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Zero SR/S Service Manual

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SR/S SERVICE MANUAL
Release 1.1
© 2022 Zero Motorcycles, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of
printing and is subject to the copyright and other intellectual property rights of Zero Motorcycles Inc. No part of this
document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic,
mechanical, photocopying, recording, or otherwise. These materials must not be modified or reposted to other sites,
without the prior expressed written permission of the copyright holder.

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Summary of Contents for Zero SR/S

  • Page 1 All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Zero Motorcycles Inc. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise.

  • Page 3: Table Of Contents

    Table of Contents General Information How To Use This Manual ..................1-1 Important Repair Information ................1-2 Maintenance and Safety Lockout Procedure Lockout Procedure ......................10-1 Adjust Drive Belt Adjust Drive Belt .......................10-2 Brake Maintenance Procedures Brake Bleeding Procedure (Front) ..................10-5 Brake Bleeding Procedure (Rear) ...................10-6 Brake Bedding ........................10-7 Key Programming...
  • Page 4 Table of Contents Charging System Chargers 3KW Rapid Charger (Front) [Before 2022MY] ............... 25-1 3KW Rapid Charger (Front and Rear) [Before 2022MY]..........25-7 6KW Charger [22MY Onwards] ..................25-14 Charge Inlet Harness......................25-17 DC/DC Converter DC/DC Converter ......................25-20 Motor and Drive System Motor Motor ..........................
  • Page 5 Table of Contents Brakes Brakes Brake Master Cylinder (Front)..................45-1 Brake Pads (Front)......................45-3 Brake Pads (Rear)......................45-5 Brake Caliper (Front) ......................45-6 Brake Caliper (Rear) ......................45-8 Brake Rotor (Front)......................45-11 Brake Rotor (Rear)......................45-15 Hydraulic Control Unit (HCU)..................45-19 Wheels Front Wheel Front Wheel ........................50-1 Rear Wheel Rear Wheel........................50-4 Body...
  • Page 6 Table of Contents Lighting Headlight ........................... 70-8 Tail Light..........................70-10 Turn Signal (Left Front) ....................70-11 Turn Signal (Right Front)....................70-12 Turn Signal (Rear) ......................70-16 Instruments Dash..........................70-19 Key Switch Key Switch........................70-21 Mode Switch Mode Switch (Without Heated Grips) ................70-23 Mode Switch (With Heated Grips).................70-26 Heated Grip Heated Grips (Left) ......................70-29 Kickstand Switch...

  • Page 7: General Information

    General Information How To Use This Manual Terminology General Information General To assist in the use of this Manual, it is divided into numbered sections (shown on the previous page). Each section starts with a contents page listing the service procedures covered within that section. Each section is numbered from page 1, and the page number is shown at the bottom of each page.

  • Page 8: Important Repair Information

    General Information Important Repair Information Abbreviations and Symbols Replacement Fasteners Alternating current Replacement fasteners must be the correct part Amp (A) Ampere number for that application. Use the correct fastener in the correct location. Fasteners requiring Auxiliary the use of thread-locking compound are specified in the repair procedure;...
  • Page 9 Zero Motorcycles are electrically powered vehicles (“e-vehicles”) under which Regulation No. 100 of UNECE [2015/505] applies. In order to safely repair Zero Motorcycles, it is essential that any electrical hazards are eliminated, and damaged motorcycles or electrically hazardous components should be handled and stored safely.
  • Page 10 General Information...

  • Page 11: Maintenance And Safety

    Lockout Procedure Maintenance and Safety WARNING! For your safety and for the safety of others, perform the following steps prior to performing work on the Zero Motorcycle! Lockout Procedure Steps 1. Set up safety barricades around your work area. 2. Confirm your work area is equipped with a high voltage safety hook.

  • Page 12: Adjust Drive Belt

    Maintenance and Safety Adjust Drive Belt Adjust Drive Belt Tools Required (includes tools required for parent jobs): • T45 • 27mm socket and ratchet • Smartphone with Gates® Carbon Drive™ Application • Motorcycle stand Removal 4. The alignment marks stamped on the swingarm are for initial alignment, but are not 1.
  • Page 13 Maintenance and Safety NOTICE: Rotating the tire in the reverse direction will give a false adjustment. Failing to follow this instruction could cause damage to the drive belt. NOTICE: Rotating the tire two full revolutions isn’t enough to normalize the belt on the two sprockets, so be sure to rotate the belt two full revolutions by counting the number of times the printing on the belt passes by the rear...
  • Page 14 Maintenance and Safety 12. Recheck the belt adjustment after the test ride and readjust, if necessary. 10-4 Adjust Drive Belt...

  • Page 15: Brake Maintenance Procedures

    Maintenance and Safety Brake Bleeding Procedure (Front) Brake Maintenance Procedures WARNING! Only use new brake fluid from and airtight container. Fluid from open containers or fluid previously used in the system will have absorbed moisture, which will adversely affect performance and must not be used. WARNING! Brake fluid is highly toxic;...

  • Page 16: Brake Bleeding Procedure (Rear)

    Maintenance and Safety Brake Bleeding Procedure (Rear) WARNING! Only use new brake fluid from and airtight container. Fluid from open containers or fluid previously used in the system will have absorbed moisture, which will adversely affect performance and must not be used. WARNING! Brake fluid is highly toxic;...

  • Page 17: Brake Bedding

    Maintenance and Safety Brake Bedding Note: Bedding in new brake systems or new pads 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 rotor.

  • Page 18: Key Programming

    Maintenance and Safety Key Programming Key Programming Items Required: • Yellow key: quantity 1 • Black keys: quantity 1 or 2 Program Programming Note: Pause for one second between each key turn. Note: Only two black keys can be programmed to one motorcycle.
  • Page 19 Maintenance and Safety 8. Turn the second black key to the ON position. 12. Turn the yellow key to the ON position. 9. Turn the second black key to the OFF position. 13. Turn the yellow key to the OFF position. This removes the motorcycle from programming 10.

  • Page 20: Motor Commissioning

    Maintenance and Safety Motor Commissioning 2. Connect a laptop (with ZDU software loaded) Motor Commissioning to the motorcycle’s OBDII diagnostic connector with CAN cable. Items Required: • Laptop (with ZDU software) • CAN cable • Black key Important Commissioning Tasks: •...
  • Page 21 Maintenance and Safety 6. Click on “Initialize SR/F”. 10. Turn the key to the ON position. 7. Look for message that says “Ready to 11. Click on Controller id: 1 square. commission motor, please open TAUCAN software and begin.” Note: If this message doesn’t appear, confirm that the key is in the OFF position, remove USBs from your computer, and remove the OBDII diagnostic cable from the motorcycle.
  • Page 22 Maintenance and Safety 14. Take note the “Offset” (if you have not 18. Turn key to the OFF position. updated the firmware prior). 19. Turn the key to the ON position. 15. Click “ENCODER” tab. 20. Test the throttle. 16. Click “COMMISSION” button. Note: Roll throttle to max speed and confirm Note: If the COMMISSION button has greyed full throttle control and smooth operation.
  • Page 23 22. Take note the value in the “Offset” box. A. If the offset angle is 0 degrees when first started up, commission the motor. Note: If it remains at 0 degrees, contact Zero Motorcycles Customer Service department for assistance. •...

  • Page 24: Motor Controller Firmware Update

    Maintenance and Safety Motor Controller Firmware Update Motor Controller Firmware Update Process 1. To update the Motor Controller Firmware, contact Zero Motorcycles Customer Service department for assistance. • North America: support@zeromotorcycles.com • Zero Motorcycles Europe: service.eu@zeromotorcycles.com 10-14 Motor Controller Firmware Update...

  • Page 25: Power Pack

    • Non-marring trim removal/pry tool • O-ring pick • Scissor jack • Ratchet straps (x2) • Hoist Zero Motorcycles Specialty Tools Required (includes tools required for parent jobs): • Power Pack fixture New Seals Required: 3. Unbolt the negative battery terminal eyelet.
  • Page 26 Power Pack 6. Remove left and right inner side fairings. See Side Fairings (Inner), page 60.19. 7. Remove tank assembly. See Tank Removal, page 60.10. 8. Remove charger. See 3KW Rapid Charger (Front) [Before 2022MY], page 25.1. 9. Remove controller. See Motor Controller [Before 2022MY], page 30.27.
  • Page 27 19. Remove bolts (x2) securing the right side of the power pack to the frame. Tool: T40. Torque: 26 lb-ft (35 Nm). 17. Support and lift the power pack with a Zero Motorcycle Power Pack Fixture and a scissor jack.
  • Page 28 Power Pack 20. Lower the power pack to gain access to the 24. Move the motorcycle backward to increase rear cover bolts. clearance to between the motor and the back of the power pack. 21. Remove bolts (x2) securing the rear cover to the power pack.
  • Page 29 Installation 1. Installation is the reverse of the removal procedure. 2. A replacement power pack from Zero Motorcycles should come pre-programmed and ready for use. If this is not the case, email Zero Motorcycles Customer Service department.

  • Page 30: Bms (Battery Management System) [Before 2022My]

    • Non-marring trim removal/pry tool • O-ring pick • Scissor jack • Ratchet straps (x2) • Hoist Zero Motorcycles Specialty Tools Required (includes tools required for parent jobs): • Power Pack fixture New Seals Required: 3. Remove high voltage DCDC and CONT fuses.
  • Page 31 Power Pack 4. Unbolt the negative battery terminal eyelet. 9. Remove bolts (x2) securing the corners of the Cover eyelet with insulating material. Use front cover to the left side of the power pack. cable tie to secure negative battery wire to the Bolt: M5x30.
  • Page 32 Power Pack 11. Remove bolts (x2) securing the middle of the 13. Remove front cover. front cover to the left side of the power pack. Bolt: M5x10. Tool: T20. Torque: 18 in-lb (2.3 Nm). Be very careful with the bolt CAUTION: lengths during installation.
  • Page 33 Power Pack 16. Remove bolts (x2) securing the bottom 18. Remove bolts (x7) securing the BMS to the connector of the BMS. Collect washers (x2). power pack. Collect flat washers (x6) and star Tool: T20. Torque: 12 in-lb (1.36 Nm). washer (x1).
  • Page 34 Power Pack 2. Torque BMS bolts with an inch pound torque 5. Protect test port from corrosion with a liberal wrench. amount of CP70. 3. Use CP70 sparingly on all gaskets. 6. Only threading two turns, install middle bolt and flat washer on the right side, securing the BMS to the power pack.
  • Page 35 Power Pack 8. Clean debris from header clamps, gaskets, 11. Torque all seven bolts securing the BMS. Bolt: and gasket surface. Re-grease gasket M4x16. Tool: T20. Torque: 12 in-lb (1.36 Nm). surfaces with CP70. 12. If the BMS flex ribbon is not bonded to the 9.
  • Page 36 Power Pack Note: You will not be able to put your whole fingers behind the BMS spacer or circuit board. NOTICE: Applying too much force with your finger behind the BMS circuit board may cause damage to the BMS. Note: Do not tighten bolts yet. 16.
  • Page 37 5 seconds. Tool: T20. 24. If you’ve exhausted all 3 positions of the BMS 20. If the BMS works after the installation, go to flex ribbon header clamp, email Zero step 25. If the BMS doesn’t work after Motorcycles Customer Service department.

  • Page 38: Battery Management Unit (Bmu) [22My Onwards]

    Battery Management Unit (BMU) 25. A replacement BMS from Zero Motorcycles should come programmed and ready for use. [22MY Onwards] If this is not the case, email Zero Motorcycles Customer Service department. • North America: CAUTION: Always perform the High Voltage Discharging procedure prior to servicing any support@zeromotorcycles.com...

  • Page 39: Power Pack Battery Signal Harness [Before 2022My]

    • Non-marring trim removal/pry tool • O-ring pick • Scissor jack • Ratchet straps (x2) • Hoist Zero Motorcycles Specialty Tools Required (includes tools required for parent jobs): • Power Pack fixture New Seals Required: • Controller cable seals (quantity: 5) •...
  • Page 40 Power Pack 6. Remove left and right inner side fairings. See Removal Side Fairings (Inner), page 60.19. 1. PERFORM LOCKOUT PROCEDURE: See Lockout Procedure, page 10.1. 7. Remove power pack. See Power Pack, page 20.1. 2. Remove high voltage DCDC and CONT fuses. High Voltage Fuses, page 70.1.
  • Page 41 Power Pack 10. Remove front cover. 13. Remove the power pack rear cover. 11. Disconnect BMS signal harness connector. 14. Disconnect contactor harness connector. 12. Remove bolts (x9) securing rear cover to the 15. Remove nut securing the MBB (Main Bike power pack.
  • Page 42 Power Pack 16. Cut cable tie securing the self amalgamating 20. Cut cable ties (x2) securing Battery Signal B- tape (PN: 81-08088) and bead type thermistor Sense Line to Battery Signal B+ Sense Line to the contactor fuse. harness. Note: Replace cable tie during the installation Note: Replace cable tie during the installation process.
  • Page 43 Power Pack 23. Maneuver both signal wire harnesses out from 2. Maneuver both (B+ and B-) orange-sheathed behind the positive HV battery cable. signal harnesses between the B+ high voltage battery wire and the power pack heat sink skin. 24. Remove bolt securing ground strap to upper battery pack.

  • Page 44: Power Pack Accessory Power Bus [Before 2022My]

    • O-ring pick • Scissor jack • Ratchet straps (x2) • Hoist Zero Motorcycles Specialty Tools Required 3. Unbolt the negative battery terminal eyelet. (includes tools required for parent jobs): Cover eyelet with insulating material. Use cable tie to secure negative battery wire to the •...
  • Page 45 Power Pack 6. Remove left and right inner side fairings. See Side Fairings (Inner), page 60.19. 7. Remove power pack. See Power Pack, page 20.1. 10. Remove front cover. 8. Remove bolts (x4) securing the four corners of the front cover to the power pack. Bolt: M5x30.
  • Page 46 Power Pack 13. Remove the power pack rear cover. 16. Cut cable tie securing Battery Signal B+ Sense Line harness. Note: Replace cable tie during the installation process. 14. Remove nut securing the MBB (Main Bike Board)/Contactor fuse holder to the high voltage fuse bracket and capture plastic washer.
  • Page 47 Power Pack 19. Disconnect Battery Signal B- Sense Line 22. Remove radsock connector clamp. harness connector. 23. Remove bolt securing cable tie to top of power 20. Disconnect contactor harness connector. pack. Bolt: M4x16. Tool: T20. Torque: 18 in-lb (2.03 Nm). 21.
  • Page 48 Power Pack Note: Replace self amalgamating tape during the installation process. 26. Release bead type thermistor. 30. Disconnect B+ radsock connector from the lower battery cell. 27. Remove bolt securing high voltage wire clamp to power pack. Tool: T25. Torque: 28 in-lb (3.16 Nm).
  • Page 49 Power Pack Note: Star washer is located between ground strap and battery. 35. Remove bolt securing B- accessory radsock to upper battery cell and collect flat washer. Bolt: M3x16. Tool: 2.5mm hex wrench. Torque: 33. Remove bolts (x2) securing contactor to upper 12 in-lb (1.36 Nm).
  • Page 50 Power Pack 38. Remove the accessory power buss from the 3. While installing the accessory power buss, power pack. make sure the plastic shield is placed between the B+ and B- high voltage accessories. Installation CAUTION: The plastic shield protects the 1.
  • Page 51 Power Pack 5. Maneuver both (B+ and B-) orange-sheathed signal harnesses between the B+ high voltage battery wire and the power pack heat sink skin. 6. When installing the rear cover, only use proper length bolt in the location shown. Bolt: M5x16. WARNING! Installing a bolt longer than 16mm will cut through the insulation of the high voltage wires and cause damage to the...

  • Page 52: Power Pack Heat Sink Skins [Before 2022My]

    • O-ring pick • Scissor jack • Ratchet straps (x2) • Hoist Zero Motorcycles Specialty Tools Required (includes tools required for parent jobs): • Power Pack fixture 3. Unbolt the negative battery terminal eyelet. Cover eyelet with insulating material. Use...
  • Page 53 Power Pack 6. Remove left and right inner side fairings. See Side Fairings (Inner), page 60.19. 7. Remove power pack. See Power Pack, page 20.1. 10. Remove front cover. 8. Remove bolts (x4) securing the four corners of the front cover to the power pack. Bolt: M5x30.
  • Page 54 Power Pack 13. Remove bolt securing the side heat sink skin 2. Maneuver both (B+ and B-) orange-sheathed perimeter to the power pack. Tool: T20. signal harnesses between the B+ high voltage Torque: 18 in-lb (2.3 Nm). battery wire and the power pack heat sink skin.

  • Page 55: Service Cover [22My Onwards]

    Power Pack Service Cover [22MY Onwards] Front Cover [22MY Onwards] NOTICE: Before carrying out any work on the CAUTION: Always perform the High Voltage electrical system, remove the key from the key Discharging procedure prior to servicing any High Voltage component or connection. Proper switch.

  • Page 56: Rear Cover [22My Onwards]

    Power Pack Rear Cover [22MY Onwards] Mid Pack Protection Unit [22MY Onwards] CAUTION: Always perform the High Voltage CAUTION: Always perform the High Voltage Discharging procedure prior to servicing any Discharging procedure prior to servicing any High Voltage component or connection. Proper High Voltage component or connection.

  • Page 57: Top Cover [22My Onwards]

    Power Pack Top Cover [22MY Onwards] Installation 1. Installation is the reverse of the removal procedure except for the following: CAUTION: Always perform the High Voltage 2. Renew discarded zip ties. Discharging procedure prior to servicing any High Voltage component or connection. Proper procedures must be followed! To protect electrical components, perform the following tasks in the order given.

  • Page 58: Cooling Fan [22My Onwards]

    Power Pack Cooling Fan [22MY Onwards] CAUTION: Always perform the High Voltage Discharging procedure prior to servicing any High Voltage component or connection. Proper procedures must be followed! To protect electrical components, perform the following tasks in the order given. Do not deviate from the repair procedure processes.

  • Page 59: Assembly Cell Management Unit (Cmu) [22My Onwards]

    Power Pack Assembly Cell Management Unit (CMU) Installation 1. Installation is the reverse of removal [22MY Onwards] procedure. CAUTION: Always perform the High Voltage Discharging procedure prior to servicing any High Voltage component or connection. Proper procedures must be followed! To protect electrical components, perform the following tasks in the order given.
  • Page 60 Power Pack 6. Apply torque incrementally to each fastener. Note: Press CMU into battery cell box before installation of fixings. 7. Renew fir tree clips. 8. Apply a small amount of CP70 into the cavities and renew cavity plugs. Note: Remove and discard the tabs of the cavity plugs.

  • Page 61: Power Leads - Positive & Negative [22My Onwards]

    Power Pack Power Leads - Positive & Negative 5. Remove controller carrier access panel. [22MY Onwards] CAUTION: Always perform the High Voltage Discharging procedure prior to servicing any High Voltage component or connection. Proper procedures must be followed! To protect electrical components, perform the following tasks in the order given.

  • Page 62: Contactor [22My Onwards]

    Power Pack Contactor [22MY Onwards] CAUTION: Always perform the High Voltage Discharging procedure prior to servicing any High Voltage component or connection. Proper procedures must be followed! To protect electrical components, perform the following tasks in the order given. Do not deviate from the repair procedure processes.

  • Page 63: Controller Bus Set [22My Onwards]

    Power Pack Controller BUS Set [22MY Onwards] CAUTION: Always perform the High Voltage Discharging procedure prior to servicing any High Voltage component or connection. Proper procedures must be followed! To protect electrical components, perform the following tasks in the order given. Do not deviate from the repair procedure processes.
  • Page 64 Power Pack 5. Remove bolts (x4) securing controller BUS 10. Remove bolts (x2) securing controller BUS set set. Torque 10 lb-ft (13.5 Nm). to controller. Torque 11 lb-ft (15 Nm). Note: Support the controller using an 11. Remove controller BUS set. adjustable scissor jack.

  • Page 65: Volt Harness [22My Onwards]

    Power Pack 12 Volt Harness [22MY Onwards] CAUTION: Always perform the High Voltage Discharging procedure prior to servicing any High Voltage component or connection. Proper procedures must be followed! To protect electrical components, perform the following tasks in the order given. Do not deviate from the repair procedure processes.

  • Page 66: Bcb Main Bus Set [22My Onwards]

    Power Pack BCB Main BUS Set [22MY Onwards] CAUTION: Always perform the High Voltage Discharging procedure prior to servicing any High Voltage component or connection. Proper procedures must be followed! To protect electrical components, perform the following tasks in the order given. Do not deviate from the repair procedure processes.
  • Page 67 Power Pack 4. Disconnect harness connector. 5. Remove BCB main BUS set. Installation 1. Installation is the reverse of the removal procedure. Power Pack 20-43...

  • Page 69: Charging System

    Charging System Chargers 3KW Rapid Charger (Front) Removal Charging System [Before 2022MY] 1. PERFORM LOCKOUT PROCEDURE: See Lockout Procedure, page 10.1. Always perform the High Voltage CAUTION: Discharging procedure prior to servicing any High Voltage component or connection. Proper procedures must be followed! To protect electrical components, perform the following tasks in the order given.
  • Page 70 Charging System 6. Remove left and right inner side fairings. See Side Fairings (Inner), page 60.19. 7. Remove tank assembly. See Tank Removal, page 60.10. 11. Remove bolts (x2) securing tank storage liner to storage liner support. Tool: T27. Torque: 2.5 lb-ft (3 Nm).
  • Page 71 Charging System 15. Disconnect harness connector. 18. Cut cable tie securing high voltage harness to harness anchor on left side of storage liner support. Note: Replace cable tie during the installation process. 16. Protect and secure charger port stand to the side of motorcycle.
  • Page 72 Charging System 21. Position harnesses aside and remove bolts 23. Remove bolts (x2) securing right side of front (x2) securing right side of storage liner closeout panel to frame. Tool: T25. Torque: support bolts to frame. Tool: T30. Torque: 3.5 lb-ft (5 Nm). 7.8 lb-ft (11 Nm).
  • Page 73 Charging System 26. Disconnect left front high voltage connector 29. Push secondary tab and disconnect from charger. connector from charger. 27. Slide connector lock to unlock. 30. Following the same connector disconnecting process, disconnect right front high voltage connector from charger. 28.
  • Page 74 Charging System 32. Remove bolt securing charger to right front charger bracket. Tool: T20. Torque: 4.5 lb-ft (6 Nm). 33. Remove bolts (x2) securing rear of charger to rear charger brackets. Tool: 7mm wrench. Torque: 4.5 lb-ft (6 Nm). 34. Remove charger from motorcycle. Installation 1.

  • Page 75: 3Kw Rapid Charger (Front And Rear) [Before 2022My]

    Charging System 3KW Rapid Charger (Front and Rear) Removal 1. PERFORM LOCKOUT PROCEDURE: See [Before 2022MY] Lockout Procedure, page 10.1. CAUTION: Always perform the High Voltage Discharging procedure prior to servicing any High Voltage component or connection. Proper procedures must be followed! To protect electrical components, perform the following tasks in the order given.
  • Page 76 Charging System 6. Remove left and right inner side fairings. See Side Fairings (Inner), page 60.19. 7. Remove tank assembly. See Tank Removal, page 60.10. 11. Remove bolts (x2) securing tank storage liner to storage liner support. Tool: T27. Torque: 2.5 lb-ft (3 Nm).
  • Page 77 Charging System 15. Disconnect harness connector. 18. To gain access to the left front bolt securing tank storage liner support to motorcycle frame, move the brake hoses toward the tank storage liner support. 16. Protect and secure charger port stand to the side of motorcycle.
  • Page 78 Charging System 21. Position the released high voltage harness 24. Due to the brake hose routing (on left side), aside to gain access to storage liner support right side of tank liner support/rear charger bolts on left side. assembly has to come out first. 22.
  • Page 79 Charging System 27. Disconnect left high voltage connector from 30. Push secondary tab and disconnect charger. connector from charger. 28. Slide connector lock to unlock. 31. Following the same process for disconnecting the high voltage connector from the right side of the charger.
  • Page 80 Charging System 37. Remove front closeout panel. Note: Position front suspension straight forward to allow access for removing front closeout panel downward in front of power pack. 34. Remove bolts (x2) securing rear charger to the right side of the tank liner support bracket. Tool: T25.
  • Page 81 Charging System 41. Push tab upward to release connector and 44. Remove bolt securing charger to left front slide. charger bracket. Tool: T20. Torque: 4.5 lb-ft (6 Nm). 42. Push secondary tab and disconnect connector from charger. 45. Remove bolt securing charger to right front charger bracket.

  • Page 82: 6Kw Charger [22My Onwards]

    Charging System 6KW Charger [22MY Onwards] CAUTION: Always perform the High Voltage Discharging procedure prior to servicing any High Voltage component or connection. Proper procedures must be followed! To protect electrical components, perform the following tasks in the order given. Do not deviate from the repair procedure processes.
  • Page 83 Charging System CAUTION: Cover/protect battery terminal eyelet to reduce the risk of accidentally contacting the negative battery terminal, which can inadvertently power up the 12 volt system and damage components. CAUTION: Secure battery terminal wire to reduce the risk of arcing and damaging electrical components.
  • Page 84 Charging System 18. Remove T40 bolt securing horn. Torque 8 lb-ft (11 Nm). 19. Disconnect wires (x2) from horn. 20. Remove horn. 24. Loosen T30 bolts (x2) securing charger connector brackets. Torque 6 lb-ft (8 Nm). 21. Disconnect charge outlet connector. 25.

  • Page 85: Charge Inlet Harness

    Charging System Charge Inlet Harness CAUTION: Always perform the High Voltage Discharging procedure prior to servicing any High Voltage component or connection. Proper procedures must be followed! To protect electrical components, perform the following tasks in the order given. Do not deviate from the repair procedure processes.
  • Page 86 Charging System 6. Remove left and right inner side fairings. See Removal Side Fairings (Inner), page 60.19. 1. PERFORM LOCKOUT PROCEDURE: See Lockout Procedure, page 10.1. 7. Remove tank assembly. See Tank Removal, page 60.10. 8. Remove charger. See 3KW Rapid Charger (Front) [Before 2022MY], page 25.1.
  • Page 87 Charging System 11. Disconnect grey harness connector. 12. Remove nuts (x4) and bolts (x4) securing charge inlet to the charge port stand and collect washers (x4). Tool: T25 & 8mm socket. Nut Torque: 4.5 lb-ft (6 Nm). Note: During installation, do not snug storage liner bolts until tank is installed.

  • Page 88: Dc/Dc Converter

    Charging System DC/DC Converter DC/DC Converter CAUTION: Always perform the High Voltage Discharging procedure prior to servicing any High Voltage component or connection. Proper procedures must be followed! To protect electrical components, perform the following tasks in the order given. Do not deviate from the repair procedure processes.
  • Page 89 Charging System 8. Squeeze tabs to release OBDII connector from 12. Disconnect DC/DC converter harness tank storage liner. connector. 9. Disconnect USB power hub harness 13. Remove bolts (x4) securing DC/DC converter connector. to the HCU bracket. Tool: T30. Torque: Hand 14.

  • Page 91: Motor And Drive System

    Motor and Drive System Motor Motor Removal Motor and Drive System 1. PERFORM LOCKOUT PROCEDURE: See Lockout Procedure, page 10.1. Tools Required (includes tools required for parent jobs): • T20 • T25 • T30 • T40 • T45 • T50 •...
  • Page 92 Motor and Drive System 6. Remove left and right inner side fairings. See Side Fairings (Inner), page 60.19. 7. Remove motor controller. See Motor Controller [Before 2022MY], page 30.27. 11. Center bolt secures the rear shock ground wire eyelet and star washer underneath it. 8.
  • Page 93 Motor and Drive System 15. Release license plate harness anchor 18. Remove rear axle nut and collect the rear axle securing the license plate light harness to the adjuster. Tool: 27mm. Torque: 75 lb-ft (102 swingarm. Tool: Non-marring trim removal/pry Nm).
  • Page 94 Motor and Drive System 21. Slide rear axle forward. 24. Lift rear tire slightly and slide rear axle out of the swing arm. 22. Slip belt off of the rear sprocket. 25. Raise rear tire and remove rear WSS (wheels speed sensor) and set aside.
  • Page 95 Motor and Drive System 28. Roll rear tire forward. 32. Slide rear caliper assembly toward wheel and slide caliper bracket off of the bracket 29. Release rear brake hose from the metal alignment pin. retaining clip. 33. Tie caliper up to the foot peg bracket. 30.
  • Page 96 Motor and Drive System 35. DO NOT LIFT THE MOTORCYLE BY 37. Raise rear of bike by the rear subframe with JACKING UP THE CONTROLLER! DO NOT the hoist just enough to remove the load from SUPPORT THE WEIGHT OF THE the rear shock.
  • Page 97 Motor and Drive System 40. Protect painted surfaces with shop cloths. 44. Release rear WSS harness from metal retaining clip. 41. Remove bolt securing ground wire to bottom of rear shock and collect star washer (between 45. Release brake hose and rear WSS harness wire eyelet and shock body).
  • Page 98 Motor and Drive System 52. Remove right foot peg bracket. 47. Remove bolts (x3) securing left foot peg bracket to the left doubler plate. Tool: T40. 53. Remove bolts (x4) securing swingarm to left Torque: 20 lb-ft (27 Nm). outer bearing cover. Tool: 13mm socket. Torque: 25 lb-ft (34 Nm).
  • Page 99 Motor and Drive System 56. Collect the shims located between the right 60. Remove bolt securing rear brake master outer bearing cover and the swingarm. cylinder reservoir and clamp to the right doubler plate. Tool: T25. Torque: 2 lb-ft (2.7 Nm). 61.
  • Page 100 Motor and Drive System 65. Support motor to keep it from rolling off the 68. Raise brake pedal to access bolts. Remove scissor jack. bolts (x2) securing rear master cylinder to master cylinder bracket. Tool: T30. Torque: 7 lb-ft (9 Nm). 66.
  • Page 101 Motor and Drive System 71. Move motor toward rear, far enough to gain 75. Tie up rear master cylinder. access to the rear brake bracket bolts. 76. Move motor assembly towards rear and away 72. Remove outer countersunk bolt securing the from the motorcycle.
  • Page 102 Motor and Drive System 78. Remove bolts (x3) securing right doubler plate 2. Remove plastic bushing from left side to the motor. Tool: T40. Torque: 25 lb-ft (sprocket side) of the wheel. (34 Nm). Tool: T45. Torque: 26 lb-ft (35 Nm). 3.
  • Page 103 Motor and Drive System 5. The order of fasteners and washers to mount the rear shock to the swingarm. 6. Adjust drive belt. See Adjust Drive Belt, page 40.39. 7. Perform Motor Commissioning. See Motor Commissioning, page 10.10. Motor 30-13...

  • Page 104: Motor Stop Switch

    Motor and Drive System Motor Stop Switch Motor Stop Switch Removal CAUTION: Always perform the High Voltage Discharging procedure prior to servicing any High Voltage component or connection. Proper procedures must be followed! To protect electrical components, perform the following tasks in the order given.
  • Page 105 Motor and Drive System 6. Remove headlight inner fairing. See Headlight Inner Fairing, page 60.3. 9. Cut cable tie securing motor stop switch connector to the throttle connector. 7. Cut cable tie securing the motor stop switch Note: Replace cable tie during the installation harness, brake switch electrical harness, process.
  • Page 106 Motor and Drive System 12. Wrap tape around the handlebar and mark the 15. Tape the throttle and grip to keep the throttle’s parting line of the front master cylinder to front cover from popping off the throttle record its location. assembly.
  • Page 107 Motor and Drive System 18. Remove bolts (x2) securing the bottom cover to the motor stop switch. Tool: #2 Phillips screwdriver 19. Remove the bottom cover to the motor stop switch. 20. Remove the motor stop switch. Installation 1. Installation is the reverse of the removal procedure.

  • Page 108: Throttle

    Motor and Drive System Throttle (Without Heated Grips) Throttle Removal CAUTION: Always perform the High Voltage Discharging procedure prior to servicing any High Voltage component or connection. Proper procedures must be followed! To protect electrical components, perform the following tasks in the order given. Do not deviate from the repair procedure processes.
  • Page 109 Motor and Drive System 6. Remove tank assembly. See Tank Removal, page 60.10. 7. Remove headlight inner fairing. See Headlight Inner Fairing, page 60.3. 10. Cut cable tie securing motor stop switch connector to the throttle connector. Note: Replace cable tie during the installation process.
  • Page 110 Motor and Drive System 13. Remove bolts (x2) securing the throttle’s rear 16. Carefully remove throttle assembly from the cover to the front cover. Tool: Tamperproof throttle assembly cover. Note: Take note of the position of the spring on the cover and how the grip assembly interlocks with the throttle assembly Installation 1.
  • Page 111 Motor and Drive System 3. Align the peg on the throttle grip with the 6. A properly installed throttle return spring will notch of the throttle mechanism. be preloaded as shown. Take care not to pull the assembly out of the throttle cover during installation.

  • Page 112: Throttle (With Heated Grips)

    Motor and Drive System Throttle (With Heated Grips) Removal CAUTION: Always perform the High Voltage Discharging procedure prior to servicing any High Voltage component or connection. Proper procedures must be followed! To protect electrical components, perform the following tasks in the order given. Do not deviate from the repair procedure processes.
  • Page 113 Motor and Drive System 6. Remove tank assembly. See Tank Removal, page 60.10. 7. Remove headlight inner fairing. See Headlight Inner Fairing, page 60.3. 10. Cut cable tie securing motor stop switch connector to the throttle connector. Note: Replace cable tie during the installation process.
  • Page 114 Motor and Drive System 13. Remove bolts (x2) securing left side of front 16. Unhook retaining clip to release tension on closeout panel to frame. Tool: T25. Torque: harnesses. 3.5 lb-ft (5 Nm). Note: Protect rear portion of front fender and front closeout panel surfaces to reduce the possibility of scratching their surfaces.
  • Page 115 Motor and Drive System 19. Remove bolts (x2) securing the throttle’s rear 22. Carefully remove throttle assembly from the cover to the front cover. Tool: Tamperproof throttle assembly cover. Note: Take note of the position of the spring on the cover and how the grip assembly interlocks with the throttle assembly Installation 1.
  • Page 116 Motor and Drive System 3. Insert throttle spring tang into the hole in the 6. While holding the throttle mechanism from throttle mechanism. popping out of the throttle cover, use a non-marring trim removal tool to slide the spring tang until the tang drops into the slot. Tool: Non-marring trim removal/pry tool.

  • Page 117: Controller

    Motor and Drive System Motor Controller [Before 2022MY] Controller CAUTION: Always perform the High Voltage Discharging procedure prior to servicing any High Voltage component or connection. Proper procedures must be followed! To protect electrical components, perform the following tasks in the order given. Do not deviate from the repair procedure processes.
  • Page 118 Motor and Drive System Removal 1. PERFORM LOCKOUT PROCEDURE: See Lockout Procedure, page 10.1. 4. Busbars. 2. Remove high voltage DCDC and CONT fuses. High Voltage Fuses, page 70.1. 5. Phase leads. 3. Unbolt the negative battery terminal eyelet. Cover eyelet with insulating material. Use cable tie to secure negative battery wire to the positive battery cable.
  • Page 119 Motor and Drive System 6. Remove left and right inner side fairings. See Side Fairings (Inner), page 60.19. 10. Remove bolts (x2) securing controller carrier to power pack, left side. Tool: T25. Torque: 3 lb-ft (4 Nm). 7. Safely support the motorcycle by using a motorcycle stand.
  • Page 120 Motor and Drive System CAUTION: Use jack to control the distance the controller assembly drops. Do not allow the controller assembly to hang and stress the signal harness. 13. Do not pry on any part of the controller assembly. 16. Remove terminal bolts (x2) securing busbars (x2) to the top of the controller.
  • Page 121 Motor and Drive System Note: Replace double loop cable tie upon installation. 19. Label phase leads to ensure they are re-installed in the correct locations upon reassembly. 22. Cut cable tie section blocking the removal of the controller signal harness connector. 20.
  • Page 122 Motor and Drive System 26. Remove controller carrier from controller. Cleaning Connectors Before Installation Note: Prior to installing the controller, check the following connector locations and clean if necessary. Clean with a microfiber cloth and/or cotton swabs. The following images show areas qualified as clean.
  • Page 123 Motor and Drive System 2. Use a shop vacuum with a brush head 5. Vacuum out the debris around the controller. attachment to remove as much dust and debris as possible from the top of the controller. 6. Apply ISO70 (isopropyl rubbing alcohol 70%) to a paper towel and clean the top of the controller.
  • Page 124 Motor and Drive System Installation 1. Installation is the reverse of the removal procedure. 8. Thoroughly clean all terminal connection surfaces of the phase leads (x3) and busbars (x2) with ISO70 and paper towels. 2. Replace orange terminal gaskets and terminal bolt O-rings prior to installation.
  • Page 125 Motor and Drive System CAUTION: Install the terminal bolts without any CP70 (or any type of insulating lubricant/gel/paste). Note: Phase lead W1 has to be torqued before moving to the next step. It will be unaccessible after the following step. Note: Confirm that the phase leads are positioned/clocked as shown on top of the controller.
  • Page 126 Motor and Drive System 11. Place the B- busbar on to the controller. 14. Place the B+ busbar on to the controller. 12. Place a new O-ring (x3) on the B- busbar. 15. Place a new O-ring (x3) on the B+ busbar. 13.
  • Page 127 Motor and Drive System 17. Use a double loop cable tie to anchor the 8-pin 20. DO NOT PINCH SIGNAL HARNESS OR harness connector to the loop on the PHASE WIRES WHILE INSTALLING THE controller. CONTROLLER! Pay close attention to the placement of the cables during the entire installation process.
  • Page 128 3 lb-ft (4 Nm). 26. After finishing the controller installation, 23. Note: Once the controller carrier bolt holes are contact Zero Motorcycles Customer Service aligned with the power pack side plates, for assistance for updating the firmware. loosely start one bolt at a time. This will allow •...

  • Page 129: Motor Controller Carrier [Before 2022My]

    Motor and Drive System Motor Controller Carrier [Before 2022MY] Removal 1. PERFORM LOCKOUT PROCEDURE: See Lockout Procedure, page 10.1. CAUTION: Always perform the High Voltage Discharging procedure prior to servicing any High Voltage component or connection. Proper procedures must be followed! To protect electrical components, perform the following tasks in the order given.
  • Page 130 Motor and Drive System 6. Remove left and right outer side fairings. See Side Fairings (Outer), page 60.14. 7. Remove left and right inner side fairings. See Side Fairings (Inner), page 60.19. 11. Remove bolts (x2) securing controller carrier to power pack, left side. Tool: T25. Torque: 3 lb-ft (4 Nm).
  • Page 131 Motor and Drive System 14. Using a non-marring pry tool, carefully pry the 16. Remove bolts (x4) and nuts (x4) securing the controller assembly straight down. Alternate controller to the controller carrier. Collect the from right to left. Alternating from side to side, plastic controller safety stands (left and right) carefully pry between the controller carrier and washers (x4).

  • Page 132: Motor Controller With Heatsink [22My Onwards]

    Motor and Drive System Motor Controller with Heatsink [22MY Onwards] CAUTION: Always perform the High Voltage Discharging procedure prior to servicing any High Voltage component or connection. Proper procedures must be followed! To protect electrical components, perform the following tasks in the order given. Do not deviate from the repair procedure processes.

  • Page 133: Rear Sprocket

    Motor and Drive System Rear Sprocket Rear Sprocket Tools Required (includes tools required for parent jobs): • T25 • T40 • T45 • 27mm socket and ratchet • 13mm wrench • Motorcycle stand 4. Release rear wheel speed sensor (WSS) harness from plastic retainer.
  • Page 134 Motor and Drive System 7. Raise rear tire and remove rear WSS sensor 11. Release rear brake hose from the metal and set aside. retaining clip. Note: Make sure the WSS sensor is hung up and not straining the WSS electrical harness. 8.
  • Page 135 Motor and Drive System 14. Slide rear caliper assembly toward wheel and 18. Remove bolts (x5) securing the brake rotor to slide caliper bracket off of the bracket the rear wheel. Tool: T45. Torque (in alignment pin. sequence shown): 26 lb-ft (35 Nm). Installation 1.
  • Page 136 Motor and Drive System 3. On the rotor-side of the rear wheel, inspect the condition of the wheel bearing (#1) and the ABS magnet ring (#2). Replace if necessary. Note: The bearing is a one-time use parts. If removed, the part will need to be replaced. 4.

  • Page 137: Suspension

    Suspension Wheel Speed Sensor (WSS) Wheel Speed Sensor (Front) Suspension Tools Required (includes tools required for parent jobs): • T25 • T30 • T50 • 3/16” standard screwdriver • 2mm hex wrench • 10mm socket and ratchet 2. Unbolt the negative battery terminal eyelet. •...
  • Page 138 Suspension 8. Remove bolts (x2) securing left side of front 11. Cut cable tie securing the motor stop switch closeout panel to frame. Tool: T25. Torque: harness, brake switch electrical harness, 3.5 lb-ft (5 Nm). throttle harness, and front wheel speed sensor to hela bracket harness anchor.
  • Page 139 Suspension 14. Cut cable tie securing the WSS harness to the 18. Wrap left front caliper and tie the caliper to the left front brake hose. frame to eliminate strain on the brake hose. Note: Replace cable tie during the installation process.
  • Page 140 Suspension 22. Loosen front axle pinch bolts (x2). Tool: 6mm 25. Safely hook the ends of the straps to a hoist. hex. Torque: 16 lb-ft (22 Nm). 26. Using the hoist, raise the front of the 23. DO NOT LIFT THE MOTORCYLE BY motorcycle until the front tire is slightly off the JACKING UP THE CONTROLLER! DO NOT floor.
  • Page 141 Suspension 28. Release the WSS from the front wheel. Installation 1. Installation is the reverse of the removal procedure, but take note of the following installation step. 2. When installing the front WSS, make sure the alignment tab is positioned against the bottom edge of the left front shock as shown.

  • Page 142: Wheel Speed Sensor (Rear)

    Suspension Wheel Speed Sensor (Rear) Tools Required (includes tools required for parent jobs): • T25 • T30 • T40 • T45 • 3/16” standard screwdriver • 2mm hex wrench 2. Unbolt the negative battery terminal eyelet. Cover eyelet with insulating material. Use •...
  • Page 143 Suspension 6. Release rear WSS harness from plastic 9. Raise rear tire and remove rear wheel speed retainer. sensor (WSS) and set aside. Note: Make sure the WSS sensor is supported and not straining the WSS electrical harness. 10. Lower the rear tire carefully to keep from damaging painted surfaces.
  • Page 144 Suspension 13. Release rear brake hose from the metal 16. Release rear brake hose and rear WSS retaining clip. harness from the metal retaining clip. 14. Position the rear brake hose on top of clip. 17. Remove bolts (x3) securing the left foot peg bracket to the left doubler plate.
  • Page 145 Suspension 19. Release harness anchor clip from the frame. 22. Disconnect rear WSS connector. 20. Cut cable tie securing the rear WSS harness 23. Release rear WSS harness from the plastic and kickstand harness to the anchor clip. clip securing it to the rear brake caliper hose. Note: Replace cable tie during the installation process.
  • Page 146 Suspension 25. Release WSS harness from metal clip. 3. Confirm that the aluminum bushing from left side (sprocket side) of the wheel is installed in the seal prior to installation of the wheel. 26. Release WSS harness from plastic clips (x2). 27.

  • Page 147: Front Suspension

    Suspension Steering Stem Front Suspension Tools Required (includes tools required for parent jobs): • T25 • T30 • T45 • T50 • 3/16” standard screwdriver • 2mm hex wrench 2. Unbolt the negative battery terminal eyelet. Cover eyelet with insulating material. Use •...
  • Page 148 Suspension 6. Remove left and right inner side fairings. See Side Fairings (Inner), page 60.19. 7. Remove tank assembly. See Tank Removal, page 60.10. 8. Remove headlight inner fairing. See Headlight Inner Fairing, page 60.3. 9. Remove front wheel speed sensor (WSS) sensor.
  • Page 149 Suspension 15. Loosen right front suspension upper clamp 18. Remove bolt capturing harness ground wire to bolt. Tool: T45. Torque: 16 lb-ft (22 Nm). the upper triple clamp. Collect star washer located between ground cable eyelet and upper triple clamp. Tool: T30. Torque: 8 lb-ft (11 Nm).
  • Page 150 Suspension 21. Remove stem nut. Tool: 41mm. Torque: 24. Remove lower triple clamp and discard 75 lb-ft (102 Nm). bearings (x2), races (x2), and seals (x2). Note: Replace bearings (x2), races (x2), and seals (x2) upon installation. Installation 1. Installation is the reverse of the removal procedure, but take note of the following installation step.
  • Page 151 Suspension 3. Only lubricate the selected parts upon installation. Lubricate the bearings prior to CAUTION: installation with appropriate bearing packing tool. CAUTION: Do not lubricate seals. 4. When installing the front WSS, make sure the alignment tab is positioned against the bottom edge of the left front shock as shown.

  • Page 152: Rear Suspension

    Suspension Rear Shock Rear Suspension Tools Required (includes tools required for parent jobs): • T20 • T25 • T30 • T50 • 3/16” standard screwdriver • 2mm hex wrench 2. Unbolt the negative battery terminal eyelet. Cover eyelet with insulating material. Use •...
  • Page 153 Suspension 4. DO NOT LIFT THE MOTORCYLE BY 6. Raise rear of bike by the rear subframe with JACKING UP THE CONTROLLER! DO NOT the hoist just enough to remove the load from SUPPORT THE WEIGHT OF THE the rear shock. MOTORCYCLE BY SUPPORTING THE CONTROLLER! Doing so, will damage the controller and other components.
  • Page 154 Suspension Installation 1. Installation is the reverse of the removal procedure, with the exception of the following installation note: 9. Protect painted surfaces with shop cloths. 2. The order of shock ground wire fasteners: bolt, wire eyelet, and steel star washer. 10.

  • Page 155: Swingarm

    Suspension Swingarm Removal Tools Required (includes tools required for parent jobs): • T20 • T25 • T30 • T40 • T45 • T50 • 3/16” standard screwdriver 1. Remove high voltage DCDC and CONT fuses. High Voltage Fuses, page 70.1. •...
  • Page 156 Suspension 3. Tape the swingarm to keep the brake caliper 6. Center bolt secures the rear shock ground from damaging the painted surfaces. wire eyelet and star washer underneath it. 4. Safely raise rear tire off the ground using a 7.
  • Page 157 Suspension 10. Release license plate harness anchor 13. Remove rear axle nut and collect the rear axle securing the license plate light harness to the adjuster. Tool: 27mm. Torque: 75 lb-ft swingarm. Tool: Non-marring trim removal/pry (102 Nm). tool Note: Replace single-use harness anchor during the installation process.
  • Page 158 Suspension 16. Slide rear axle forward. 19. Lift rear tire slightly and slide rear axle out of the swing arm. 17. Slip belt off of the rear sprocket. 20. Raise rear tire and remove rear WSS (wheels speed sensor) and set aside. Note: Make sure the WSS is supported and not straining the WSS harness.
  • Page 159 Suspension 23. Roll rear tire forward. 27. Slide rear caliper assembly toward wheel and slide caliper bracket off of the bracket 24. Release rear brake hose from the metal alignment pin. retaining clip. 28. Tie caliper up to the foot peg bracket. 25.
  • Page 160 Suspension 30. DO NOT LIFT THE MOTORCYLE BY 32. Raise rear of bike by the rear subframe with JACKING UP THE CONTROLLER! DO NOT the hoist just enough to remove the load from SUPPORT THE WEIGHT OF THE the rear shock. MOTORCYCLE BY SUPPORTING THE CONTROLLER! Doing so, will damage the controller and other components.
  • Page 161 Suspension 35. Protect painted surfaces with shop cloths. 39. Release rear WSS harness from metal retaining clip. 36. Remove bolt securing ground wire to bottom of rear shock and collect star washer (between 40. Release brake hose and rear WSS harness wire eyelet and shock body).
  • Page 162 Suspension 47. Remove right foot peg bracket. 42. Remove bolts (x3) securing left foot peg bracket to the left doubler plate. Tool: T40. 48. Remove bolts (x4) securing swingarm to left Torque: 20 lb-ft (27 Nm). outer bearing cover. Tool: 13mm socket. Torque (in sequence shown): 24.5 lb-ft 43.
  • Page 163 1. Installation is the reverse of the removal the bearings are in good condition, contact procedure, but take note of the following Zero Motorcycles Customer Service installation step. department for assistance. • North America: support@zeromotorcycles.com...
  • Page 164 Suspension 5. When installing the WSS sensor, make sure the alignment tab is positioned against the top edge of the rear brake bracket as shown. 6. The order of shock ground wire fasteners: bolt, wire eyelet, and steel star washer. 7.

  • Page 165: Doubler Plate Seals

    Suspension Doubler Plate Seals Removal 1. PERFORM LOCKOUT PROCEDURE: See Lockout Procedure, page 10.1. Tools Required (includes tools required for parent jobs): • T20 • T25 • T30 • T40 • T45 • T50 • 3/16” standard screwdriver • 2mm hex wrench 2.
  • Page 166 Suspension 6. Remove left and right inner side fairings. See Side Fairings (Inner), page 60.19. 7. Remove motor controller. See Motor Controller [Before 2022MY], page 30.27. 8. Remove motor. See Motor, page 30.1. 2. The inside seal for the outer bearing cover has a rib (see arrow) on one side that must be pressed into the seal groove in the outer bearing cover.
  • Page 167 Suspension 5. Press the seal into the groove at the 3 o’clock 8. Press the seal into the groove at about the 5 position. o’clock position. 6. Press the seal into the groove at the 9 o’clock 9. Press the seal into the groove at about the 2 position.
  • Page 168 Suspension 11. Press the seal into the groove at about the 10 14. Follow the same process to evenly install the o’clock position. seal in the second outer bearing cover. 12. Press the seal into the groove at about the 4 15.
  • Page 169 Suspension 16. The exterior seal for the outer bearing cover 19. Slide the seal around the doubler plate to has a front and a back side. The part number center the seal over the outer bearing cover is only printed on the back side of the seal. and the doubler plate.
  • Page 170 Suspension 22. Press the seal into the groove at the 3 o’clock 25. Press the seal into the groove at about the 7 to position. 8 o’clock position. 23. Press the seal into the groove at the 9 o’clock 26. Continue alternating from side to side, position.

  • Page 171: Replace Drive Belt

    Suspension Replace Drive Belt Tools Required (includes tools required for parent jobs): • T45 • 27mm socket and ratchet • 13mm wrench • Motorcycle stand New Fasteners Required: 3. Safely raise rear tire off the ground using a • Cable tie (quantity: 2) motorcycle stand.
  • Page 172 Suspension Note: Replace cable tie during the installation process. 6. Remove bolt securing the rear inner fender to the rear swingarm. Tool: T25. Torque: 3.5 lb-ft (5 Nm). 10. Cut cable tie securing the license plate harness to the ROF (rear outer fender) arm. 7.
  • Page 173 Suspension 13. Disconnect license plate light harness 17. Remove left adjuster bolt and collect the left connector. swingarm end cap. Tool: T45 14. Remove bolts (x3) securing the rear fender 18. Remove left adjuster bolt and collect the right arm to the swingarm. Collect the nuts (x3) and swingarm end cap.
  • Page 174 Suspension 20. Slip belt off of the rear sprocket. Installation 1. Installation is the reverse of the removal procedure, but take note of the following installation step. 2. Adjust drive belt after installation is complete. Adjust Drive Belt, page 40.39. 40-38 Rear Suspension...

  • Page 175: Adjust Drive Belt

    Suspension Adjust Drive Belt Tools Required (includes tools required for parent jobs): • T45 • 27mm socket and ratchet • Smartphone with Gates® Carbon Drive™ Application • Motorcycle stand Removal 4. The alignment marks stamped on the 1. Remove the key from the key switch. swingarm are for initial alignment, but are not equal on both sides of the swingarm and should not be used as final adjustment marks.
  • Page 176 Suspension NOTICE: Rotating the tire in the reverse direction will give a false adjustment. Failing to follow this instruction could cause damage to the drive belt. NOTICE: Rotating the tire two full revolutions isn’t enough to normalize the belt on the two sprockets, so be sure to rotate the belt two full revolutions by counting the number of times the printing on the belt passes by the rear...
  • Page 177 Suspension 12. Recheck the belt adjustment after the test ride and readjust, if necessary. Rear Suspension 40-41...

  • Page 179: Brakes

    Brakes Brakes Brake Master Cylinder (Front) Brakes Removal WARNING! Do not clamp brake hoses, as they will be damaged and will require replacement. WARNING! Only use new brake fluid from an airtight container. Fluid from open containers or fluid previously the system will have absorbed moisture, which will adversely performance and must not be used.
  • Page 180 Brakes 3. Wrap tape around the handlebar and mark the parting line of the front master cylinder to record its location. 4. Remove the front master cylinder clamp bolts (x2) securing the master cylinder assembly to the handlebar. Tool: 5mm hex wrench. Torque: 8 lb-ft (11 Nm).

  • Page 181: Brake Pads (Front)

    Brakes Brake Pads (Front) CAUTION: Do not operate the brake lever while the master cylinder, and or brake caliper(s) is/ are removed or while the brake system is disassembled. Tools Required (includes tools required for parent jobs): • T25 Removal 3.
  • Page 182 Brakes 3. Install the upper brake pad pin (1), capturing the anti-rattle clip first. Install the lower brake pad pin (2), capturing the anti-rattle clip second. Tool: T25. Torque: 6 lb-ft (8 Nm). 4. After installing new brake pads, perform the brake pad bedding procedure.

  • Page 183: Brake Pads (Rear)

    Brakes Brake Pads (Rear) CAUTION: Do not operate the brake lever while the master cylinder, and or brake caliper(s) is/ are removed or while the brake system is disassembled. Tools Required (includes tools required for parent jobs): • T25 Removal 3.

  • Page 184: Brake Caliper (Front)

    Brakes Brake Caliper (Front) CAUTION: Do not operate the brake lever while the master cylinder, and or brake caliper(s) is/ are removed or while the brake system is disassembled. Tools Required (includes tools required for parent jobs): • 8mm hex wrench •...
  • Page 185 Brakes 2. Perform brake bleeding procedure. See Brake Bleeding Procedure (Front), page 10.5. 3. If new brake pads have been installed, perform the brake pad bedding procedure. Brake Bedding, page 10.7. Brakes 45-7...

  • Page 186: Brake Caliper (Rear)

    Brakes Brake Caliper (Rear) Tools Required (includes tools required for parent jobs): • 9mm hex wrench • T25 • T40 • T45 • 27mm socket and ratchet • 13mm wrench 4. Remove rear caliper banjo bolt and discard crush washers (x2). Tool: 14mm flare nut •...
  • Page 187 Brakes 10. Roll rear tire forward. 6. Lift rear tire slightly and slide rear axle out of the swing arm. 11. Release rear brake hose from the metal retaining clip. 7. Raise rear tire and remove rear wheel speed sensor (WSS) and set aside. 12.
  • Page 188 Brakes 14. Slide rear caliper assembly toward wheel and 3. Confirm that the aluminum bushing from left slide caliper bracket off of the bracket side (sprocket side) of the wheel is installed in alignment pin. the seal prior to installation of the wheel. 15.

  • Page 189: Brake Rotor (Front)

    Brakes Brake Rotor (Front) Tools Required (includes tools required for parent jobs): • T25 • T30 • T40 • T50 • 3/16” standard screwdriver • 2mm hex wrench 2. Unbolt the negative battery terminal eyelet. Cover eyelet with insulating material. Use •...
  • Page 190 Brakes 8. Remove bolts (x2) securing left side of front 12. Remove left front caliper bolts (x2) and collect closeout panel to frame. Tool: T25. Torque: retaining clip. Tool: T50. Torque: 30 lb-ft 3.5 lb-ft (5 Nm). (41 Nm). Note: Protect rear portion of front fender and 13.
  • Page 191 Brakes 17. Wrap right front caliper and tie the caliper to 20. Safely loop straps around the motorcycle the frame to eliminate strain on the brake frame on the left (shown) and right. hose. 21. Safely hook the ends of the straps to a hoist. 18.
  • Page 192 Brakes 23. Remove front axle and collect the front wheel. 2. Install bolts (x5) securing the brake rotor to the Tool: 17mm hex bit socket. Torque: 40 lb-ft front wheel in a star pattern. Tool: T40. (54 Nm). Torque: 20 lb-ft (27 Nm). 24.

  • Page 193: Brake Rotor (Rear)

    Brakes Brake Rotor (Rear) Tools Required (includes tools required for parent jobs): • T25 • T40 • T45 • 27mm socket and ratchet • 13mm wrench • Motorcycle stand 4. Release rear WSS harness from plastic retainer. New Fasteners Required: •...
  • Page 194 Brakes 7. Raise rear tire and remove rear WSS and set 11. Release rear brake hose from the metal aside. retaining clip. Note: Make sure the WSS is supported and is not straining the WSS harness. 8. Lower the rear tire carefully to keep from damaging painted surfaces.
  • Page 195 Brakes 14. Slide rear caliper assembly toward wheel and 18. Remove bolts (x5) securing the brake rotor to slide caliper bracket off of the bracket the rear wheel. Tool: T40. Torque: 26 lb-ft alignment pin. (35 Nm). Installation 1. Installation is the reverse of the removal procedure, with the exception of the following: 15.
  • Page 196 Brakes 4. After replacing the brake rotor, perform the brake pad bedding procedure. See Brake Bedding, page 10.7. 45-18 Brakes...

  • Page 197: Hydraulic Control Unit (Hcu)

    Brakes Hydraulic Control Unit (HCU) Tools Required (includes tools required for parent jobs): • T20 • T25 • T27 • T30 • 3/16” standard screwdriver • 2mm hex wrench 2. Unbolt the negative battery terminal eyelet. Cover eyelet with insulating material. Use •...
  • Page 198 Brakes 9. Remove bolts (x2) securing left side of front 12. Remove bolt securing the front WSS harness closeout panel to frame. Tool: T25. Torque: cushion clamp and front brake hose. Tool: 3.5 lb-ft (5 Nm). T30. Torque: 5 lb-ft (7 Nm). Note: Protect rear portion of front fender and front closeout panel surfaces to reduce the possibility of scratching their surfaces.
  • Page 199 Brakes 16. Disconnect key switch wiring harness 19. Remove bolts (x2) securing IMU to the HCU connector. bracket. Tool: T30. Torque: Hand tight. Note: Take note of harness routing for installation process. 20. Release clip securing IMU harness to HCU bracket.
  • Page 200 Brakes 23. Release DC/DC converter harness connector. 27. Remove bolt securing right front of HCU bracket to frame. Tool: T30. Torque: 6 lb-ft (8 Nm). 24. Release clip securing the DC/DC controller harness to HCU bracket. Tool: O-ring pick 28. Remove bolts (x2) securing rear of HCU Note: The locking tab is located on the lower bracket to frame.
  • Page 201 Brakes CAUTION: Plug all open connections to prevent ingress of moisture and debris. CAUTION: Brake fluid is extremely harmful to paint, so if brake fluid contacts a painted surface, wash the surface immediately. Note: Position a suitable container to contain fluid spillage.
  • Page 202 Brakes 35. Move HCU bracket assembly towards the rear and disconnect the harness connector. 36. Remove bolts (x2) securing the HCU to the HCU bracket and collect washers (x2). Tool: 37. Remove the HCU. Brake fluid is extremely harmful CAUTION: to paint, so if brake fluid contacts a painted surface, wash the surface immediately.

  • Page 203: Wheels

    Wheels Front Wheel Front Wheel Wheels Tools Required (includes tools required for parent jobs): • T30 • T50 • 6mm Allen wrench • 17mm hex bit socket and ratchet • Ratchet straps (x2) • Hoist 3. Cut cable tie securing the WSS sensor harness to the left front brake hose.
  • Page 204 Wheels 7. Wrap left front caliper and tie the caliper to the 11. Loosen front axle pinch bolts (x2). Tool: 6mm frame to eliminate strain on the brake hose. hex. Torque: 16 lb-ft (22 Nm). 8. Remove right front caliper bolts (x2). Tool: 12.
  • Page 205 Wheels 16. Release the WSS sensor from the front wheel. Installation 1. Installation is the reverse of the removal procedure, but take note of the following installation step. 14. Using the hoist, raise the front of the motorcycle until the front tire is slightly off the floor.

  • Page 206: Rear Wheel

    Wheels Rear Wheel Rear Wheel Tools Required (includes tools required for parent jobs): • T25 • T40 • T45 • 27mm socket and ratchet • 13mm wrench • Motorcycle stand 4. Place rag over rear caliper to protect painted surfaces. New Fasteners Required: •...
  • Page 207 Wheels 8. Place rag over the left side of the swingarm 12. Tip the top of the rear tire to the left. between the rear sprocket and the swing arm to protect painted surfaces. 9. Roll rear tire forward. 13. Slide rear caliper assembly toward wheel and slide caliper bracket off of the bracket alignment pin.
  • Page 208 Wheels 16. Remove plastic bushing from left side 2. On the sprocket-side of the rear wheel, inspect (sprocket side) of the wheel. the condition of the inner (#1) and outer (#2) bearings and the seal (#3). Replace if necessary. Note: The bearings and seal are one-time use parts.
  • Page 209 Wheels 4. Install bolts (x5) securing the brake rotor to the rear wheel. Tool: T40. Torque (in sequence shown): 20 lb-ft (27 Nm). 5. Install bolts (x5) securing the rear sprocket to the rear wheel. Tool: T40. Torque (in sequence shown): 26 lb-ft (35 Nm). 6.

  • Page 211: Body Trim

    Body Trim Rider’s Seat Body Tools Required (includes tools required for parent jobs): • T30 Removal 1. Insert the key into the lock and turn it clockwise to release the passenger seat. 2. Remove bolt securing the rider’s seat. Tool: T30.

  • Page 212: Headlight Upper Fairing

    Body Headlight Upper Fairing Body Tools Required (includes tools required for parent jobs): • T25 Removal 1. PERFORM LOCKOUT PROCEDURE: See Lockout Procedure, page 10.1. 4. Remove short bolts (x2) securing bottom of headlight upper fairing to the headlight inner fairing.

  • Page 213: Headlight Inner Fairing

    Body Headlight Inner Fairing Tools Required (includes tools required for parent jobs): • T25 • T30 • 2mm hex wrench • 3/16” standard screwdriver • 10mm socket and ratchet 3. Unbolt the negative battery terminal eyelet. New Fasteners Required: Cover eyelet with insulating material. Use •...
  • Page 214 Body 6. For the rest of this procedure, there will be 9. Remove short bolt securing dash center cover references to shouldered-bolts securing body to the hela bracket. Tool: T25. Torque: 3 lb-ft panels, that are 2 different lengths. (4 Nm). Short bolts: designated on photos with orange arrows, used to attach a single body panel layer.
  • Page 215 Body 13. Remove headlight inner fairing. Note: Take note of the wire wiring harness routing prior to removing the headlight inner fairing to assist during the installation process. Note: The headlight inner fairing is an interference fit, take care during removal to prevent damage.

  • Page 216: Hela Bracket

    Body Hela Bracket Tools Required (includes tools required for parent jobs): • T25 • T30 • 2mm hex wrench • 3/16” standard screwdriver • 10mm socket and ratchet 3. Unbolt the negative battery terminal eyelet. New Fasteners Required: Cover eyelet with insulating material. Use •...
  • Page 217 Body 6. Remove headlight inner fairing. See Headlight 9. Cut cable tie securing the front turn signal Inner Fairing, page 60.3. electrical harnesses to hela bracket. Note: Replace cable tie during the installation process. 7. Cut cable tie securing the mode switch electrical harness to hela bracket.
  • Page 218 Body 12. Cut cable tie securing the throttle electrical 15. Disconnect the headlight switch electrical harness connector to the motor stop switch harness connector. electrical connector. Note: Replace cable tie during the installation process. 16. Disconnect the mode switch electrical harness connector.
  • Page 219 Body 18. Remove bolts (x2) securing the right side of the hela bracket to the frame head tube. Tool: T30. Torque: 8 lb-ft (11 Nm). 19. Remove hela bracket. Installation 1. Installation is the reverse of the removal procedure. Body 60-9...

  • Page 220: Tank Removal

    Body Tank Removal NOTICE: Before carrying out any work on the electrical system, remove the key from the key switch. Tools Required (includes tools required for parent jobs): • T25 • T30 • 2mm hex wrench 3. Unbolt the negative battery terminal eyelet. •...
  • Page 221 Body 5. Remove headlight upper fairing. See 11. Remove the left panel retainer. Headlight Upper Fairing, page 60.2. 6. Remove left and right outer side fairings. See Side Fairings (Outer), page 60.14. 12. Push the center of the panel retainer (securing the right inner fairing arm to the headlight inner fairing) inward to release it.
  • Page 222 Body 16. Push charger port rubber boot down around 2. Slightly spread the outer fairing arms charger port base. around the headlight during installation to keep from damaging painted surfaces. 17. Slightly spread the outer fairing arms around the headlight during removal to 3.
  • Page 223 Body 5. While installing the left turn signal harness, 8. After connecting the right front turn signal insert it through the cable tie attached to the harness, cinch the cable tie securing the left outer fairing arm. harness to the right outer fairing arm. 6.

  • Page 224: Side Fairings (Outer)

    Body Side Fairings (Outer) NOTICE: Before carrying out any work on the electrical system, remove the key from the key switch. Tools Required (includes tools required for parent jobs): • T25 • T30 • 2mm hex wrench 3. Unbolt the negative battery terminal eyelet. •...
  • Page 225 Body 6. Cut cable tie securing right front turn signal 8. Disconnect right front turn signal harness electrical harness to the right outer fairing arm. connectors. Note: Replace cable tie during the installation Note: Take note of the wire insulation colors. process.
  • Page 226 Body 10. Remove long bolts (x2) securing bottom of 13. While removing right outer side fairing, guide right outer side fairing to bodywork. Tool: T25. the right front turn signal harness wires Torque: 3 lb-ft (4 Nm). through their access hole in the right inner side fairing.
  • Page 227 Body 16. While removing left outer side fairing, guide 3. Prior to installing the right outer side fairing, the left front turn signal harness wires through install cable tie through the right outer fairing their access hole in the left inner side fairing. arm cable retainer hole.
  • Page 228 Body 6. After connecting the left front turn signal harness, cinch the cable tie securing the harness to the left outer fairing arm. 7. After connecting the right front turn signal harness, cinch the cable tie securing the harness to the right outer fairing arm. 60-18 Body...

  • Page 229: Side Fairings (Inner)

    Body Side Fairings (Inner) NOTICE: Before carrying out any work on the electrical system, remove the key from the key switch. Tools Required (includes tools required for parent jobs): • T25 • T30 • 2mm hex wrench 3. Unbolt the negative battery terminal eyelet. •...
  • Page 230 Body Long bolts: designated on photos with blue arrows, used to attach 2 layers of body panels. Note: Non-shouldered body bolts designated with green arrows are present in this procedure. 10. Remove bolts (x2) securing the lower half of the left inner side fairing to the motorcycle frame.
  • Page 231 Body 13. Remove the right inner side fairing. 14. Remove long bolt (x1[blue arrow]) and short bolts (x2[orange arrows]) securing the upper half of the left inner side fairing to the motorcycle frame and bodywork. Tool: T25. Torque: 3 lb-ft (4 Nm). Note: Take note of length of the bolts.

  • Page 232: Tank (Disassembly And Reassembly)

    Body Tank (Disassembly and Reassembly) NOTICE: Before carrying out any work on the electrical system, remove the key from the key switch. Tools Required (includes tools required for parent jobs): • #2 Phillips screwdriver • T30 Disassemble 4. Release the lock cable end from the tank 1.
  • Page 233 Body 7. For this procedure, there will be references to 9. Remove large screws (x5) securing the right screws securing body panels, that are 2 knee grip to the tank collar. Tool: #2 Phillips different sized screws. screwdriver. Torque: Hand tighten - Do not over-tighten.
  • Page 234 Body 12. Remove small screws (x11) securing the tank 15. To remove the left tank lid hinge pin, press rear to the tank collar. Tool: #2 Phillips locking pin (arrow #1) while pressing hinge pin screwdriver. Torque: Hand tighten - Do not (arrow #2) out of tank collar.
  • Page 235 Body 17. To remove the left charge inlet lid hinge pin, 20. Release locking tabs securing the right fairing press locking pin (arrow #1) while pressing arm inner to the right fairing arm outer. hinge pin (arrow #2) out of tank collar. Assemble 18.
  • Page 236 Body 3. Place the tank collar on a bench, upside down 5. Apply pressure to the left tank lid spring (arrow so the tank lid can be open (as shown) during #1) while pressing hinge pin (arrow #2) installation of the tank lid hinge pins and through hole in tank collar.

  • Page 237: For This Procedure, There Will Be References To Screws Securing Body Panels, That Are

    Body 7. Apply pressure to the right tank lid spring 9. While installing the charge inlet lid, place (arrow #1) while pressing hinge pin (arrow #2) washer (arrow #1) between the charge inlet lid through hole in tank collar. hinge and the tank collar, while pressing hinge pin (arrow #2) through hole in tank collar.

  • Page 238: Screwdriver. Torque: Hand Tighten - Do Not

    Body 11. Install small screws (x11) securing the tank 14. Install clip-on U-nut onto left outer fairing arm. rear to the tank collar. Tool: #2 Phillips screwdriver. Torque: Hand tighten - Do not over-tighten. 15. Install clip-on U-nut onto right outer fairing arm.
  • Page 239 Body 17. Insert locking tabs securing the right inner 20. While assembling the left outer fairing arm, fairing arm to the right outer fairing arm. confirm the alignment tab of the fairing outer arm fits under the edge of the tank rear. 18.
  • Page 240 Body 23. Install small screws (x7) securing the right 26. Release the cable end from the tank lock fairing arm inner and right fairing arm outer to bracket. the tank collar. Tool: #2 Phillips screwdriver. Torque: Hand tighten - Do not over-tighten. 27.
  • Page 241 Body 29. Release the lock cable end from the tank collar cable bracket. 30. Release the plastic cable retainer from the tank lock latch mechanism. Body 60-31...

  • Page 242: Grab Handles (Right And Left)

    Body Grab Handles (Right and Left) Tools Required (includes tools required for parent jobs): • T25 • T30 • 10mm socket and ratchet Removal 1. PERFORM LOCKOUT PROCEDURE:See Lockout Procedure, page 10.1. 4. Remove bolts (x4) securing rear of seat tray to tail frame assembly.
  • Page 243 Body 9. Remove right grab handle. Installation 1. Installation is the reverse of the removal procedure. Body 60-33...

  • Page 244: Tank Storage Liner

    Body Tank Storage Liner CAUTION: Always perform the High Voltage Discharging procedure prior to servicing any High Voltage component or connection. Proper procedures must be followed! To protect electrical components, perform the following tasks in the order given. Do not deviate from the repair procedure processes.
  • Page 245 Body 5. Remove bolts (x4) securing MBB to the tank 8. Remove bolts (x2) securing USB power hub to storage liner and collect washers (x4). tank storage liner. Tool: T20. Torque: 2 lb-ft Tool: 6mm hex (2.7 Nm). CAUTION: Replace vibration-resistant rubber isolator nuts if they are damaged or worn.

  • Page 246: Tail

    Body Tail Assembly 6. Disconnect battery signal harness connector. Tail CAUTION: Always perform the High Voltage Discharging procedure prior to servicing any High Voltage component or connection. Proper procedures must be followed! To protect electrical components, perform the following tasks in the order given. Do not deviate from the repair procedure processes.
  • Page 247 Body 11. Slide fuse box/panel back and off its mounts, 14. Release brake line/WSS wire from clip on tail then down to remove from frame. frame. NOTE: Fuse box will come out with (+) battery lead.Remove bolts (x3) securing frame cover to frame.
  • Page 248 Body 17. Support tail frame and remove T40 bolt securing tail to bike main frame. Torque 20 lb-ft (27 Nm). 18. Remove tail structure. Installation 1. Installation is the reverse of removal procedure. 60-38 Tail...

  • Page 249: Electrical

    Electrical High Voltage Fuses High Voltage Fuses Electrical NOTICE: Before carrying out any work on the electrical system, remove the key from the key switch. Tools Required (includes tools required for parent jobs): • 3/16” standard screwdriver • 2mm hex wrench Removal 3.
  • Page 250 Electrical 6. Remove high voltage contactor fuse. Installation 1. Installation is the reverse of the removal procedure. 70-2 High Voltage Fuses...

  • Page 251: 12 Volt Battery

    Electrical 12 Volt Battery (Disconnect) 12 Volt Battery NOTICE: Before carrying out any work on the electrical system, remove the key from the key switch. Tools Required (includes tools required for parent jobs): • T25 • 2mm hex wrench • 3/16” standard screwdriver 5.
  • Page 252 Electrical 8. Remove high voltage contactor fuse. 11. Cover negative battery terminal eyelet with insulating material. Cover/protect battery terminal CAUTION: eyelet to reduce the risk of accidentally contacting the negative battery terminal, which can inadvertently power up the 12 volt system and damage components. 9.
  • Page 253 Electrical 12 Volt Battery (Removal) NOTICE: Before carrying out any work on the electrical system, remove the key from the key switch. Tools Required (includes tools required for parent jobs): • T25 • T30 • 2mm hex wrench 5. Insert screwdriver into fuse cap, push inward, •...
  • Page 254 Electrical 8. Remove high voltage contactor fuse. 11. Cover negative battery terminal eyelet with insulating material. Cover/protect battery terminal CAUTION: eyelet to reduce the risk of accidentally contacting the negative battery terminal, which can inadvertently power up the 12 volt system and damage components. 9.
  • Page 255 Electrical 13. Disconnect the battery heater harness connector. 14. Unhook the battery retaining strap. 15. Remove the battery from the frame. Installation 1. Installation is the reverse of the removal procedure. 12 Volt Battery 70-7...

  • Page 256: Lighting

    Electrical Headlight Lighting Removal 1. PERFORM LOCKOUT PROCEDURE: See Lockout Procedure, page 10.1. CAUTION: Always perform the High Voltage Discharging procedure prior to servicing any High Voltage component or connection. Proper procedures must be followed! To protect electrical components, perform the following tasks in the order given.
  • Page 257 Electrical 6. Remove left and right inner side fairings. See Side Fairings (Inner), page 60.19. 7. Remove tank assembly. See Tank Removal, page 60.10. 8. Remove headlight inner fairing. See Headlight Inner Fairing, page 60.3. 12. Remove bolts (x2) securing right side of the headlight to the hela bracket.

  • Page 258: Tail Light

    Electrical Tail Light 5. Remove seat tray. NOTICE: Before carrying out any work on the electrical system, remove the key from the key switch. Tools Required (includes tools required for parent jobs): • T25 • T30 • 10mm socket and ratchet Removal 6.

  • Page 259: Turn Signal (Left Front)

    Electrical Turn Signal (Left Front) Removal 1. PERFORM LOCKOUT PROCEDURE: See Lockout Procedure, page 10.1. CAUTION: Always perform the High Voltage Discharging procedure prior to servicing any High Voltage component or connection. Proper procedures must be followed! To protect electrical components, perform the following tasks in the order given.

  • Page 260: Turn Signal (Right Front)

    Electrical Turn Signal (Right Front) CAUTION: Always perform the High Voltage Discharging procedure prior to servicing any High Voltage component or connection. Proper procedures must be followed! To protect electrical components, perform the following tasks in the order given. Do not deviate from the repair procedure processes.
  • Page 261 Electrical Removal 1. PERFORM LOCKOUT PROCEDURE: See Lockout Procedure, page 10.1. 5. Cut cable tie securing right front turn signal electrical harness to hela bracket. Note: Replace cable tie during the installation process. 2. Remove high voltage DCDC and CONT fuses. High Voltage Fuses, page 70.1.
  • Page 262 Electrical 7. For the rest of this procedure, there will be 9. Remove long bolts (x2[blue arrows]) and references to shouldered-bolts securing body short bolts (x2[orange arrows]) securing the panels, that are 2 different lengths. leading edge of the right outer side fairing to bodywork.
  • Page 263 Electrical 12. Remove nut securing right front turn signal to the right outer side fairing and collect star washer. Tool: 17mm wrench. Torque: 8 lb-ft (11 Nm). 13. Remove right front turn signal. Installation 1. Installation is the reverse of the removal procedure.

  • Page 264: Turn Signal (Rear)

    Electrical Turn Signal (Rear) NOTICE: Before carrying out any work on the electrical system, remove the key from the key switch. Tools Required (includes tools required for parent jobs): • T25 • T30 • 17mm combination wrench 3. Unbolt the negative battery terminal eyelet. •...
  • Page 265 Electrical Left turn signal wire colors: black and white. 7. Move rear lighting harness to the right, from under tail frame to gain access to the harness 10. Disconnect right rear turn signal harness connectors. connectors. Note: Take note of the wire insulation colors. The turn signal wire colors match the colors of the main wire harness.
  • Page 266 Electrical 16. Remove left rear turn signal. 17. Remove nut securing the right rear turn signal. Tool: 17mm wrench. Torque: 8 lb-ft (11 Nm). 18. Remove nut from right rear turn signal harness and collect star washer. 19. Remove right rear turn signal. Installation 1.

  • Page 267: Dash

    Electrical Dash Instruments WARNING! For your safety against electric shock and to protect electrical components, perform the following tasks: • Remove Low Power B+ (CONT) high voltage fuse. • Remove DC/DC high voltage fuse. • Disconnect the negative lead from the 12 volt battery.
  • Page 268 Electrical 6. Remove dash display. Installation 1. Installation is the reverse of the removal procedure. Note: Replacement dash panel from Zero Motorcycles will come preloaded with the correct firmware. 70-20 Instruments...

  • Page 269: Key Switch

    Electrical Key Switch Key Switch WARNING! For your safety against electric shock and to protect electrical components, perform the following tasks: • Remove Low Power B+ (CONT) high voltage fuse. • Remove DC/DC high voltage fuse. • Disconnect the negative lead from the 12 volt battery.
  • Page 270 Electrical 8. Unclip harness retaining clip. 11. Remove bolts (x2) securing key switch to the motorcycle frame. Note: Use a bolt extractor to extract the breakaway bolts. Note: Replace break away bolts (x2) during the installation process. 12. Remove key switch. Installation 1.

  • Page 271: Mode Switch

    Electrical Mode Switch (Without Heated Grips) Mode Switch Removal CAUTION: Always perform the High Voltage Discharging procedure prior to servicing any High Voltage component or connection. Proper procedures must be followed! To protect electrical components, perform the following tasks in the order given. Do not deviate from the repair procedure processes.

  • Page 272: Mode Switch (With Heated Grips)

    Electrical 6. Remove headlight inner fairing. See Headlight Inner Fairing, page 60.3. 10. Cut cable tie securing mode switch harness to the left side of the handlebar. 7. Cut cable tie securing the mode switch Note: Replace cable tie during the installation electrical harness to hela bracket.
  • Page 273 Electrical Installation 1. Installation is the reverse of the removal procedure. Mode Switch 70-25...
  • Page 274 Electrical Mode Switch (With Heated Grips) Removal CAUTION: Always perform the High Voltage Discharging procedure prior to servicing any High Voltage component or connection. Proper procedures must be followed! To protect electrical components, perform the following tasks in the order given. Do not deviate from the repair procedure processes.
  • Page 275 Electrical 6. Remove headlight inner fairing. See Headlight Inner Fairing, page 60.3. 7. Remove storage liner. See Tank Storage Liner, page 60.34. 11. Cut cable tie securing mode switch harness to the left side of the handlebar. Note: Replace cable tie during the installation process.
  • Page 276 Electrical 14. Remove mode switch assembly from the handlebar. Note: Confirm mode switch shim is in place upon installation. Installation 1. Installation is the reverse of the removal procedure. 70-28 Mode Switch...

  • Page 277: Heated Grip

    Electrical Heated Grips (Left) Heated Grip Removal CAUTION: Always perform the High Voltage Discharging procedure prior to servicing any High Voltage component or connection. Proper procedures must be followed! To protect electrical components, perform the following tasks in the order given. Do not deviate from the repair procedure processes.
  • Page 278 Electrical 6. Remove tank assembly. See Tank Removal, page 60.10. 7. Remove headlight inner fairing. See Headlight Inner Fairing, page 60.3. 8. Remove storage liner. See Tank Storage Liner, page 60.34. 11. Disconnect the mode switch harness connector. 9. Cut cable tie securing the mode switch electrical harness to hela bracket.
  • Page 279 Electrical Note: Position front suspension straight forward to allow access for removing front closeout panel downward in front of power pack. 18. Cut cable tie securing mode switch harness to the left side of the handlebar. Note: Replace cable tie during the installation process.
  • Page 280 Electrical 21. Remove second bolt securing the left heated grip to the handlebar. Tool: #2 Phillips screwdriver. 22. Remove left heated grip to the handlebar. Installation 1. Installation is the reverse of the removal procedure. 70-32 Heated Grip...

  • Page 281: Kickstand Switch

    Electrical Kickstand Switch Kickstand Switch Tools Required (includes tools required for parent jobs): • T25 • T30 • T40 • T50 • 3/16” standard screwdriver • 2mm hex wrench 2. Unbolt the negative battery terminal eyelet. Cover eyelet with insulating material. Use •...
  • Page 282 Electrical 4. DO NOT LIFT THE MOTORCYLE BY 7. Release harness anchor clip from the frame. JACKING UP THE CONTROLLER! DO NOT SUPPORT THE WEIGHT OF THE MOTORCYCLE BY SUPPORTING THE CONTROLLER! Doing so, will damage the controller and other components. 8.
  • Page 283 Electrical 10. Disconnect kickstand harness connector. 14. Remove bolts (x2) securing the brake stand switch. Tool: 2.5mm hex wrench. Torque: 2 lb-ft (3 Nm). Installation 1. Installation is the reverse of the removal procedure. 11. Cut cable tie securing the kickstand harness to the left doubler plate.

  • Page 284: Cellular Connectivity Module (Ccm)

    Electrical Cellular Connectivity Module (CCM) Cellular Connectivity Module (CCM) CAUTION: Always perform the High Voltage Discharging procedure prior to servicing any High Voltage component or connection. Proper procedures must be followed! To protect electrical components, perform the following tasks in the order given. Do not deviate from the repair procedure processes.
  • Page 285 Electrical 7. Roll the CCM rubber cap down and remove it. 2. Insert the CCM harness connector. 8. Roll the CCM rubber harness cover upward to 3. Roll the CCM rubber harness cover down over reveal the harness connector. the CCM as far as it will go. Note: The satellite logo on the CCM is the side that needs to be facing up when installed on the motorcycle.
  • Page 286 10. Once the CCM is physically installed, you must email Zero Motorcycles Customer Service department to complete the installation procedure and activate the module. Zero Motorcycles will need the VIN of the motorcycle and additional information to complete the installation. • North America: 6.

  • Page 287: Main Bike Board (Mbb)

    Electrical Main Bike Board (MBB) Main Bike Board (MBB) CAUTION: Always perform the High Voltage Discharging procedure prior to servicing any High Voltage component or connection. Proper procedures must be followed! To protect electrical components, perform the following tasks in the order given. Do not deviate from the repair procedure processes.
  • Page 288 Electrical 7. Remove bolts (x4) securing MBB to the tank storage liner and collect washers (x4). Tool: 6mm hex CAUTION: Replace vibration-resistant rubber isolator nuts if they are damaged or worn. Note: Do not over-tighten bolts. 8. Remove MBB. Installation 1.
  • Page 289 Electrical Main Bike Board (MBB) 70-41...

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