusible element will melt and create an open or incomplete circuit.
  • Page 99 General Maintenance To access the 12 volt fuse center (see arrow): 1. Remove the front power pack to gain access to the fuse center. 2. Remove the cover from inside the cavity. 3. Replace the fuse(s). 4. Reinstall the cover. 5.
  • Page 100 General Maintenance ABS 12 Volt Fuse To access the 12 volt ABS fuse: The ABS 12 volt fuse is located on the frame above the 1. Remove the front power pack to gain access to the front power pack. ABS fuse. 2.
  • Page 101 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. 2. Remove both power packs to gain access to fasteners and fuses.
  • Page 102 ABC4A DC/DC Converter 4. Remove the flexible protective cover to gain access to JLLN70 ACCY Charge Fuse (in-line) the fuse. ABC10A Charge Fuse (on-board) Note: If the charge fuse (3) needs replacement, contact your Zero Motorcycles dealer. 5.30...

  • Page 103: Service Record

    Service Record Follow the maintenance schedules on page 5.2. After a scheduled service or routine is performed, record the information Service Record on the chart below. DATE ITEM SERVICE/ROUTINE DESCRIPTION 5.31...
  • Page 104 Service Record DATE ITEM SERVICE/ROUTINE DESCRIPTION 5.32...

  • Page 105: Troubleshooting

    If you are unable to solve an for your safety. issue with your Zero FX Motorcycle, take it to an Do not touch, attempt to remove or replace any high authorized dealer at your convenience. If there is no dealer voltage parts, wiring (identified by the orange out sleeving) in your area call Zero Motorcycles Customer Service.

  • Page 106: System Warning Indicator

    Troubleshooting System Warning Indicator If a fault has been detected, count the number of times the red indicator light (A) flashes. Refer to the table on the following pages for a possible cause and solution to the issue.
  • Page 107 Motor Stop Switch Disabled or Kickstand motor stop switch ON button. Kickstand is down. Switch Disabled Raise kickstand. Self-Test Failed Contact Zero or your dealer. Charger Connected Unplug charger. Throttle is ON or throttle/connection is bad. Verify High Throttle Disable throttle action and/or check connection.
  • Page 108 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 109: 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 3.12 Refer to the table starting on the next page to identify the error associated with the Error Code number.
  • Page 110 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 111 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...

  • Page 112: 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 6.11.

  • Page 113: 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 114 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 115 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 116 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 117 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 118 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 119: 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).

  • Page 120: 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 121 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 122 Notes 6.18...

  • Page 123: Limited Warranty Information

    Should a ZF2.8 Power Pack be purchased to upgrade first, from the “in service date” for ZF2.8 Power Pack the capacity of a Zero FX ZF2.8 to ZF5.7 after the initial Modules on the Zero FX. “in service date” of the host Zero motorcycle, the Power •...

  • Page 124: Who Does This Limited Warranty Cover

    • “Proper use” means only the use of a motorcycle in the submission of a new registration card by the new owner. manner intended for a rider and passenger on a Zero See “Transfer Of Ownership And Warranty”, on page 7.6.
  • Page 125 • Any cosmetic concerns that arise as a result of specifications from those set by Zero, or the use of new or used parts not approved by Zero; environmental conditions, owner abuse, misuse, lack of •...

  • Page 126: What Other Limitations Or Disclaimers Apply To This Limited Warranty

    Warranty does not cover - and Zero cannot assume • Zero does not assume – or authorize any person to responsibility for - any injury arising from the unsafe or assume – any other obligation or liability on its behalf.

  • Page 127: What Are Your Responsibilities As A Customer

    Packs, or parts that are covered by this Limited Warranty injury or death can result from improper operation or failure and found by Zero or an authorized Zero dealer to be to observe warnings and safety instructions on any defective in factory materials or workmanship.

  • Page 128: How Do You Obtain Service Under This Limited Warranty

    How Do You Obtain Service Under This Transfer Of Ownership And Warranty Limited Warranty? When it comes time to sell your Zero Motorcycle, please visit the Zero Motorcycles website and access the Owner Warranty services may be obtained by contacting your Resources section to fill out the on-line transfer of local Zero Motorcycle dealer.

  • Page 129: Customer Information

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

  • Page 130: 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 131: Index

    Index Drive Chain ..............5.16 Adjustment Procedure..........5.18 Accessories ..............5.25 Cleaning ..............5.16 Lubricating...............5.17 Bolt Torque Specifications..........5.5 Brake/Tail Light Bulb Replacement ......5.22 Emissions Information ..........1.12 Brakes ................5.9 Brake Fluid Level Inspection ........5.9 Brake Pad Inspection ..........5.10 First Time Set-Up............4.1 Braking ..............4.18 Fuses ................5.26 DOT 4 brake fluid ............5.10 High Voltage Fuse Center ........5.29 Front Brake ...............5.9...
  • Page 132 Index Important Operating Information ........2.2 Parking ................ 5.25 Inspection Parts/Maintenance Items..........5.1 Pre-Ride..............4.3 Performance Level Switch........... 3.19 Instrument Panel ..........3.8 3.10 ECO Position ............3.19 SPORT Position............3.19 Power Pack ..............5.8 Keys Plug in Your Z-Force Power Pack......1.2 Replacement Code Number ........
  • Page 133 Location............. 1.4 Front (Factory) ............4.23 Understanding Your VIN Number ......1.5 Rear (Factory) ............4.28 Vehicle Range ...............1.8 VIN.................1.4 Technical Specifications Zero FX Technical Specifications......1.6 Warning Lights............. 3.8 3.10 Temperature Indicator Warranty Power Pack Full (High Power Pack-Voltage)..6.13 Coverage..............7.1 Tire Inflation..............5.13 Exclusions ..............7.2...
  • Page 134 Notes INDEX.4...

  • Page 135: First Responder Information - High Voltage Components Locations

    First Responder Information - High Voltage Components Locations First Responder Information - High Voltage Components Locations...
  • Page 136 TAKE CHARGE ™ ZEROMOTORCYCLES.COM...

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