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Zero S 2013 Owner's Manual

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2013 OWNER'S MANUAL
ZERO S
™
ZERO DS
™

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Summary of Contents for Zero S 2013

  • Page 1 2013 OWNER’S MANUAL ZERO S ™ ZERO DS ™...

  • Page 3: Table Of Contents

    Table Of Contents Introduction ........... 1.1 Controls and Components ......3.1 Introduction..............1.1 Controls and Components.......... 3.1 An Important Message To You From Zero Motorcycle Controls ..........3.2 Motorcycles ............... 1.1 Left Side View ............3.4 About This Manual ............ 1.1 Right Side View............
  • Page 4 General Maintenance ..........5.10 Brakes..............5.10 Warranty and Customer Information... 7.1 Suspension ..............5.13 Warranty Information ..........7.1 Wheels And Tires.............5.14 Zero Motorcycles Warranties ........7.1 Tire Inflation .............5.14 Standard Warranty............ 7.1 Drive Belt ..............5.15 Standard Warranty Exclusions........7.1 Drive Chain (Optional) ..........5.17 Disclaimers Applicable to Standard Warranty...

  • Page 5: Introduction

     Dual Sport Tires When it comes time to sell your Zero S/DS, please  Belt Drive remember to hand over this manual; it is, by law, an ...

  • 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. Dealer Information Motorcycle Information Name Address Model Power Pack Serial Number Telephone No. Motor Serial Number E-mail Key Code Date of Purchase...

  • Page 8: Key Code 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 VIN Break Down The following breakdown of the VIN will help understand the significance of each digit or character in case you need to reference it when contacting Zero or ordering parts. World Manufacturer Identifier 538 = Zero Motorcycles Inc.

  • Page 10: General Information

    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). CHAdeMO Recharge 1.0 hour...
  • Page 11 General Information DRIVETRAIN DIMENSION Transmission Clutchless Direct Drive Wheel Base 55.4 in (1,406 mm) Final Drive 132T/28T,Poly Chain® GT® Carbon™ belt Seat Height 31.3 in (794 mm) CHASSIS/SUSPENSION/BRAKES Rake 23.8 degrees Front Suspension Travel 5.51 in (140 mm) Trail 3.2 in (82 mm) Rear Suspension Travel 5.85 in (149 mm) WEIGHT...
  • Page 12 General Information Zero DS CHAdeMO Recharge 1.0 hour Time (0 to 95%) MOTOR CHAdeMO Recharge 1.5 hours Type Z-Force™ 75-7 passively air-cooled, Time (0 to 100%) high-efficiency, radial flux, permanent Input Standard 110 V AC or 220 V AC magnet, brushless motor.
  • Page 13 General Information CHASSIS/SUSPENSION/BRAKES WEIGHT Front Suspension Travel 7 in (178 mm) Frame 19.5 lbs(8.8 kg)  ZF8.5 363 lbs(165 kg) Rear Suspension Travel 7.69 in (195 mm) Curb Weight  ZF11.4 395 lbs(179 kg) Front Brakes Nissin 2 piston hydraulic 313 mm OD rotor, 4.0 mm thick ...

  • Page 14: Vehicle Range

    Environmental Protection Agency (EPA) in order to reflection of your riding habits. The more conservative you simulate city-type riding. ride the better range you can expect from your Zero S/DS motorcycle. 2. “Highway”: This test procedure uses two separate constant speeds of 55 mph and 70 mph to simulate Some of the factors which affect range include speed, highway riding.

  • Page 15: Public Charging Stations

    How to Predict the Range CHAdeMO Charger To generally predict how an electric motorcycle’s range will Your Zero motorcycle can utilize a quick charging be affected, you can use the four factors: CHAdeMO charger system. A CHAdeMO charger can  route charge your motorcycle in about one hour.
  • Page 16 General Information RANGE LOW SPEED HIGH SPEED FEWER STOPS STOP & GO FLAT ELEVATION CHANGES SMOOTH PAVEMENT SOFT GRAVEL MODULATED RIDING AGGRESSIVE RIDING STREAMLINED FULLY UPRIGHT REDUCED CARGO HEAVIER ZOM0156 1.12...
  • Page 17 General Information RANGE WARM WEATHER COLD WEATHER NO WINDS HIGH HEAD WINDS DRY ROADS SLIPPERY ROADS INFLATED TIRES UNDERINFLATED TIRES LUBED CHAIN DRY CHAIN ADJUSTED CHAIN STRETCHED CHAIN BALANCED PACK UNBALANCED PACK ZOM0157 1.13...

  • Page 18: Emissions Information

    WARNING! Please use only Zero approved parts and accessories for your Zero motorcycle. Parts and accessories for your Zero motorcycle have been checked and tested for safety and suitability. Zero is unable to accept any liability whatsoever for parts and accessories which have not been approved...

  • Page 19: Transporting

    General Information Transporting It is recommended that the motorcycle be tied-down using ratchet straps. 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 20 Notes 1.16...

  • Page 21: General Safety Precautions

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

  • Page 22: Important Operating Information

     The power pack should be plugged in when storing the motorcycle for extended periods of time.  Keep your Zero connected to the charger when your motorcycle is sitting in storage or if it will be sitting unused for more than 30 days.

  • Page 23: 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: ZOM0105 A. VIN label (European Union) - certification label C. VIN label (North America) - certification label shown B.
  • Page 24 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 25 Location of Important Labels High Voltage Warning Label Affixed to battery...
  • Page 26 Notes...

  • Page 27: Controls And Components

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

  • Page 28: Motorcycle Controls

    Controls and Components Motorcycle Controls ZOM0102...
  • Page 29 Controls and Components A. Mirrors H. Motor Stop Switch 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 3-12. offer a greater field of view than a similar flat mirror. I.

  • Page 30: Left Side View

    Controls and Components Left Side View...
  • Page 31 Controls and Components A. Headlight G. Kickstand Switch This switch is a safety feature that prevents motor  For headlight operation, see “Handlebar Controls”, on operation when the kickstand is down. If the kickstand page 3-12. were down when riding it could contact the ground ...

  • Page 32: Right Side View

    Controls and Components Right Side View ZOM0155...
  • Page 33 Controls and Components A. Rear Break Fluid Reservoir See “Rear Brake”, on page 5-12 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 34: Instrument Panel

    Controls and Components Instrument Panel ZOM0152...
  • Page 35 (km/h) or miles per hour (mph). J. Adjust Button The analog display portion provides the tachometer By pressing the adjust button you can toggle between (large dial) information. the trip odometer settings. Holding it down will clear the trip odometer resetting it back to zero.
  • Page 36 Controls and Components K. Select Button By pressing the select button you can change the display units that appear on the instrument panel between English or Metric. L. Charging Indicator Flashes slowly when the motorcycle is accepting a charge. The indicator flashes rapidly when a charging error is detected.

  • Page 37: Performance Level Switch

    Controls and Components Performance Level Switch The SPORT position causes the motorcycle to accelerate at a significantly faster rate. This position is recommended for advanced riders. Those who take advantage of the ECO position are likely to see a slight increase in range and experience greater regenerative braking.

  • Page 38: Handlebar Controls

    Controls and Components Handlebar Controls 3.12...
  • Page 39 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 40 Controls and Components E. Motor Stop Switch G. Horn Button When the switch (A) is pressed, it cuts off power to the When the key is in the ON position, the horn sounds motor controller. The motor controller remains in this when the button is pressed.

  • Page 41: Tank Bag

    Controls and Components Tank Bag Smartphone Application Your Zero motorcycle makes use of a tank bag for You can download a smartphone application that lets you additional storage. You can remove the tank bag by pulling perform the following tasks related to your motorcycle: upwards on its sides.
  • Page 42 Notes 3.16...

  • Page 43: Starting And Operating

    1. Remove the motorcycle from its shipping crate. See Unpacking Your Zero motorcycle on page 4.2. 2. Your Zero Motorcycle is shipped fully charged from the factory. If necessary, see “Power Pack”, on page 4.5. 3. Identify and inspect wheels for spoke tension and/ or damage (DS only).

  • Page 44: Unpacking Your Zero Motorcycle

     Carefully lift front wheel out of crate base. Unpacking Your Zero Motorcycle  Deploy kickstand, lean motorcycle and inspect in Although unpacking your Zero motorcycle can be done by accordance with delivery inspection sheet. a single person, it is recommended to have a second...

  • Page 45: General Operation

    0.08 in (2 mm) or less. Pre-Ride Inspection CAUTION: Under-inflation is the most common cause of Before operating the Zero S/DS motorcycle, check the tire failure and may result in severe tire cracking, tread following to make sure the motorcycle is secure and intact: separation, “blowout,”...

  • Page 46: 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 47: Power Pack

    The battery is located within the power pack and requires the electrical system. no special break in period. The 2013 Zero S and DS leverage a completely new battery ON Position cell chemistry and configuration. Not only does the ZF11.4 This position is used for operating the motorcycle.
  • Page 48 90 days if stored fully charged. Zero recommends The BMS also monitors the power pack for a host of you plug in your Zero motorcycle after 90 days, even if fully predefined conditions, and then takes actions according to charged.
  • Page 49 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 50 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 51 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 10 amps from the 120 V AC circuit when charging.
  • Page 52 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 53 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 54 “IIIIII” to “I”. CHAdeMO Charger B. 80% Charge Your Zero motorcycle can utilize an optional quick charging The 80% Charge LED is an amber indicator. If it is on CHAdeMO charger system. A CHAdeMO charger can solid, the bulk charge phase is complete, 80% charge your motorcycle in about one hour.

  • Page 55: Operating Your Motorcycle

    We suggest performance and durability of its powertrain. progressive use of the brakes to bring the Zero motorcycle to a complete stop without locking the wheels. Your Zero motorcycle is a light weight performance product and...
  • Page 56 Please note that the lighting of this temperature indicator does not indicate that there’s anything malfunctioning with your Zero motorcycle; it is simply letting you know that the thermal strategy is working. If you do not moderate your speed/power, the bike’s system will reduce your...

  • Page 57: 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 58 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 59: 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 60 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 61 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 62 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 63 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 Models ADJUSTMENT SETTING Rear Shock Compression 10 clicks out from fully closed Rear Shock Rebound 4 clicks out from fully closed Rear Shock Spring Preload...
  • Page 64 Notes 4.22...

  • Page 65: 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 66: Maintenance Schedule

    Maintaining Your Motorcycle Maintenance Schedule The scheduled maintenance must be performed in accordance with this chart to keep the Zero S/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 67 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 68 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 69: Component Fasteners

    Maintaining Your Motorcycle Component Fasteners Periodically check and tighten the following fasteners on your motorcycle. Torque Table LOCATION ITEM TORQUE NOTES Front axle end bolts 19 lb ft (26 Nm) Use LOCTITE® 242® (or equivalent) Headlight bolts 12 lb ft (16 Nm) Use LOCTITE®...
  • Page 70 Maintaining Your Motorcycle Left Side of Motorcycle ZOM0154 Refer to Torque table on page 5.5.
  • Page 71 Maintaining Your Motorcycle Right Side of Motorcycle ZOM0153 Refer to Torque table on page 5.5.
  • Page 72 Maintaining Your Motorcycle Handlebars Refer to Torque table, page 5.5.

  • Page 73: Power Pack

    The power pack must be charged within 24 hours if fully discharged, and charged within 90 days if stored fully charged. Zero recommends you plug in your Zero motorcycle after 7 days, even if fully charged. Please leave your Zero motorcycle plugged in whenever possible.

  • Page 74: General Maintenance

    General Maintenance Brakes Rear Brake Pads General Maintenance An example of the front 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 Nissin brake pads for stopping power. Both front and rear pad examples are shown below.
  • Page 75 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 76 General Maintenance Rear Brake The reservoir housing is located inboard on the frame behind the heel guard. Unscrew the cap and add new DOT 4 brake fluid. Inspect the cap seal ensuring that it is free of any wear or damage then reinstall the cap.

  • Page 77: Suspension

    General Maintenance Brake Pad Inspection Suspension 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 78: Wheels And Tires

    General Maintenance Wheels And Tires Tire Inflation Inspect both wheels for the following: CAUTION: Under-inflation is the most 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 79: 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 80 General Maintenance Drive Belt Adjustment Procedure 1. Remove key from the key switch. 2. Loosen the rear axle nut (C). 3. Loosen left and right (A) jam nuts (13mm) in order to make adjustments. 4. Turn adjustment bolt (B) to adjust belt tension. 1.

  • Page 81: Drive Chain (Optional)

    General Maintenance Drive Chain (Optional) 3. Using a brush, fill the bristles with spray from the chain cleaner. Begin gently scrubbing the chain on the top of Cleaning The Drive Chain your swingarm using the brush. CAUTION: Wear safety glasses when cleaning the chain 4.
  • Page 82 General Maintenance Lubricating The Drive Chain Checking the Drive Chain CAUTION: Wear safety glasses when lubricating the chain 1. Remove the key from the key switch. to prevent eye injuries. 2. Using a ruler, grasp the chain halfway between the front and rear sprockets.
  • Page 83 General Maintenance Adjusting the Drive Chain 1. Remove the key from the key switch. 2. Loosen the 13 mm jam nut (A) on the chain tensioner. 3. Turn the adjuster bolt (B) a 1/4 turn at a time until the chain adjustment is within specification.

  • Page 84: 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 85 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.
  • Page 86 General Maintenance 2. Remove the headlight bulb retainer (A) by turning it 5. Install the headlight bulb retainer and turn it clockwise counter-clockwise. until it locks into position. 6. Install the headlight bulb rubber cover. 7. Connect the headlight bulb connector. 3.

  • Page 87: Turn Signal Light Bulb Replacement

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

  • Page 88: 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 89: 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 90: Parking And Long Term Storage

    For more information on the power pack and the electrical system see page 4.13. WARNING! Opening of the power pack is for trained Zero Motorcycles technicians. Please be aware that incorrect handling of a Zero power pack can be dangerous. DO NOT OPEN! 5.26...
  • Page 91 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). 4 5 6 ZOM0119 The 12-volt fuse values are listed below: The fuse center (see arrow) has a protective cover that FUSE RATING...
  • Page 92 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). ATM30 Quick Charger ABC20A Charger ABC4A...

  • Page 93: 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 5.29...
  • Page 94 Notes 5.30...

  • Page 95: Troubleshooting

    If you are unable to solve an Always observe and obey the instructions on labels attached to issue with your Zero S/DS electric motorcycle, take it to an components on the vehicle - they are there for your safety.

  • Page 96: 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 97 50 ms 60 sec Pack Low Charge power pack  50 ms 1 sec Number of Cell Packs Not Set Contact Zero or the Dealer  50 ms 1 sec Self-Test Failed Contact Zero or the Dealer  50 ms...
  • Page 98 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 99 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 100 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 101 BMS Error Beep Pattern It is possible to encounter the power ON self-test result error-beeps from a badly malfunctioning or damaged power pack. If so, the user should return the power pack to Zero for repair or replacement. PATTERN WHEN MEANING...

  • Page 102: 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 103 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) for 2013 Model Year), the charger reduces its charge current to the battery, increasing charge time accordingly;...

  • Page 104: 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 105 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 106: System Warning Indicator

    Troubleshooting System Warning Indicator If a fault has been detected, count the number of times the red LED (A) flashes. Refer to the table starting on the next page for possible causes and solutions to the issue. 6.12...
  • Page 107 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. Throttle is ON or throttle/connection is bad. Verify Charger Connected throttle action and/or check connection.
  • Page 108 Zero or your dealer. Turn the ignition OFF and allow to cool off and then Temperature Protection Error restart. If problem persists contact Zero or your dealer. Turn the ignition OFF and ON. If problem persists Throttle Output Error contact Zero or your dealer.

  • Page 109: 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 6.3 or see Understanding BMS Flash Code Patterns starting on page 6.3.
  • Page 110 Notes 6.16...

  • Page 111: Warranty Information

    Zero Motorcycles Inc. assumes no liability electrical sub-assemblies. for any misuse or improper operation of Zero motorcycles. This warranty covers Zero manufactured accessories Under this limited warranty and liability agreement, Zero installed at the time of purchase.

  • Page 112: Disclaimers Applicable To Standard Warranty

    Zero Motorcycles Inc. assumes no responsibility for incidental, consequential or other damages including but not limited to: expense of returning the Zero product to a...

  • Page 113: Proper Use

    30 Submit the warranty registration card for your Zero days, or keeping it on the charger when in storage or out of motorcycle within the required time period as printed on regular use.

  • Page 114: Warranty Procedures

    Zero Motorcycles BV Warranty services may be obtained by contacting your Fluorietweg 12D local Zero Motorcycle dealer; please see the locator on www.zeromotorcycles.com for the nearest location. In the Alkmaar, 1812 RR event that a dealer is not in your state, province, or country, you can contact Zero Motorcycles Inc.

  • Page 115: Transfer Of Ownership And Warranty

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

  • Page 116: Customer Information

    Customer Information Customer Assistance Customer Information Please have the following available when contacting Zero Motorcycles Inc. as they are essential to effectively and efficiently answer your questions or resolve your concerns.  Owner’s name and address  Owner’s telephone number ...

  • Page 117: Reporting Safety Defects

    However, NHTSA cannot become involved in individual problems between you, your dealer, or Zero Motorcycles Inc. To contact NHTSA, you may call the Vehicle Safety Hotline toll-free at: 1-888-327-4236 (TTY: 1-800-424-9153);...
  • Page 118 Notes...

  • Page 119: Index

    Index Accessories ..............5.26 Emissions Information ..........1.14 Brake/Tail Light Bulb Replacement ......5.23 First Time Set-Up............4.1 Brakes ................. 5.10 Fuses ................5.26 Brake Fluid Level Inspection ........5.11 High Voltage Fuse Center ........5.28 Brake Pad Inspection ..........5.13 Braking ..............4.13 General Operation ............4.3 DOT 4 brake fluid ............5.12 Key Switch/Steering Lock Positions......4.4 Front Brake .............5.11 Pre-Ride Inspection...........4.3...
  • Page 120 Index Serial Number ............1.4 Pre-Ride Inspection ............4.3 Keys Public Charging Stations ..........1.11 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............1.11 Motor Serial Number ............. 1.4 Safe Riding Information ..........
  • Page 121 Rear (Factory) ............4.21 Warranty ................7.1 Disclaimers Applicable to Standard Warranty ...7.2 Standard..............7.1 Technical Specifications Standard Warranty Exclusions ........7.1 Zero DS Technical Specifications ......1.8 Transfer Of Ownership And Warranty .......7.5 Zero S Technical Specifications........1.6 Wheels And Tires ............5.14 Tire Inflation..............5.14 Transporting ..............1.15 Troubleshooting Battery Management System (BMS)......6.2...
  • Page 122 Notes INDEX.4...

  • Page 123: First Responder Information

    First Responder Information - High Voltage Components Locations WARNING WARNING NEVER cut high voltage components or cabling. Cutting could result in serious injury or death. DO NOT CUT DO NOT CUT High voltage cables and components may remain energized for COLORED COLORED ZONES...
  • Page 124 TAKE CHARGE ™ WWW.ZEROMOTORCYCLES.COM...

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