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Zero FX 2016 Owner's Manual

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ZERO FX
ZERO FXS
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2016 OWNER'S MANUAL

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Summary of Contents for Zero FX 2016

  • Page 1 ™ ZERO FX ZERO FXS ™ 2016 OWNER’S MANUAL...

  • Page 3: Table Of Contents

    Introduction ............ 1.1 Safety Information ......... 2.1 Introduction..............1.1 General Safety Precautions ........2.1 An Important Message From Zero Motorcycles ..1.1 General Safety Precautions ........2.1 About This Manual ............ 1.1 Important Operating Information ....... 2.2 Useful Information For Safe Riding ......1.2 Location of Important Labels ........
  • Page 4 Add On Electrical Equipment ........5.11 Turn Signal Light Bulb Replacement ...... 6.22 Brake/Tail Light Bulb Replacement......6.23 Running Light Bulb Replacement ......6.23 Cleaning..............6.25 Parking and Long Term Storage......6.26 Zero Motorcycles Accessories ........ 6.26 Fuses ..............6.27 TOC.2...
  • Page 5 Table Of Contents Troubleshooting..........7.1 What Will Zero Motorcycles Do Under This Limited Warranty?..............9.7 Troubleshooting ............7.1 How Does This Limited Warranty Relate To State Electric Motorcycle Precautions ........ 7.1 Law?................9.7 Troubleshooting Your Motorcycle ......7.1 How Do You Obtain Service Under This Limited System Warning Indicator .........

  • Page 7: Introduction

    About This Manual Congratulations and thank you for purchasing the 2016 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 Motorcycles 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

    General Information Reported motorcycle range values are measured using Maximizing Your Range two different types of industry standard test procedures: Range varies in electric motorcycles similarly to how it 1. “City”: This range test is specified to determine riding varies in gas motorcycles. However, the big difference during “stop-and-go”...
  • 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 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 17: 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 18: Important Operating Information

    • Turn the motor stop switch OFF when backing up or instructions as described in this Zero Motorcycles pushing the motorcycle while dismounted. Owner’s Manual may void the warranty of your Zero • Use the rear brake when you are stopped on an incline. motorcycle. These guidelines have been rigorously...

  • Page 19: Location Of Important Labels

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

  • 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 3.16. 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. 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 26: Right Side View

    Controls and Components Right Side View...
  • Page 27 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 6.14. pedal is pressed. When braking, the throttle should be in the closed position. B.

  • 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 3.12. “Performance Level Mode Button”, on page 3.19. B. Select Button (SEL) I.

  • Page 30: Warning Indicator Lights

    Controls and Components Warning Indicator Lights 3.10...
  • Page 31 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 32: 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 33 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 34 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 35: 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 36: Handlebar Controls

    Controls and Components Handlebar Controls 3.16...
  • Page 37 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 38: 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 39 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 40 Notes 3.20...

  • Page 41: 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 42: 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 43 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 sequence occurs: • Lights turn ON • Dash display turns ON...

  • Page 44: 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 Your Motorcycle...
  • Page 45 Please note that the lighting of this temperature indicator does not indicate that there’s anything malfunctioning with your Zero motorcycle; it is simply letting you know that the thermal strategy is working. If you do not moderate your speed/power, the bike’s system will reduce your...

  • Page 46: Abs (Anti-Lock Brake System)

    General Operation ABS (Anti-lock Brake 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 47 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 48 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 49: 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 50 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 51 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 52 General Operation Compression Damping too slow will pack-up (feel harsh over consecutive bumps), while compression that is set too fast will cause the fork to The compression damping is adjusted by turning a screw bottom out harshly. If the fork is bottoming out, turn the on the bottom of each fork leg.

  • Page 53: 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 54 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 55 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 56 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 57 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 out from fully closed Rear Shock Rebound 12 clicks out from fully closed Rear Shock Spring Preload...
  • Page 58 Notes 4.18...

  • Page 59: Power Pack And Charging

    The integrated on-board 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 60 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 61: Power Pack Swapping

    Note: If necessary, assist removal by also pushing battery from opposite side of the motorcycle. The Zero FX and FXS feature a quick change power pack. Note: The power pack weighs 42 lbs (19 kg). This allows the rider to charge one power pack while using another.

  • Page 62: 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 63: Charging The Power Pack

    Always keep the power cord with It is possible for lithium-ion cells to overheat and fail. 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 64 Power Pack and Charging 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 65: Quick Charging (Off-Board Accessory Charger)

    Note: For 2016 motorcycles, the max number of accessory B. AC Power Cord Connection chargers is: • C. Power Pack Charger Zero FX, Zero FXS 3.3 = 2 • D. Charger LED Indicators Zero FX, Zero FXS 6.5 = 4 E. Connector (to motorcycle)
  • Page 66 Power Pack and Charging Using the Quick Charger: 5. Either connect the on-board charger (see “Charging the Power Pack”, on page 5.5) or change the key switch to 1. Ensure that the key switch is in the OFF position. the ON position. You should hear the contactors close 2.
  • Page 67 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 68 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 69: Public Charging Stations

    Level 2 charging station can damage your motorcycle, prevent other components with the optional J1772 Zero Motorcycles charging adapter from working as they should, and/or dramatically reduce accessory (Zero PN: 10-03267). These charging stations the range and/or life expectancy of the power pack.
  • Page 70 Notes 5.12...

  • Page 71: 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 72: 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 73 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 74 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 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: 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 77 Maintaining Your Motorcycle Left Side Of Motorcycle Refer to Torque table on page 6.6.
  • Page 78 Maintaining Your Motorcycle Right Side Of Motorcycle Refer to Torque table on page 6.6.

  • Page 79: Power Pack

    90 days if stored fully charged. Zero recommends you plug in your Zero motorcycle after 90 days, even if fully charged. Please leave your Zero motorcycle plugged in whenever possible. 1. The power pack is a lithium-ion power system. While it does require charging, it does not require maintenance.

  • Page 80: 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 (C). If the fluid level is (Anti-lock Brake System), brake pad examples (specific...
  • Page 81 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 82 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 83: 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 84: Tire Inflation

    General Maintenance Tire Inflation Drive Belt WARNING! Under-inflation is a common cause of tire The drive belt provides low maintenance and quiet failure and may result in severe tire cracking, tread operation with minimal stretch. Keep dirt, grease, oil, and separation, “blowout,”...
  • Page 85 General Maintenance Checking Drive Belt Tension Proper belt tension is essential for optimum operation of the drive system. Lack of belt tension can lead to “ratcheting.” The teeth of the belt slide over the teeth of the rear sprocket. This causes an unpleasant sound;...
  • Page 86 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 (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 87: 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 88 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 89 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 90: 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 91 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 92: 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 93: 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 94 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. 6.24...

  • Page 95: 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 96: 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! 6.26...

  • Page 97: 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 98 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 99 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 100 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 101 ABC4A DC/DC Converter 4. Remove the flexible protective cover to gain access to JLLN100 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. 6.31...
  • Page 102 Notes 6.32...

  • Page 103: Troubleshooting

    If you are unable to solve an parts, wiring (identified by the orange outer sleeving) or issue with your Zero FX/FXS electric motorcycle, take it to connectors. If the motorcycle is involved in an accident do not an authorized dealer at your convenience.

  • Page 104: 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 105 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 106 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 107: 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 108 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 109 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 110: 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 111: 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 112 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 113 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 114 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 115 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 116 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 117: 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 118: 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 119 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 120 Notes 7.18...

  • Page 121: Specifications

    Specifications Zero FX Technical Specifications Specifications Charger Type 650 W Integrated • ZF3.3: 92,000 miles (148,000 km) Estimated Power Pack Life MOTOR to 80% (city) • ZF6.5: 185,000 miles (298,000 km) Type Z-Force 75-5 passively air-cooled, high RANGE efficiency, radial flux permanent magnet, •...
  • Page 122 Specifications DRIVETRAIN DIMENSIONS Transmission Clutchless Direct Drive Wheelbase 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 25.4 degrees Front Suspension Travel 8.60 in (218 mm) Trail 4.1 in (104 mm) Rear Suspension Travel 8.94 in (227 mm) WEIGHT...

  • Page 123: Zero Fxs

    Specifications Zero FXS Charger Type 650 W Integrated • ZF3.3: 101,000 miles (163,000 km) Estimated Power Pack Life MOTOR to 80% (city) • ZF6.5: 203,000 miles (327,000 km) Type Z-Force® 75-5 passively air-cooled, RANGE high-efficiency, radial flux, interior • ZF3.3: 45 miles (72 km)
  • Page 124 Specifications DRIVETRAIN DIMENSIONS Transmission Clutchless Direct Drive Wheelbase 56.0 in (1,422 mm) Final Drive 132T/25T, Poly Chain® GT® 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 8.94 in (227 mm) WEIGHT...

  • Page 125: Limited Warranty Information

    Should a ZF3.3 Power Pack be purchased to upgrade And Warranty”, on page 9.9. the capacity of a Zero ZF3.3 to ZF6.5 after the initial “in service date” of the host Zero motorcycle, the Power Pack warranty duration will match the remaining Power Pack warranty from the host Zero motorcycle.

  • Page 126: What Is The Coverage Period Of This Limited Warranty

    • Five (5) years or 50,000 miles (80,000 km), whichever The duration of this Limited Warranty depends upon occurs first, from the “in service date” for ZF3.3 Power whether your 2016 Zero motorcycle is a demonstrator or a Pack Modules on the Zero FX/FXS. non-demonstrator.

  • Page 127: 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 128 • Any cosmetic concerns that arise as a result of specifications from those set by Zero, or the use of new environmental conditions, owner abuse, misuse, lack of or used parts not approved by Zero;...

  • Page 129: What Other Limitations Or Disclaimers Apply To This Limited Warranty

    • Zero does not assume – or authorize any person to windstorms, or other similar occurrences; assume – any other obligation or liability on its behalf.

  • Page 130: What Are Your Responsibilities As A Customer

    Zero motorcycle • At all times when operating a Zero motorcycle wear warranty registration form is responsible for conveying the Owner’s Manual and all safety warnings,...

  • Page 131: What Will Zero Motorcycles Do Under This Limited Warranty

    2016 Zero motorcycle, Power Packs, or parts that are covered by this Limited Warranty and found by Zero or an authorized Zero dealer to be defective in factory materials or workmanship. How Does This Limited Warranty Relate To...

  • Page 132: How Do You Obtain Service Under This Limited Warranty

    Zero Motorcycles Europe Fluorietweg 12D Warranty services may be obtained by contacting your Alkmaar, Noord Holland 1812 RR local Zero Motorcycles dealer. Please refer to the dealer Netherlands locator on our website (www.zeromotorcycles.com/locator) for your nearest location. (U.S. and International Patents and Trademarks Pending) In the event that a dealer is not in your state, province, or country, you can contact Zero Motorcycles Inc.

  • Page 133: Transfer Of Ownership And Warranty

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

  • Page 134: 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/ 9.10...

  • Page 135: 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 136 Notes 9.12...

  • Page 137: 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 138 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 139 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 140 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 141: Index

    Pre-Ride Inspection...........4.1 General Safety Precautions...........2.1 Charging the Power Pack..........5.5 General Troubleshooting ..........7.8 Cleaning Your Motorcycle ...........6.25 Contact information NHTSA ..............9.11 Headlight Zero Motorcycles ............9.10 Alignment ..............6.20 Bulb Replacement ...........6.20 Dash Settings .............. 3.12 Drive Belt ..............6.14 Checking Drive Belt Tension........6.15 INDEX.1...
  • Page 142 Index Important Operating Information ........2.2 Parking ................ 6.26 Inspection Parts/Maintenance Items..........6.2 Pre-Ride..............4.1 Performance Level Switch........... 3.19 Instrument Panel ..........3.8 3.10 ECO Position ............3.19 SPORT Position............3.19 Power Pack ..............6.9 Keys Plug in Your Z-Force Power Pack......1.2 Replacement Code Number ........
  • Page 143 Front (Factory) ............4.12 Coverage..............9.1 Rear (Factory) ............4.17 Exclusions ..............9.3 Transfer Of Ownership And Warranty .......9.9 Wheels And Tires ............6.13 Technical Specifications Zero FX ..............8.1 Zero FXS..............8.3 Tire Inflation..............6.14 Transporting ..............1.10 Troubleshooting Battery Management System (BMS)......7.9 Charge Mode ............7.11 Run Mode ...............7.12...
  • Page 144 Notes INDEX.4...

  • Page 145: First Responder Information - High Voltage Components Locations

    First Responder Information - High Voltage Components Locations First Responder Information - High Voltage Components Locations...
  • Page 146 TAKE CHARGE ™ ZEROMOTORCYCLES.COM Y Y LES.COM 88-08467 .03...

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