1. Manuals
  2. Brands
  3. Zero Manuals
  4. Motorcycle
  5. DSR 2018
  6. Owner's manual

Zero DSR 2018 Owner's Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
™
ZERO S
ZERO SR
™
™
ZERO DS
™
ZERO DSR
2018
OWNER'S MANUAL

Advertisement

Table of Contents
loading

Related Manuals for Zero DSR 2018

Summary of Contents for Zero DSR 2018

  • Page 1 ™ ZERO S ZERO SR ™ ™ ZERO DS ™ ZERO DSR 2018 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 ......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 Power Pack..............5.1 Cleaning..............6.26 On-Board Power Pack Charger .........5.2 Parking and Long Term Storage......6.27 Charging the Power Pack ..........5.4 Zero Motorcycles Accessories ........ 6.27 Quick Charging (Off-Board Accessory Charger)..5.6 Fuses ..............6.27 Charge Tank (if equipped) .........5.9 Public Charging Stations..........5.10 Troubleshooting ..........
  • Page 5 What Is Not Covered By This Limited Warranty?..9.3 What Other Limitations Or Disclaimers Apply To This Limited Warranty ..........9.5 What Are Your Responsibilities As A Customer? ..9.6 What Will Zero Do Under This Limited Warranty? ..9.7 TOC.3...

  • Page 7: Introduction

    About This Manual Congratulations and thank you for purchasing the 2018 This manual covers the following motorcycles (standard Zero S, Zero SR, Zero DS, or Zero DSR electric features and equipment include Integrated Z-Force® motorcycle; we welcome you to the community of Zero Power Pack and charger, belt drive, 17-inch wheels Motorcycles riders.

  • 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) / Chassis Number The Power Pack serial number is located on the upper front left of the power pack. The VIN / Chassis Number (A) is a 17-digit number stamped on the head tube of the frame. Do not alter or Motor Serial Number remove this number as it is the legal identifier for your motorcycle.

  • Page 11: 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 S/SR/DS/DSR runs solely on S/SR/DS/DSR motorcycle.

  • Page 12: Maximizing Your Range

    Range varies in electric motorcycles similarly to how it 134/2014 Annex VII. varies in gas motorcycles. However, the big difference For Zero motorcycles sold in all other countries, range is between electric and gas is that energy consumption is calculated using the following types of industry standard...
  • Page 13 General Information...
  • Page 14 General Information...

  • Page 15: Transporting

    General Information Transporting It is recommended that the motorcycle be tied-down using ratchet straps while it is being transported. Place the ratchet straps around a frame contact point. Soft straps must be used to reduce scratches or other damage. Use two ratchet straps in the front and two in the rear. The tie down straps should be at a 45°...
  • Page 16 Notes 1.10...

  • Page 17: General Safety Precautions

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

  • Page 18: Important Operating Information

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

  • Page 19: Location Of Important Labels

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

  • 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 3.8. For description and operation, see “Handlebar D. Cavity for Accessory 12 Volt Socket Controls”, on page 3.17. Location for Zero dealer-installed 12 volt accessory socket. E. Front Brake Fluid Reservoir For description and operation, see “Brakes”, on page 6.10.

  • Page 24: Left Side View

    Controls and Components Left Side View...
  • Page 25 Controls and Components A. Headlight F. Kickstand  For headlight operation, see “Handlebar Controls”, on The kickstand swings out from the side and supports page 3.17. the motorcycle when parked. The key switch should  For headlight bulb replacement, see “Headlight Bulb be in the OFF position when parked.

  • Page 26: Right Side View

    Controls and Components Right Side View...
  • Page 27 Controls and Components A. Rear Brake Fluid Reservoir See “Rear Brake Fluid Reservoir”, on page 6.11. B. Auxiliary Power Pack Charging Connection For description and operation, see “Quick Charging (Off-Board Accessory Charger)”, on page 5.6. The auxiliary connector is located above the motor. C.

  • Page 28: Dash Overview

    Controls and Components Dash Overview...
  • Page 29 Controls and Components A. Adjust Button (ADJ) the rider using the performance level mode button located on the right handlebar control assembly. See See “Dash Settings”, on page 3.13. “Performance Level Mode Button”, on page 3.21. B. Select Button (SEL) I.

  • Page 30: Warning Indicator Lights

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

  • Page 33: Dash Settings

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

  • Page 36: Smartphone Application

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

  • Page 37: Handlebar Controls

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

  • Page 39: Performance Level Mode Button

    Controls and Components F. Motor Stop Switch H. Hazard Warning Flasher Switch When the top of the switch (A) is pressed, it cuts off When the top of the switch is pressed, the turn signals power to the run signal. The motor controller remains flash to warn other drivers of situations, which include in this state until the bottom portion of the switch (B) is needing to stop or park under emergency conditions.
  • Page 40 Controls and Components J. Horn Button When the key is in the ON position, the horn (A) sounds when the button is pressed. Electric vehicles run quietly; the horn can be used to warn pedestrians or other motorists of your presence. 3.20...
  • Page 41 Controls and Components Performance Level Mode Button The SPORT selection causes the motorcycle to accelerate at a significantly faster rate but decreases the amount of regeneration when the throttle is released. This position is recommended for advanced riders. The CUSTOM selection has customizable performance settings by using the smartphone application (refer to “Smartphone Application”, on page 3.16).

  • Page 42: Front Brake Lever Adjuster

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

  • Page 43: Tank Storage Compartment

    4. Place leash eye over tank storage compartment stud. 5. Close tank storage compartment lid and lock with key. Unless other optional equipment is specified on your Zero 6. Place helmet securely on tank storage compartment lid. Motorcycle, a lockable tank storage compartment will be installed as standard.

  • Page 44: Power Tank (If Equipped)

    Controls and Components Power Tank (if equipped) Charge Tank (if equipped) Your Zero Motorcycle may be equipped with an optional Your Zero Motorcycle may be equipped with the accessory Power Tank installed in place of the tank storage Charge Tank installed in place of the tank storage compartment.

  • Page 45: Side Storage Compartment (If Equipped)

    WARNING! Always make sure that the storage compartment is locked and the side panel is securely Depending on the specification of your Zero Motorcycle, it fastened before riding. An incorrectly fastened side panel may be equipped with a side storage compartment. To...
  • Page 46 Notes 3.26...

  • Page 47: 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 48: 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 49: Motorcycle Tip-Over Sensor

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

  • Page 50: Operating Your Motorcycle

    This could cause you to lose control of the motorcycle and could lead to serious injury or death. Progressive use of the brakes should bring the motorcycle to a complete stop without locking the wheels. Your Zero...
  • Page 51 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 52: Abs (Anti-Lock Braking System)

    General Operation ABS (Anti-lock Braking System) WARNING! ABS prevents the wheels from locking, therefore maximizing the effectiveness of the braking system in emergencies and when riding on slippery surfaces. The potentially shorter braking distances ABS allows under certain conditions are not a substitute for good riding practices.
  • Page 53 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 54 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 55: 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 56 General Operation 9. Record this measurement (this is the measurement Example: referred to as M2). Measurement Operator Value 4.13 in (105 mm) 2.36 in (60 mm) 1.77 in (45 mm) The total sag is 1.77 in (45 mm). Refer to the chart below for the correct sag.
  • Page 57 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 58 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 59 5.5 turns clockwise from the full out Front Fork Compression 8 clicks counter-clockwise from position maximum (H) position. Zero DS (ZF13.0), Zero DS (ZF14.4) & Zero DSR (ZF14.4) Front Fork Rebound 9 clicks counter-clockwise from maximum (H) position ADJUSTMENT SETTING Front Fork Preload 7.5 turns clockwise from the full out...

  • Page 60: 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 61 General Operation Example: Measurement Operator Value 23.62 in (600 mm) 21.65 in (550 mm) 1.97 in (50 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 62 General Operation Spring Preload Adjustment Rebound Adjustment The rebound adjuster knob (A) is at the bottom of the 1. Clean any dirt or debris from the slots of the shock shock. Printed on the knob is “H” meaning Hard (MAX, adjusting collar (A).
  • Page 63 General Operation Compression Adjustment The compression adjustment knob is at the top of the shock. Printed on the knob is “H” meaning Hard (MAX, which is for slower compression) and “S” meaning Soft (MIN, which is for faster compression). Turn the adjuster clockwise for a harder ride (slower compression).
  • Page 64 Rear Shock Spring Preload 5th position from minimum unloaded Rear Shock Compression 14 clicks counter-clockwise from position. maximum (H) position. Zero S (ZF13.0), Zero S (ZF14.4) & Zero DSR ZF14.4 Rear Shock Rebound 9 clicks counter-clockwise from maximum (H) position. ADJUSTMENT SETTING...

  • Page 65: Power Pack And Charging

    The integrated on-board charger more), you may want to plug the motorcycle into an AC minimizes charge time and can work in parallel with Zero’s power source to charge it for a few hours prior to your next quick charge accessories to cut charge times by as much ride.

  • Page 66: On-Board Power Pack Charger

    CAUTION: Only charge the Zero power pack with the Zero charger. The on-board charger is located under the power pack.
  • Page 67 Power Pack and Charging  When connected to the charger, the power pack will receive a full charge. Once fully charged, the charger will cycle between 90% and 100% state of charge. When the state of charge gets close to 90%, the charger will recharge to 100% and repeat.

  • Page 68: Charging The Power Pack

    Charging the Power Pack To charge using the standard on-board charging equipment: WARNING! Always charge the Zero power pack in a 1. Plug the supplied power cord (A) into the on-board location that is well-ventilated and away from combustible charger connector. Always keep the power cord with materials.
  • Page 69 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 14 amps from the 120 V AC circuit when charging.

  • Page 70: Quick Charging (Off-Board Accessory Charger)

    Damage, malfunctions, or performance problems caused by the installation or use of any charger not sold or C. Power Pack Charger approved by Zero will void the warranty of your Zero D. Charger LED Indicators Motorcycle. E. Connector (to motorcycle)
  • Page 71 Power Pack and Charging Using the Quick Charger and the current State of Charge (SOC) should display on the dash. To charge using a Quick Charger: 5. Plug in the AC Power Cord to an AC power outlet. Note: If you connect the on-board charger (see “Charging Always connect the charger to a GROUNDED outlet.
  • Page 72 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 73: Charge Tank (If Equipped)

    Power Pack and Charging Charge Tank (if equipped) The Charge Tank is a quick charging accessory. It reduces the time to fully charge the power pack (compared to the to the Level 1 existing integrated charger) and is designed to work with Level 2 public charging stations operating on the popular J1772/IEC 62196 standard.

  • Page 74: Public Charging Stations

    Note: Use of a Level 2 charging adapter accessory cord (Zero PN: 10-03267) doesn’t improve charge times unless a supplemental accessory charger is also used. Note: If your Zero Motorcycle is equipped with a Charge Tank, use of a Level 2 charger would greatly improve charge times.

  • Page 75: 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 76: 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 77 Maintaining Your Motorcycle ITEM ROUTINE EVERY INITIAL INITIAL ODOMETER MILEAGE READING RIDE 600 mi 4K mi 8K mi 12K mi 16K mi 20K mi (1K km) (7K km) (13K km) (19K km) (25K km) (31K km) 1 month 6 months 12 months 18 months 24 months...
  • Page 78 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 79 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 80: Component Fasteners

    Maintaining Your Motorcycle Component Fasteners Periodically check and tighten the following fasteners on your motorcycle. LOCATION ITEM TORQUE NOTES Headlight bolts 8 lb·ft (11 Nm) Use LOCTITE® 242® (or equivalent) Handlebar clamp mount bolts 19 lb·ft (26 Nm) Rear shock mount bolts 40 lb·ft (54 Nm) Seat retaining bolts 16 lb·ft (22 Nm)
  • Page 81 Maintaining Your Motorcycle Left Side of Motorcycle Refer to Torque table on page 6.6.
  • Page 82 Maintaining Your Motorcycle Right Side of Motorcycle Refer to Torque table on page 6.6.

  • Page 83: Power Pack

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

  • Page 84: General Maintenance

    Inspect the level of the front This section describes how to maintain the brake system brake fluid, visible through the of your Zero S/SR/DS/DSR motorcycle. It covers the ABS reservoir (C). If the fluid level (Anti-lock Brake System), brake pad examples (specific...
  • Page 85 General Maintenance Rear Brake Fluid Reservoir Clean any dirt or debris from the cap and reservoir opening (A) before opening the reservoir. The reservoir is located inboard on the frame behind the heel guard. Note: The motorcycle should be in an upright position prior to checking fluid level.
  • Page 86 General Maintenance Brake Pad Inspection Brake Pad Replacement The brake pads must be inspected when specified in the Bedding in new brake pads and/or new brake discs is maintenance schedule, see page 6.2. Visually inspect the recommended to ensure proper brake performance and brakes by looking at the remaining brake pad material maximize brake life.
  • Page 87 General Maintenance Rear brake pads WARNING! With new brake systems or just new pads, the first few braking applications will result in very little braking power. Gently use the brakes a few times at low speeds (less than 25 mph [40 km/h]) to develop proper braking friction.

  • Page 88: Parking Brake

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

  • Page 89: Suspension

    General Maintenance Suspension Front  For maintenance, see Maintenance Schedule on page 6.2.  To adjust the fork, see Suspension Adjustment on page 4.9. Rear WARNING! The shock absorber assembly contains highly pressurized gas.  Do not attempt to tamper with or open the cylinder or shock.

  • Page 90: Wheels And Tires

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

  • Page 91: Drive Belt

    General Maintenance Drive Belt Checking Drive Belt Tension Proper belt tension is essential for optimum operation of The drive belt provides low maintenance and quiet the drive system. operation with minimal stretch. Keep dirt, grease, oil, and Lack of belt tension can lead to “ratcheting.” The teeth of debris off the belt and sprockets.The drive belt tension the belt slide over the teeth of the rear sprocket.
  • Page 92 General Maintenance Drive Belt Tension Tester 1. Remove the key from the ignition switch. The Tension Tester has a plastic measurement arm, 2. Press the Tension Tester steadily to the non-cogged located in a slot. Along this slot there is a measuring scale. side of the belt, half of the distance between the The point of intersection of the measurement arm and the motor-driven sprocket and rear wheel drive sprocket.
  • Page 93 General Maintenance Gates® Carbon Drive™ Smartphone Application 1. Remove the key from the ignition switch. The drive belt tension can be checked by 2. From the application, click the Tension icon and using the Gates® Carbon Drive™ Smartphone Measure. application, which measures belt tension 3.
  • Page 94 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 95: Headlight Alignment

    General Maintenance Headlight Alignment The headlight should be checked for correct alignment periodically. It must be aligned any time the suspension sag is adjusted because this affects the headlight alignment. Before the headlight can be aligned, the suspension sag and tire pressure must be correctly adjusted.
  • Page 96 General Maintenance Headlight Bulb Replacement To replace the bulb: WARNING! Halogen bulbs contain gas under pressure. 1. Working from behind the headlight, disconnect the Handling a bulb improperly could cause it to shatter into headlight bulb connector (A) and rubber cover (B). flying glass fragments, which could result in serious injury.
  • Page 97 General Maintenance 2. Remove the headlight bulb retainer (A) by turning it 4. Install the headlight bulb into the lens. counter-clockwise. 5. Install the headlight bulb retainer and turn it clockwise until it locks into position. 6. Install the headlight bulb rubber cover. 7.

  • Page 98: Turn Signal Light Bulb Replacement

    1. Remove the turn signal lens screw (A) and remove the The brake/tail LED (A) is not serviceable. Please contact lens. your Zero Motorcycle dealer for replacement. 2. Push in on the bulb, turn the bulb counterclockwise, and then pull the bulb out.

  • Page 99: Running Light Bulb Replacement

    General Maintenance Running Light Bulb Replacement 1. Working from behind the headlight, remove the bulb socket (A) from the headlight by squeezing the metal clip. 2. Pull the old bulb straight out from the socket. 3. Push the new bulb into the socket, and push the socket into the headlight.

  • Page 100: Cleaning

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

  • Page 101: Parking And Long Term Storage

    WARNING! Opening of the power pack is for trained Zero Motorcycles technicians. Please be aware that incorrect handling of a Zero power pack can be dangerous. DO NOT OPEN! 6.27...
  • Page 102 General Maintenance 12 Volt Fuse Center 3. Squeeze the tabs (A) on the fuse center to remove the cover. The 12 volt fuse center is located underneath the seat. 4. Replace the fuse(s). The 12-volt fuse values are listed below: The fuse center (see arrow) has a protective cover that FUSE RATING...
  • Page 103 General Maintenance ABS 12 Volt Fuse 3. Gently pull the tab (A) away from the red cap to release the fuse holder and pull upwards. The ABS 12 volt fuse is located underneath the seat. 4. Replace the fuse. The 12-volt fuse value is listed below: The ABS fuse holder (see arrow) is plugged into a FUSE RATING...
  • Page 104 ZF13.0 & ZF14.4 illustrated. ZF7.2 similar except for fuse 1. FUSE RATING CIRCUITS CONTROLLED SPT3.15A Low Power B+ ABC 4A MBB (Main Bike Board)/Controller ABC 4A DC/DC Converter 100A Charge Fuse (in-line) Note: If the charge fuse (4) needs replacement, contact your Zero Motorcycles dealer. 6.30...
  • Page 105 General Maintenance Low Power B+ Fuse (ZF7.2) To access the fuse: 1. Remove bolt (A) securing the fuse cover. 2. Remove cover (B) to gain access to the fuse. 3. Unscrew the fuse cap (C) and withdraw the fuse from the battery.
  • Page 106 Notes 6.32...

  • Page 107: Troubleshooting

    If there touch any high voltage wiring connectors or the components is no dealer in your area call Zero Motorcycles Customer connected to the wiring. If a motorcycle fire occurs, extinguish Service.

  • Page 108: 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 109 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 110 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 111: Dash Error Codes

    Troubleshooting Dash Error Codes If an error code has been recorded, it can be retrieved from the dash Display A. To retrieve the error code, see Display A on the “Displays A&B”, on page 3.13. Refer to the table starting on the next page to identify the error associated with the Error Code number.
  • Page 112 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 113 Troubleshooting CODE ERROR DESCRIPTION BMS Charger Connected Disable MBB Charger Connected Disable SEVCON Startup Disable Contactor Open Disable BMS Self-Test Error BMS Self-Test Warning Reserve Partition Disable BMS Internal Disable Internal Disable Error Internal Fault Error Monolith Not Connected Module Did Not Connect BMS Sensor Warning BMS System Warning Bike Configuration...

  • Page 114: 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. Charger not working A/C power missing.

  • Page 115: 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 116 Troubleshooting Hot Weather Operation Operation of the motorcycle in hot temperatures should not result in any noticeable performance changes. However, the BMS will not allow motorcycle operation and its associated battery discharge above 140°F (60°C), as measured at the battery. In hot temperatures greater than 110°F (43°C), the charger reduces its charge current to the battery, increasing charge time accordingly;...

  • Page 117: Safety Interlocks

    Troubleshooting Safety Interlocks Throttle Disable Interlock The BMS communicates with the main motorcycle control If the BMS detects a serious internal fault, it can take either module. The BMS can send a signal to the main or both of two actions to prevent damage to the power motorcycle controller requesting that the throttle control on pack: the motorcycle be disabled.
  • Page 118 Notes 7.12...

  • Page 119: Specifications (Europe)

    Specifications (Europe) VIN Breakdown Technical Specifications Specifications (Europe) 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 120: Zero S (11Kw)

    Specifications (Europe) Zero S (11kW) POWER SYSTEM MOTOR  ZF7.2: Z-Force® 75-5 passively Type Z-Force® Li-Ion Intelligent Power Pack Type air-cooled, high-efficiency magnet,  ZF7.2: 7.2 kWh Maximum Capacity brushless motor  ZF14.4: 14.4 kWh  ZF14.4: Z-Force® 75-7 passively ...
  • Page 121 Specifications (Europe) DRIVETRAIN DIMENSION Transmission Clutchless Direct Drive Wheel Base 1,410 mm  ZF7.2: 90T/18T, Poly Chain® HTD® Final Drive Seat Height 807 mm Carbon™ belt Rake 24.0 degrees  ZF14.4: 90T/20T, Poly Chain® GT® Trail 80 mm Carbon™ belt WEIGHT CHASSIS/SUSPENSION/BRAKES ...

  • Page 122: Zero S

    Specifications (Europe) Zero S POWER SYSTEM MOTOR Type Z-Force® Li-Ion Intelligent Power Pack Type Z-Force® 75-7 passively air-cooled, high-efficiency magnet, brushless motor Maximum Capacity 14.4 kWh Magnet Configuration Radial flux interior permanent Nominal Capacity 12.6 kWh Controller High efficiency, 550 amp, 3-phase Charge Time (standard) 9.8 hours (100% charged) /...
  • Page 123 Specifications (Europe) DRIVETRAIN DIMENSION Transmission Clutchless Direct Drive Wheel Base 1,410 mm Final Drive 90T/20T, Poly Chain® GT® Carbon™ belt Seat Height 807 mm CHASSIS/SUSPENSION/BRAKES Rake 24.0 degrees Front Suspension Travel 159 mm Trail 80 mm Rear Suspension Travel 161 mm WEIGHT Front Brakes Bosch Gen 9 ABS, J-Juan asymmetric dual...

  • Page 124: Zero Sr

    Specifications (Europe) Zero SR POWER SYSTEM MOTOR Type Z-Force® Li-Ion Intelligent Power Pack Type Z-Force® 75-7R passively air-cooled, high-efficiency magnet, brushless motor Maximum Capacity 14.4 kWh Magnet Configuration Radial flux interior permanent hi-temp Nominal Capacity 12.6 kWh Controller High efficiency, 775 amp, 3-phase brushless Charge Time (standard) 9.8 hours (100% charged) /...
  • Page 125 Specifications (Europe) DRIVETRAIN DIMENSION Transmission Clutchless Direct Drive Wheel Base 1,410 mm Final Drive 90T/20T, Poly Chain® HTD® Carbon™ belt Seat Height 807 mm CHASSIS/SUSPENSION/BRAKES Rake 24.0 degrees Front Suspension Travel 159 mm Trail 80 mm Rear Suspension Travel 161 mm WEIGHT Front Brakes Bosch Gen 9 ABS, J-Juan asymmetric dual...

  • Page 126: Zero Ds (11Kw)

    Specifications (Europe) Zero DS (11kW) POWER SYSTEM MOTOR  ZF7.2: Z-Force® 75-5 passively Type Z-Force® Li-Ion Intelligent Power Pack Type  ZF7.2: 7.2 kWh air-cooled, high-efficiency magnet, Maximum Capacity brushless motor  ZF14.4: 14.4 kWh  ZF14.4: Z-Force® 75-7 passively ...
  • Page 127 Specifications (Europe) DRIVETRAIN DIMENSION Transmission Clutchless Direct Drive Wheel Base 1,427 mm  ZF7.2: 90T / 18T, Poly Chain® HTD® Drive System (standard) Seat Height 843 mm Carbon™ belt Rake 26.5 degrees  ZF14.4: 90T / 20T, Poly Chain® HTD® Trail 117 mm Carbon™...

  • Page 128: Zero Ds

    Specifications (Europe) Zero DS POWER SYSTEM MOTOR Type Z-Force® Li-Ion Intelligent Power Pack Type Z-Force® 75-7 passively air-cooled, high-efficiency magnet, brushless motor Maximum Capacity 14.4 kWh Magnet Configuration Radial flux interior permanent Nominal Capacity 12.6 kWh Controller High efficiency, 550 amp, 3-phase brushless Charge Time (standard) 9.8 hours (100% charged) /...
  • Page 129 Specifications (Europe) DRIVETRAIN DIMENSION Transmission Clutchless Direct Drive Wheel Base 1,427 mm Drive System (standard) 90T / 20T, Poly Chain® HTD® Carbon™ belt Seat Height 843 mm CHASSIS/SUSPENSION/BRAKES Rake 26.5 degrees Front Suspension Travel 178 mm Trail 117 mm Rear Suspension Travel 179 mm WEIGHT Front Brakes...

  • Page 130: Zero Dsr

    Specifications (Europe) Zero DSR POWER SYSTEM MOTOR Type Z-Force® Li-Ion Intelligent Power Pack Type Z-Force® 75-7R passively air-cooled, high-efficiency magnet, brushless motor Maximum Capacity 14.4 kWh Magnet Configuration Radial flux interior permanent hi-temp Nominal Capacity 12.6 kWh Controller High efficiency, 775 amp, 3-phase brushless Charge Time (standard) 9.8 hours (100% charged) /...
  • Page 131 Specifications (Europe) DRIVETRAIN DIMENSION Transmission Clutchless Direct Drive Wheel Base 1,427 mm Final Drive 90T/20T, Poly Chain® HTD® Carbon™ belt Seat Height 843 mm CHASSIS/SUSPENSION/BRAKES Rake 26.5 degrees Front Suspension Travel 178 mm Trail 117 mm Rear Suspension Travel 179 mm WEIGHT Front Brakes Bosch Gen 9 ABS, J-Juan asymmetric dual...

  • Page 132: Specifications (Rest Of The World)

    Specifications (Rest Of The World) VIN Breakdown Specifications (Rest Of The World) 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. 8.14...

  • Page 133: Zero S

    Specifications (Rest Of The World) Zero S  ZF7.2: 3.1 hours (100% charged) / Supplemental Charger Quick Charge Time (with 2.6 hours (95% charged) one accessory charger)  ZF13.0: 5.2 hours (100% charged) / MOTOR 4.7 hours (95% charged)  ZF7.2: Z-Force® 75-5 passively Type ...
  • Page 134 Specifications (Rest Of The World) DRIVETRAIN DIMENSION Transmission Clutchless Direct Drive Wheel Base 55.5 in (1,410 mm)  ZF7.2: 90T/18T, Poly Chain® HTD® Final Drive Seat Height 31.8 in (807 mm) Carbon™ belt Rake 24.0 degrees  ZF13.0: 90T/20T, Poly Chain® HTD® Trail 3.2 in (80 mm) Carbon™...

  • Page 135: Zero Sr

    Specifications (Rest Of The World) Zero SR Estimated Power Pack 241,000 miles (388,000 km) MOTOR Life to 80% (city) Type Z-Force® 75-7R passively air-cooled, RANGE high-efficiency magnet, brushless motor City (EPA UDDS) 179 miles (288 km) Magnet Configuration Radial flux interior permanent hi-temp...
  • Page 136 Specifications (Rest Of The World) DRIVETRAIN DIMENSION Transmission Clutchless Direct Drive Wheel Base 55.5 in (1,410 mm) Final Drive 90T/20T, Poly Chain® HTD® Carbon™ belt Seat Height 31.8 in (807 mm) CHASSIS/SUSPENSION/BRAKES Rake 24.0 degrees Front Suspension Travel 6.25 in (159 mm) Trail 3.2 in (80 mm) Rear Suspension Travel...

  • Page 137: Zero Ds

    Specifications (Rest Of The World) Zero DS  ZF7.2: 3.1 hours (100% charged) / Supplemental Charger Quick Charge Time (with 2.6 hours (95% charged) one accessory charger)  ZF13.0: 5.2 hours (100% charged) / MOTOR 4.7 hours (95% charged)  ZF7.2: Z-Force® 75-5 passively Type ...
  • Page 138 Specifications (Rest Of The World) DRIVETRAIN DIMENSION Transmission Clutchless Direct Drive Wheel Base 56.2 in (1,427 mm)  ZF7.2: 90T / 18T, Poly Chain® HTD® Drive System (standard) Seat Height 33.2 in (843 mm) Carbon™ belt Rake 26.5 degrees  ZF13.0: 90T / 20T, Poly Chain® HTD® Trail 4.6 in (117 mm) Carbon™...

  • Page 139: Zero Dsr

    Specifications (Rest Of The World) Zero DSR Estimated Power Pack 220,000 miles (354,000 km) MOTOR Life to 80% (city) Type Z-Force® 75-7R passively air-cooled, RANGE high-efficiency magnet, brushless motor City (EPA UDDS) 163 miles (262 km) Magnet Configuration Radial flux interior permanent hi-temp...
  • Page 140 Specifications (Rest Of The World) DRIVETRAIN DIMENSION Transmission Clutchless Direct Drive Wheel Base 56.2 in (1,427 mm) Final Drive 90T/20T, Poly Chain® HTD® Carbon™ belt Seat Height 33.2 in (843 mm) CHASSIS/SUSPENSION/BRAKES Rake 26.5 degrees Front Suspension Travel 7.00 in (178 mm) Trail 4.6 in (117 mm) Rear Suspension Travel...

  • Page 141: Limited Warranty Information

     The Z-Force® Power Tank accessory that may be card via mail at the time of purchase to ensure timely service. When a covered 2018 Zero Motorcycle is sold to a mounted in a Zero S/SR/DS/DSR model motorcycle. subsequent owner, the original owner should submit a Should the Z-Force®...

  • Page 142: What Is The Coverage Period Of This Limited Warranty

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

  • Page 143: 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 144 Zero, the installation and use of any  Parts or components damaged by use or operation parties or accessories that alter the motorcycle’s under abnormal circumstances or contrary to the specifications from those set by Zero, or the use of new...

  • Page 145: What Other Limitations Or Disclaimers Apply To This Limited Warranty

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

  • Page 146: What Are Your Responsibilities As A Customer

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

  • Page 147: What Will Zero Do Under This Limited Warranty

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

  • Page 148: How Do You Obtain Service Under This Limited Warranty

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

  • Page 149: Transfer Of Ownership And Limited Warranty

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

  • Page 150: Customer Information

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

  • Page 151: 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 152 Notes 9.12...

  • Page 153: 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 154 Maintenance Record 20,000 miles (31,000 km) or 30 months 32,000 miles (49,000km) 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 155 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 156 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 157 Pre-Ride Inspection...........4.1 Charge Tank..............5.9 General Safety Precautions...........2.1 Charging Stations ............5.10 General Troubleshooting ..........7.8 Charging the Power Pack..........5.4 Cleaning Your Motorcycle ...........6.26 Contact information Headlight NHTSA ..............9.11 Alignment ..............6.21 Zero Motorcycles ............9.10 Bulb Replacement ...........6.22 Helmet leash cable ............3.23 INDEX.1...
  • Page 158 Index Important Operating Information ........2.2 Parking ................ 6.27 Inspection Parts/Maintenance Items..........6.2 Pre-Ride..............4.1 Performance Level Switch........... 3.21 Instrument Panel ..........3.8 3.10 ECO Position ............3.21 SPORT Position............3.21 Power Pack ..............6.9 Keys Plug in Your Z-Force Power Pack......1.2 Replacement Code Number ........
  • Page 159 Zero DS - Rest of the World........8.19 Zero DS (11kW) - Europe ......... 8.8 Zero DSR - Europe ..........8.12 Zero DSR - Rest of the World ......... 8.21 Zero S - Europe ............8.4 Zero S - Rest of the World ........8.15 Zero S (11kW) - Europe ..........
  • Page 160 Notes INDEX.4...
  • Page 161 First Responder Information – High Voltage Component Locations First Responder Information – High Voltage Component Locations...
  • Page 162 TAKE CHARGE ™ ZEROMOTORCYCLES.COM Y Y LES.COM 88-08922.03...

This manual is also suitable for:

S 2018Sr 2018Ds 2018

Table of Contents