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Zero Motorcycles Zero S Series 2014 Owner's Manual

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2014 OWNER'S MANUAL
ZERO S
™
ZERO SR
™
ZERO DS
™

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Summary of Contents for Zero Motorcycles Zero S Series 2014

  • Page 1 2014 OWNER’S MANUAL ZERO S ™ ZERO SR ™ ZERO DS ™...

  • Page 3: Table Of Contents

    Introduction ........... 1.1 Location of Important Labels ........2.3 Location of Important Labels ........2.3 Introduction..............1.1 An Important Message To You From Zero Motorcycles Controls and Components ......3.1 Controls and Components.......... 3.1 About This Manual ............ 1.1 Motorcycle Controls ..........3.2 Useful Information For Safe Riding ......
  • Page 4 How Do You Obtain Service Under This Limited Cleaning..............5.21 Warranty? ..............7.6 Parking and Long Term Storage......5.22 Transfer Of Ownership And Warranty....... 7.6 Zero Motorcycles Accessories .........5.22 Customer Information ..........7.7 Fuses ...............5.22 Customer Assistance ..........7.7 Service Record ............5.25 Reporting Safety Defects ..........

  • Page 5: Introduction

    Zero S/SR/DS electric motorcycle; we welcome you to the  Zero S: Street community of Zero Motorcycles riders. This manual is designed to provide you with a better understanding of the  Integrated Z-Force™ Power Pack and Charger operation, inspection, and basic maintenance ...

  • Page 6: Useful Information For Safe Riding

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

  • Page 7: 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 8: Power Pack Serial Number

    Identification Numbers Power Pack Serial Number Vehicle Identification Number (VIN) The Power Pack serial number is located on the upper The VIN is a 17-digit number stamped on the head tube of front left of the power pack. the frame. Do not alter or remove this number as it is the legal identifier for your motorcycle.
  • Page 9 Identification Numbers VIN Break Down The following breakdown of the VIN will help you understand the significance of each digit or character in case you need to reference it when contacting Zero or ordering parts.

  • Page 10: General Information

    General Information Technical Specifications General Information  ZF8.5 3.6 hours (100% charged) /  Supplemental Charger Quick Charge Time 3.1 hours (95% charged) Zero S (accessory)  ZF11.4 4.6 hours (100% charged) /  The Zero S specifications below apply to both the S ZF8.5 4.1 hours (95% charged) and ZF11.4 models (unless otherwise specified).
  • Page 11 General Information DRIVETRAIN DIMENSION Transmission Clutchless Direct Drive Wheel Base 55.5 in (1,410 mm) Final Drive 132T/28T,Poly Chain® GT® 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 6.35 in (161 mm) WEIGHT...
  • Page 12 General Information Zero SR CHAdeMO Recharge 1.5 hours Time (0 to 100%) MOTOR Input Standard 110 V AC or 220 V AC Type Z-Force™ 75-7 passively air-cooled, Charger Type 1.3kW Integrated high-efficiency, radial flux, permanent  ZF11.4: 308,000 miles (496,000 km) hi-temp magnet, brushless motor.
  • Page 13 General Information DRIVETRAIN DIMENSION Transmission Clutchless Direct Drive Wheel Base 55.4 in (1,410 mm) Final Drive 132T/30T,Poly Chain® GT® 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 6.35 in (161 mm) WEIGHT...
  • Page 14 General Information Zero DS CHAdeMO Recharge 1.5 hours Time (0 to 100%) MOTOR Input Standard 110 V AC or 220 V AC Type Z-Force™ 75-7 passively air-cooled, Charger Type 1.3 kW Integrated high-efficiency, radial flux, permanent  ZF8.5 213,000 miles (343,000 km) magnet, brushless motor.
  • Page 15 General Information CHASSIS/SUSPENSION/BRAKES WEIGHT Front Suspension Travel 7 in (178 mm) Frame 22 lbs(10 kg)  ZF8.5 372 lbs (169 kg) Rear Suspension Travel 7.03 in (195 mm) Curb Weight  ZF11.4 404 lbs (183 kg) Nissin 2 piston hydraulic  Front Brakes 313 mm OD rotor, 4.0 mm thick...

  • Page 16: Vehicle Range

    General Information Vehicle Range Reported motorcycle range values are measured using two different types of industry standard test procedures: The range of an electric vehicle is defined as the distance 1. “City (EPA UDDS)”: This test procedure uses a duty the vehicle travels on a single full charge of the power cycle known as the “Universal Dynamometer Driving pack.

  • Page 17: Public Charging Stations

    CHAdeMO charger system. A CHAdeMO charger can  route charge your motorcycle in about one hour. For additional  rider information contact your Zero Motorcycles dealer.  weather  motorcycle By considering each of these factors, you can use specifications such as ‘city range’ as standards to estimate what the motorcycle’s real world range will be under the...
  • Page 18 General Information 1.14...
  • Page 19 General Information 1.15...

  • Page 20: Emissions Information

    General Information Emissions Information The Zero S/SR/DS electric motorcycle is a true freeway capable zero emissions vehicle under California Air Resources Board (CARB), U.S. Federal (EPA), and European Union standards. It uses no gasoline or other liquid fuel. It has no tailpipe and therefore no tailpipe emissions.

  • Page 21: Transporting

    General Information Transporting It is recommended that the motorcycle be tied-down using ratchet straps. Place the ratchet straps around a frame When the front fork is compressed, the built up pressure contact point. Soft straps must be used to prevent must be released to help prevent fork seal leaks.
  • Page 22 Notes 1.18...

  • Page 23: General Safety Precautions

    General Safety Precautions  Prior to each use the rider must check everything in the General Safety Precautions Safety Information General Safety Precautions “every ride” column of the maintenance schedule on  This is a performance motorcycle and should be page 5.2, and the charge level of the power pack as treated with extreme caution.

  • Page 24: Important Operating Information

     Failure to follow power pack storage and charging  Turn the motor stop switch OFF when backing up or instructions as described in this Zero Motorcycles pushing the motorcycle while dismounted. Owner’s Manual may void the warranty of your Zero ...

  • Page 25: Location Of Important Labels

    Location of Important Labels Location of Important Labels Location of Important Labels The vehicle could contain the following information for both North American and European models: A. VECI (Vehicle Emission Control Information) label C. VIN label (North America) - certification label shown B.
  • Page 26 Location of Important Labels Anti-Tamper Control Label (Europe only) The anti-tamper control label (shown below) is located on the left-side of the frame.
  • Page 27 Location of Important Labels High Voltage Warning Label Affixed to battery...
  • Page 28 Notes...

  • Page 29: Controls And Components

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

  • Page 30: Motorcycle Controls

    Controls and Components Motorcycle Controls...
  • Page 31 Controls and Components A. Mirrors G. Front Brake Lever This motorcycle is equipped with convex mirrors. A For description and operation see “Handlebar convex mirror has a curved surface. Convex mirrors Controls”, on page 3-16. offer a greater field of view than a similar flat mirror. H.

  • Page 32: Left Side View

    Controls and Components Left Side View...
  • Page 33 Controls and Components A. Headlight the motorcycle when parked. The key switch should be in the OFF position when parked.  For headlight operation, see “Handlebar Controls”, on G. Kickstand Switch page 3-16. This switch is a safety feature that prevents motor ...

  • Page 34: Right Side View

    Controls and Components Right Side View...
  • Page 35 Controls and Components A. Rear Break Fluid Reservoir See “Rear Brake”, on page 5-11 B. Auxiliary Power Pack Charging Connection For description and operation see “Quick Charging (Off Board Accessory Charger)”, on page 4-10. The auxiliary connector is located above the motor. C.

  • Page 36: Dash Overview

    Controls and Components Dash Overview...
  • Page 37 Controls and Components A. Adjust Button (ADJ) the rider using the performance level mode button located on the right handlebar control assembly. See See “Dash Settings”, on page 3-12. “Performance Level Mode Button”, on page 3-19 B. Select Button (SEL) I.

  • Page 38: Warning Indicator Lights

    Controls and Components Warning Indicator Lights 3.10...
  • Page 39 Controls and Components A. Left Indicator Turn Signal E. Charging Indicator An arrow on the lower dash flashes green Flashes slowly when the motorcycle is in the same direction as selected by the accepting a charge. The indicator flashes turn signal switch. This arrow remains on rapidly when a charging error is detected.

  • Page 40: Dash Settings

    Controls and Components Dash Settings Displays A&B Display A The displays on the dash can be customized to your personal preferences by using the ADJ (Adjust) and SEL To select Display A with the dash in its normal operating (Select) buttons. mode, momentarily press the SEL button once.
  • Page 41 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 42 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 43: Smartphone Application

    Controls and Components Smartphone Application Bluetooth Pairing ® You can download a smartphone application that lets you The following steps must be taken to properly pair a perform the following tasks related to your motorcycle: Bluetooth®-equipped smartphone with your motorcycle. ...

  • Page 44: Handlebar Controls

    Controls and Components Handlebar Controls 3.16...
  • Page 45 Controls and Components A. Flash-to-Pass braking feature activates. Regenerative braking takes some of the energy from the moving motorcycle and When the headlight is in the low beam position, push turns it back into electrical energy. This energy is then the flash-to-pass switch and the high beam illuminates stored back into the power pack, contributing to and stays illuminated until the switch is released.
  • Page 46 Controls and Components E. Motor Stop Switch G. Turn Signal Switch When the top of the switch (A) is pressed, it cuts off When the turn signal switch is pushed in power to the motor controller. The motor controller the left or right position, the corresponding remains in this state until the bottom portion of the front and rear turn signals flash.

  • Page 47: Performance Level Mode Button

    Controls and Components Performance Level Mode Button The SPORT selection causes the motorcycle to accelerate at a significantly faster rate. This position is recommended for advanced riders. The CUSTOM selection has customizable performance settings by using the smartphone application (refer to “Smartphone Application”, on page 3-15).

  • Page 48: Tank Bag

    Controls and Components Tank Bag Your Zero motorcycle makes use of a tank bag for additional storage. You can remove the tank bag by pulling upwards on its sides. Note: Before riding your Zero motorcycle, secure the tank bag with the lock (above the tank bag). At high speeds the bag could eject, if is not secured.

  • Page 49: Power Tank (If Equipped)

    Controls and Components Power Tank (if equipped) If your Zero S/SR/DS motorcycle is equipped with a dealer-installed optional equipment Power Tank in place of the tank bag, the power pack size will be increased from a ZF11.4 to a ZF14.2, which increases charge time and riding range.
  • Page 50 Notes 3.22...

  • Page 51: Starting And Operating

    Starting and Operating First Time Set-Up Starting and Operating Starting and Operating If your motorcycle was direct-shipped you will need to perform the following: 1. Remove the motorcycle from its shipping crate. See Unpacking Your Zero motorcycle on page 4.2. 2.

  • Page 52: Unpacking Your Zero Motorcycle

    Recycling crate base. Your Zero Motorcycles shipping crate and packaging materials were designed to be completely recycled. Please Outer Box Cover cut down and recycle all cardboard, plastic, and wood ...

  • Page 53: General Operation

    General Operation  Tires. Check both tires for condition and tread depth. General Operation General Operation Check cold tire pressure frequently. Check for damage This section describes several items you should examine and alignment. Maintain correct tire pressure as before operation. specified on page 5.13.

  • Page 54: 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. Push the key down from the OFF position and turn the key counter-clockwise while still pushing it in.

  • Page 55: Power Pack

    General Operation Power Pack OFF Position This position is used to turn the motorcycle OFF, disabling The battery is located within the power pack and requires the electrical system. no special break in period. The 2014 Zero S/SR/DS leverages the 2013’s battery cell ON Position chemistry, configuration, and enhanced reliability.
  • Page 56 General Operation The power pack must be charged within 24 hours if fully Add On Electrical Equipment discharged, and charged within 90 days if stored fully WARNING! Do not add electrical components to your charged. Zero recommends you plug in your Zero motorcycle unless approved by an authorized Zero motorcycle after 90 days, even if fully charged.
  • Page 57 General Operation When charging the motorcycle’s power pack, the charger can be left ON, even after the power pack is fully charged. There are two possible cases that can occur:  When connected to the charger, the power pack will receive a full charge.
  • Page 58 General Operation Charging the Power Pack To charge using the standard charger: WARNING! Charge the Zero power pack with the Zero 1. Plug the supplied power cord (A) into the onboard charger. charger connector. Always keep the power cord with the motorcycle.
  • Page 59 General Operation Note: AVOID connecting the Zero charger and another device to a single 120 V AC 15A/20A circuit, as it may become overloaded. Zero chargers draw as much as 12 amps from the 120 V AC circuit when charging. 3.
  • Page 60 General Operation Quick Charging (Off Board Accessory Charger) The “scalable” quick charging feature allows up to three supplemental accessory chargers (in addition to the existing integrated charger) to be connected to the motorcycle. Use of supplemental accessory chargers can reduce the charging time by up to 70%. Note: The time for charging the motorcycle using quick charging will vary with the number of chargers used.
  • Page 61 General Operation To charge using the Quick Charger 120 V AC or 240 V AC current. The voltage does not change the amount of time that the motorcycle takes to 1. Ensure that the key switch is in the OFF position. charge.
  • Page 62 CHAdeMO charger system. A CHAdeMO charger can charged. Charger is now in absorption phase. If the charge your motorcycle in about one hour. For additional indicator is flashing, there are two issues that can information contact your Zero Motorcycles dealer. cause this to occur: 4.12...

  • Page 63: Operating Your Motorcycle

    3. Be sure to charge the power pack after each ride. decreases. Temperature Indicator Braking Zero Motorcycles has developed the most advanced On the right handlebar is the hand operated brake lever. passively air-cooled electric powertrain for your Zero The brake lever controls the front brake when the lever is motorcycle, delivering an unsurpassed level of simplicity, squeezed.
  • Page 64 General Operation a different sustained high power event, such as continued powering through a low traction surface, power will simply be reduced to ensure the continued safe operation of your powertrain. Please note that the lighting of this temperature indicator does not indicate that there’s anything malfunctioning with your Zero motorcycle;...

  • Page 65: Front Suspension Adjustment

    General Operation Front Suspension Adjustment Rebound Damping The rebound damping is adjusted by turning the slotted A shock has two main actions: compression when the brass adjuster screw (B) on the top of both fork legs. Next shock gets loaded, and rebound when the shock returns to the screw are the letters “S-F,”...
  • Page 66 General Operation Compression Damping too slow will pack-up (feel harsh over consecutive bumps) while compression that is set too fast will cause the fork to The compression damping is adjusted by turning a screw bottom out harshly. If the fork is bottoming out, turn the on the bottom of each fork leg.

  • Page 67: Rear Shock Adjustment

    General Operation Rear Shock Adjustment Spring Adjustment Obtaining the correct rear spring preload is critical for proper handling. The spring preload must be set to match the weight of the rider. The spring is preloaded for an 180 lb (82 kg) rider. This puts the rear tire 1/3 of the way through its vertical travel.
  • Page 68 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 pre-load should be adjusted.
  • Page 69 General Operation Spring Pre-load Adjustment Rebound Adjustment The rebound adjuster knob (A) is at the bottom of the 1. Clean any dirt or debris from the threads of the shock shock. It has 8 stages of adjustment. Printed on the knob is near the lock ring (A).
  • Page 70 General Operation Compression Adjustment The compression adjustment knob is at the top of the shock. It has 18 stages of adjustment. The knob has “+” (slower compression) and “-” (faster compression). Turn the adjuster clockwise for slower compression. To speed up compression, turn the adjuster counter-clockwise.
  • Page 71 General Operation Factory Supplied Rear Suspension Settings The following information will allow you to adjust the rear suspension back to the factory settings the motorcycle was originally supplied with. S & SR Models ADJUSTMENT SETTING Rear Shock Compression 16 clicks out from fully closed Rear Shock Rebound 2 clicks out from fully closed Rear Shock Spring Preload...
  • Page 72 Notes 4.22...

  • Page 73: Maintaining Your Motorcycle

    Turn Signal Light Bulb (amber) RY10W (10 watt) motorcycle as detailed in this owner’s manual. Brake/Tail Light Bulb LED (replace the entire unit)  Use only Zero approved parts and Zero Motorcycles Front Running Light Bulb W3W (3 watt) accessories. Brake Fluid DOT 4 ...

  • Page 74: Maintenance Schedule

    Maintaining Your Motorcycle Maintenance Schedule The scheduled maintenance must be performed in accordance with this chart to keep the Zero S/SR/DS motorcycle in top running condition. The initial maintenance is vitally important and must not be neglected. Where time and mileage are listed, follow the interval that occurs first.
  • Page 75 Maintaining Your Motorcycle ITEM ROUTINE EVERY INITIAL INITIAL ODOMETER MILEAGE READING RIDE 600 mi 4K mi 8K mi 12K mi 16K mi 20K mi (1K km) (7K km) (13K km) (19K km) (25K km) (31K km) 1 month 6 months 12 months 18 months 24 months...
  • Page 76 Maintaining Your Motorcycle ITEM ROUTINE EVERY INITIAL INITIAL ODOMETER MILEAGE READING RIDE 600 mi 4K mi 8K mi 12K mi 16K mi 20K mi (1K km) (7K km) (13K km) (19K km) (25K km) (31K km) 1 month 6 months 12 months 18 months 24 months...

  • Page 77: Component Fasteners

    Maintaining Your Motorcycle Component Fasteners Periodically check and tighten the following fasteners on your motorcycle. Torque Table LOCATION ITEM TORQUE NOTES 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...
  • Page 78 Maintaining Your Motorcycle Left Side of Motorcycle Refer to Torque table on page 5.5.
  • Page 79 Maintaining Your Motorcycle Right Side of Motorcycle Refer to Torque table on page 5.5.

  • Page 80: Power Pack

    Power Pack Power Pack Power Pack WARNING! You must leave your motorcycle on the charger if you expect it to sit in storage or unused for over 90 days. The power pack must be charged within 24 hours if fully discharged, and charged within 90 days if stored fully charged.

  • Page 81: General Maintenance

    General Maintenance Brakes Rear Brake Pads General Maintenance An example of the rear brake pads is shown below. This section describes how to inspect the brake fluid level for both the front and rear brakes. Your motorcycle uses specific brake pads for stopping power. Both front and rear pad examples are shown in the following sections.
  • Page 82 General Maintenance Brake Fluid Level Inspection WARNING! Do not spill brake fluid on painted surfaces; the finish could be damaged. Spilling brake fluid on the ABS body plastics will cause them to crack. Clean off any brake fluid spills immediately. Always place a shop towel under the master cylinder reservoir prior to removing cover/cap.
  • Page 83 General Maintenance Rear Brake overfill. Clean any dirt or debris from the cap and reservoir opening (A) before opening the reservoir. The reservoir housing 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 84: Suspension

    General Maintenance Suspension Brake Pad Inspection The brake pads must be inspected when specified in the Front maintenance schedule. See the Maintenance Schedule on  For maintenance, see Maintenance Schedule on page 5.2 for additional information. Visually inspect the page 5.2. brakes by looking at the remaining brake pad material ...

  • Page 85: Wheels And Tires

    General Maintenance Wheels And Tires Tire Inflation Inspect both wheels for the following: CAUTION: Under-inflation is a common cause of tire failure and may result in severe tire cracking, tread  Bent, loose, or missing spokes (DS only) separation, “blowout,” or unexpected loss of motorcycle ...

  • Page 86: Drive Belt

    General Maintenance Drive Belt Checking Drive Belt Tension Proper belt tension is essential for optimum operation of The drive belt provides low maintenance and quiet the drive system. operation with minimal stretch. Keep dirt, grease, oil, and Lack of belt tension can lead to “ratcheting.” The teeth of debris off the belt and sprockets.The drive belt tension the belt slide over the teeth of the rear sprocket.
  • Page 87 General Maintenance Drive Belt Adjustment Procedure Note: Adjust both sides equally. 1. Remove key from the key switch. 2. Loosen the rear axle nut (A). 3. Loosen the (left and right) 13 mm jam nuts (C). 4. Turn the (left and right) 13 mm adjustment bolts (B) 1/4 turn at a time until the belt adjustment is within specification.

  • Page 88: 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 89 General Maintenance Headlight Bulb Replacement To replace the bulb: CAUTION: 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 90 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 91: Turn Signal Light Bulb Replacement

    General Maintenance Turn Signal Light Bulb Replacement Brake/Tail LED 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 92: 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 93: Cleaning

    General Maintenance Cleaning 1. Gently wash your motorcycle with a sponge or a clean soft cloth, mild detergent, and plenty of water. WARNING! 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 94: Parking And Long Term Storage

    A full line of parts, accessories, and apparel can be found checked every 72 hours to ensure that the cells are on the Zero Motorcycles website. balanced and that the power pack is full.  To prolong the life of your power pack you should store Fuses your motorcycle in a cool area.
  • Page 95 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 96 General Maintenance High Voltage Fuse Center The high voltage fuse values are listed below: The high voltage fuse center sits in front of the low voltage FUSE RATING CIRCUITS CONTROLLED fuse center (in a cluster of four fuses). ABC20A Charger ABC4A Main Bike Board/Controller ABC4A...

  • Page 97: Service Record

    Service Record Follow the maintenance schedules on page 5.2. After a scheduled service or routine is performed, record the information Service Record on the chart below. DATE ITEM SERVICE/ROUTINE DESCRIPTION 5.25...
  • Page 98 Notes 5.26...

  • Page 99: Troubleshooting

    If the motorcycle is involved in an accident do not an authorized dealer at your convenience. If there is no touch any high voltage wiring connectors or the components dealer in your area call Zero Motorcycles Customer connected to the wiring. If a motorcycle fire occurs, extinguish Service.

  • Page 100: System Warning Indicator

    Troubleshooting System Warning Indicator If a fault has been detected, count the number of times the red indicator light (A) flashes. Refer to the table starting on the next page for possible causes and solutions to the issue.
  • Page 101 Troubleshooting NUMBER OF RED FLASHES CAUSE SOLUTION Motor stop switch is in the OFF position. Press the Motor Stop Switch Disabled or Kickstand motor stop switch ON button. Kickstand is down. Switch Disabled Raise kickstand. Indicator Always ON Contact Zero or your dealer. Self-Test Failed Unplug charger.
  • Page 102 Troubleshooting NUMBER OF RED FLASHES CAUSE SOLUTION MBB Voltage Error Contact Zero or your dealer. Board may have overheated. Let the motorcycle Board Temperature Warning cool down. Problem with current sensor or Current Sensor Error connection. Contact your dealer. Welded Contactor Contact Zero or your dealer.

  • Page 103: General Troubleshooting

    Troubleshooting General Troubleshooting SYMPTOM POTENTIAL CAUSE POTENTIAL SOLUTION Motorcycle does not turn on Power Pack not charged. Key not properly engaged. Charge Power Pack. Recheck key in ignition, turn OFF/ON Motor stop switch turned OFF. Fault code set. again. Press the motor stop Switch ON button. See Charge Fault Code chart on page 6.7 or see Understanding BMS Flash Code Patterns starting on page 6.7.

  • Page 104: Battery Management System

    Troubleshooting Battery Management System The Battery Management System (BMS) is located inside the power pack and is fitted with a window (A) to provide visual notification about the status of the power pack. There are four LED lamps that will flash: one red and three green lamps.
  • Page 105 Troubleshooting Understanding BMS Flash Code Patterns (Idle Mode) In this mode the key is OFF and the power pack is not being charged (the BMS is only monitoring the battery). 1 RED 2 GREEN 3 GREEN 4 GREEN MEANING SOLUTION ...
  • Page 106 Troubleshooting Understanding BMS Flash Code Patterns (Charge Mode) This mode is with the charging cord plugged into the AC power, and the key in the OFF position. During the Charging process, first all lights will flash. Next, lights 1 through 4 will flash depending on the power pack’s state of charge. 1 RED 2 GREEN 3 GREEN...
  • Page 107 Troubleshooting Understanding BMS Flash Code Patterns (Run Mode) In this mode, the key is in the ON position. 1 RED 2 GREEN 3 GREEN 4 GREEN MEANING SOLUTION  5 sec 1 sec 25% of Power Remaining Charge Soon  ...
  • Page 108 Troubleshooting Power Pack Empty Power Pack Too Hot If the power pack is completely empty, an error-beep The power pack contains internal temperature sensors. If sounds and the BMS disables the throttle. You cannot ride the BMS measures excessive internal temperatures, it the motorcycle until you recharge the power pack.
  • Page 109 Troubleshooting Other Error-Flash Patterns If the BMS in your power pack produces an error code which is not described in Understanding BMS Flash Code Patterns, then the power pack has encountered a serious internal hardware problem and must be repaired or replaced by a dealer.

  • Page 110: 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) permanent impact on its battery pack/cells;...
  • Page 111 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 112: 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 113 Troubleshooting Charger-Disable Interlock When the charger is attached and plugged in to AC power, the BMS communicates with the charger. The BMS can send a signal to the charger requesting that charging terminates immediately. When the charger is disabled, the indicator lights on the charger displays that charging has stopped.
  • Page 114 Notes 6.16...

  • Page 115: Limited Warranty Information

    Warranty and Customer Information Limited Warranty Information Warranty? Zero Motorcycles Inc. ("Zero") warrants that all factory manufactured 2014 Zero S/DS/SR motorcycles are free The duration of this Limited Warranty for 2014 Zero from defects in material and workmanship during the S/DS/SR motorcycles, not including the Power Packs, is a period of this Limited Warranty.

  • Page 116: Who Does This Limited Warranty Cover

    Limited Warranty Information Who Does This Limited Warranty Cover? are operated according to “proper use” and “under normal operating conditions.” For purposes of this exclusion, the This Limited Warranty applies to all original owners who following definitions apply: submit the warranty registration card within the required ...
  • Page 117  Damage, malfunctions, or performance problems requirements described in this Owner's Manual. caused by continued operation of the motorcycle after a  Zero motorcycles and Power Packs used for racing or warning light, gauge reading, or other warning indicates other competitive events;...

  • Page 118: What Other Limitations Or Disclaimers Apply To This Limited Warranty

    The following additional limitations and disclaimers apply state.) to this Limited Warranty:  Zero Motorcycles reserves the right to change or  This Limited Warranty is the only express warranty improve the design of any Zero motorcycle, Power made in connection with the sale of this Zero Pack, or any other Zero parts (collectively, “Zero...

  • Page 119: What Are Your Responsibilities As A Customer

    Limited Warranty Information What Are Your Responsibilities As A What Will Zero Do Under This Limited Customer? Warranty? As the owner of a product covered by this Limited During the duration of this Limited Warranty, an authorized Warranty, it is your responsibility to read and understand Zero dealer will repair or replace (at Zero’s discretion), this Owner's Manual, this Limited Warranty, and all product without charge, any 2014 Zero S/DS/SR motorcycle,...

  • Page 120: How Do You Obtain Service Under This Limited Warranty

    Zero Motorcycle dealer. Please refer to the dealer ownership and warranty form. This must be performed to locator on our website (www.zeromotorcycles.com/locator) allow Zero Motorcycles the ability to contact the new owner for your nearest location. in the unlikely event of a safety related issue. Use the...

  • Page 121: Customer Information

    An owner information chart is provided on page 1-3 to individual problems between you, your dealer, or Zero record this information. Motorcycles Inc. Zero Motorcycles Inc. can be contacted as follows: To contact NHTSA, you may call the Vehicle Safety Hotline toll-free at: Zero Motorcycles Inc.
  • Page 122 Notes...
  • Page 123 Index Accessories ..............5.22 Emissions Information ..........1.16 Brake/Tail Light Bulb Replacement ......5.19 First Time Set-Up............4.1 Brakes ................5.9 Fuses ................5.22 Brake Fluid Level Inspection ........5.10 High Voltage Fuse Center........5.24 Brake Pad Inspection ..........5.12 Braking ..............4.13 General Operation ............4.3 DOT 4 brake fluid ............5.11 Key Switch/Steering Lock Positions......4.4 Front Brake .............5.10 Pre-Ride Inspection...........4.3...
  • Page 124 Index Serial Number ............1.4 Pre-Ride Inspection ............4.3 Keys Public Charging Stations ..........1.13 Replacement Code Number ........1.4 Quick Charging............4.10 Location Of Important Labels ........2.3 Reporting safety defects..........7.7 Maintenance Schedule..........5.2 Maximizing Range............1.13 Motor Serial Number ............. 1.4 Safe Riding Information ..........
  • Page 125 Index Suspension settings Front (Factory) ............4.16 Warning Lights............. 3.8 3.10 Rear (Factory) ............4.21 Warranty Coverage..............7.1 Exclusions ..............7.2 Technical Specifications Transfer Of Ownership And Warranty .......7.6 Zero DS Technical Specifications ....1.8 1.10 Wheels And Tires ............5.13 Zero S Technical Specifications........1.6 Tire Inflation..............5.13 Transporting ..............1.17 Troubleshooting Battery Management System (BMS)......
  • Page 126 Notes INDEX.4...
  • Page 127 First Responder Information - High Voltage Components Locations...
  • Page 128 TAKE CHARGE ™ WWW.ZEROMOTORCYCLES.COM...

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