Zero Motorcycles DS 2010, Owner'S Manual

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Page 2: ...g Your Riding Style 1 9 Public Charging Stations 1 10 Emissions Information 1 10 Transporting 1 11 Safety Information 2 1 General Safety Precautions 2 1 Important Operating Information 2 2 Location Of...

Page 3: ...r Pack And Charger 6 1 Understanding Beep Sequences 6 3 Safety Interlocks 6 6 General Troubleshooting 6 11 Right Side View 3 5 Instrument Panel 3 7 Indicators 3 8 Handlebar Controls 3 9 Starting And O...

Page 4: ...orcycles Limited Warranties 7 3 Standard Warranty 7 3 Extended Warranty 7 4 No Fault Warranty 7 5 Disclaimers Applicable to Standard Warranty Extended Warranty and No Fault Warranty 7 5 Proper Use 7 6...

Page 5: ...TOC 4 NOTES...

Page 6: ...Because of this your motorcycle may differ from the information supplied in this owner s manual No legal claims can be made on the basis of data in this manual When it comes time to sell your Zero mot...

Page 7: ...rating features and until you have been trained in safe and proper riding techniques Regular inspections and careful maintenance along with good riding skills will help you to safely enjoy the capabil...

Page 8: ...ress Model Date of Purchase VIN Telephone No E mail Battery Serial Number Owner Information Record important information here pertaining to your motorcycle When contacting your Certified Service Cente...

Page 9: ...n Number VIN See Location Of Important Labels on page 2 3 VIN Break Down VIN Location The VIN is a 17 digit number stamped on the head tube of the frame Do not alter or remove this number as it is the...

Page 10: ...cle Type 2 168 Cell 3 2nd Generation 4 336 Cell M Mars P Perm Z Z Motor Force A Agni 05 0 50 HP 51 50 100 HP 10 100 HP 9 2009 A 2010 B 2011 Production Number S 3 9 1 M 9 05 123456 Model Line Motor Typ...

Page 11: ...nless Rotor Foot Actuated Front Tire 110 70 16 in Rear Tire 140 70 16 in Front Wheel 16 x 3 0 in Rear Wheel 16 x 4 0 in MOTOR Type Brushed permanent magnetic electric Est Top Speed 108 km h 67 mph POW...

Page 12: ...pounds Power Pack 43 1 kg 95 pounds Curb Weight 123 8 kg 273 pounds GVWR 260 8 kg 575 pounds Carrying Capacity 136 0 kg 302 pounds ECONOMY Typical Cost to Recharge Less than 01 per mile or kilometer M...

Page 13: ...Carrying Capacity 134 7 kg 297 pounds ECONOMY Typical Cost to Recharge Less than 01 per mile or kilometer DRIVETRAIN Transmission Clutchless one speed Drive System 16T 53T Sprockets 420 Chain CHASSIS...

Page 14: ...tics if you so desire This applies mainly to riders with trip profiles which are at the edge of the performance envelope Those of you with relatively short commutes can expect to ride quite aggressive...

Page 15: ...air pollution global warming and energy security problems facing the country and the world WARNING Please use only Zero approved parts and accessories for your Zero motorcycle Parts and products for y...

Page 16: ...the screw slowly but do not remove Once all the air is out tighten the bleed screw It is recommended that the motorcycle be tied down using ratchet straps and a fork support A to prevent fork damage...

Page 17: ...1 12 Use two ratchet straps in the front and two in the rear The tie down straps should be at a 45 angle from the motorcycle Follow the manufacturer s instructions for the ratchet straps you are using...

Page 18: ...1 13 NOTES...

Page 19: ...1 14 NOTES...

Page 20: ...orcycle without proper instruction These are performance motorcycles and should be treated with extreme caution 6 Do not ride on wet frozen oily or pitted surfaces Avoid potholes surface cracks and ot...

Page 21: ...e it is silent An accident can occur if the motorcycle is left powered up while getting on or off the motorcycle 2 Switch the power OFF when backing up or pushing the motorcycle while dismounted It is...

Page 22: ...Axle Weight Rating GAWR Front and Rear Vehicle Identification Number VIN Rim Size Tire Pressures Manufactured Date 6 Always firmly apply the rear brake while turning the key switch ON or OFF In the ev...

Page 23: ...2 4 Power Pack Information Label 7...

Page 24: ...2 5 There is no engine braking A B Throttle And Speed Control Label Power Pack Labels A Power Pack Battery Fuse Label B Main Power Cut Off Label...

Page 25: ...2 6 MAIN POWER CUT OFF ON OFF SLIDE DOWN SLIDE UP Power Pack Battery Fuse Label Main Power Cut Off Label...

Page 26: ...bility to start from a standstill up a steep 10 grade when fully loaded It is not recommended that you stop on a grade of more than 10 with a fully loaded motorcycle Z ForceAir Induction System The ai...

Page 27: ...fast blink is clearly seen on the dash mounted warning indicator The power to the motor begins to drop off resulting in a noticeable reduction in available torque This provides tactile feedback to th...

Page 28: ...l have time to back off the throttle to reduce heat This will restore full power to the motor and eliminate the warning indicator Stage 3 If the critical temperature threshold of the brush carrier is...

Page 29: ...2 10 NOTES...

Page 30: ...0 A A C B E F D G I H Controls And Components Motorcycle Controls A Mirrors B Fork Lock C Instrument Panel D Warning Indicator E Front Brake Fluid Reservoir Master Cylinder F Front Brake Lever G Left...

Page 31: ...operation see pages 3 7 and 3 8 D Warning Indicator See System Error Indicator on page 2 8 E Front Brake Fluid Reservoir Master Cylinder For description and operation see Brakes on page 5 6 F Front B...

Page 32: ...C D B E F G H I Left Side View A Headlamp B Main Power Cut Off C Stop Tail Lamp D Rear Turn Signal E Front Turn Signal F AC Charger Power Connection G On Board Battery Charger H Kickstand Switch I Kic...

Page 33: ...eplacement on page 5 16 F AC Charger Power Connection For description and operation see Charging The Power Pack on page 4 12 G On Board Battery Charger For description and operation see Battery Charge...

Page 34: ...3 5 A B C D A Rear Brake Fluid Reservoir B Drive Chain Adjuster C Rear Brake Pedal D Power Pack Right Side View...

Page 35: ...nt Procedure on page 5 12 C Rear Brake Pedal The rear brake pedal controls the rear brake when the pedal is pressed When braking the throttle should be in the neutral returned position The stop lamp w...

Page 36: ...B A Left Turn Signal Indicator B High Beam Indicator C Speedometer D Main Power Indicator E Energy Gauge F Right Turn Signal Indicator G Select Button H Adjust Button I Warning Indicator J Trip Odome...

Page 37: ...mp high beams are on this indicator will illuminate blue and will remain on until the high beams are turned off C Speedometer The speedometer is an analog and digital display in either kilometers per...

Page 38: ...3 9 A B C E D F G H A High Beam Flash to Pass B Headlamp High Low Beam Switch C Front Brake Lever D High Beam Indicator E Horn Switch Handlebar Controls F Turn Signal Switch G Kill Switch H Throttle...

Page 39: ...or other motorists of your presence F Turn Signal Switch When the turn signal switch is pushed in the left or right position the corresponding front and rear turn signal will flash When the turn sign...

Page 40: ...e ON B button is pressed The switch does not turn off all electrical circuits just the operation of the motor H Throttle Control Twist the throttle in a counter clockwise rotation A to energize the mo...

Page 41: ...3 12 NOTES...

Page 42: ...pecifications See Tire Inflation on page 5 9 5 Inspect the hydraulic brake system Follow the hydraulic line from the reservoirs to the calipers and verify that there are no leaks or damage to the brak...

Page 43: ...e Zero motorcycle It is possible during shipping that sharp edges or points may occur please use caution Retain the crate and all other shipping items for future shipping of the motorcycle Note The sh...

Page 44: ...cle upright remove the ratchet straps B 4 Fold down the ramp A and lower the protective plastic 5 Remove the fork support A located between the wheel and front fender 6 Carefully roll the motorcycle o...

Page 45: ...rake lever and press the brake pedal individually while pushing the motorcycle to see if it rolls You should be able to lock up the wheels completely by applying the brakes Throttle With the key switc...

Page 46: ...The key B can be folded down Fork Lock CAUTION Do not operate the motorcycle with the fork locked This will prevent the motorcycle s ability to steer and could cause personal injury Using the fork loc...

Page 47: ...This switch is used to connect or disconnect the Z Force power pack from the motorcycle When the switch is slid down to OFF disconnected all electricity to the motorcycle is turned off this includes t...

Page 48: ...l turn off the motor controller outside of this range It is recommended that you leave the motorcycle on the charger if you expect it to sit in storage or unused for over 7 days The power pack must be...

Page 49: ...is section explains the different beep patterns and their meanings Battery Management System BMS Every power pack contains a Battery Management System BMS which monitors the condition of the cells and...

Page 50: ...rner of the power pack The BMS will beep under only two circumstances When the motorcycle key switch is turned from OFF to ON When the motorcycle is turned ON the BMS will perform a self test It will...

Page 51: ...at the power pack is full it will continue to attempt to fully charge the power pack In this event the green light may not illuminate however the power pack may be fully charged To ensure that the pow...

Page 52: ...phase complete 80 charged In Absorption phase With no power pack connected indicates algorithm selected by number of flashes Flashing Also displays algorithm 1 6 for 11 seconds if no power pack is con...

Page 53: ...hen not under load the power pack needs to be charged Frequent top off charging is good for the power pack s life span so do not hesitate to charge frequently 2 Ensure that the key switch is in the OF...

Page 54: ...with an Emergency Energy Reserve Beep When your power pack makes an audible beep it has only a few miles of range left This beep tells you your power pack is dangerously low on energy and needs to be...

Page 55: ...the OFF position and remove the key To prevent theft the key should be removed anytime the motorcycle is left unattended 3 Be sure to charge the power pack after each ride See Charging The Power Pack...

Page 56: ...g on page 1 11 Bleeding the fork Bleed the fork regularly let any excess air out after each ride 2 Rebound Damping The rebound damping is adjusted by turning the slotted brass adjuster screw B on the...

Page 57: ...n turn the adjuster counter clockwise Start with a middle setting and fine tune the compression from there Proper compression will allow the tire to track the ground over consecutive bumps Compression...

Page 58: ...rect for your weight This adjustment is a recommendation guideline personal riding preference may vary from the specifications given Checking Sag 1 Support your motorcycle on a stand with the rear whe...

Page 59: ...in the spring pre load should be adjusted See Spring Pre load Adjustment M1 600 mm 23 6 in M2 500 mm 19 6 in Sag 100 mm 4 in 8 Have a second assistant take a measurement using the same locations as in...

Page 60: ...the spring nut B clockwise on the shock 4 Recheck the sag If the sag is correct tighten the lock nut A Rebound Adjustment The rebound adjuster knob C is at the bottom of the shock It has 8 stages of...

Page 61: ...4 20 NOTES...

Page 62: ...re and maintenance of your electric motorcycle as detailed in this owner s manual 3 Use only genuine Zero approved parts and accessories 4 The operator is responsible for learning and obeying all coun...

Page 63: ...Use LOCTITE 242 Front axle end bolts 18 20 N m 13 15 lb ft F Front caliper mount bolts 11 13 N m 8 10 lb ft Use LOCTITE 242 G Charger bolts 5 6 N m 44 53 lb in Use LOCTITE 242 H Main pivot bolt nut sw...

Page 64: ...5 3 B C J I H F E D G See Bolt Torque Table on page 5 2...

Page 65: ...5 4 L M K See Bolt Torque Table on page 5 2...

Page 66: ...e heat The lithium ion cells should not get above 71 C 160 F Do not store in a hot car or trailer or leave the power pack in direct sunlight 3 Only an authorized service agent is qualified to have acc...

Page 67: ...immediately Low fluid levels may indicate worn brake pads or a leak in the hydraulic system Inspect the brake pads for wear and or the hydraulic system for leaks Use only new DOT 4 brake fluid from a...

Page 68: ...w DOT 4 brake fluid Inspect the cap seal ensuring that it is free of any wear or damage then reinstall the cap Brake Pad Inspection The brake pads must be inspected when specified in the maintenance s...

Page 69: ...to explode causing personal injury or death To adjust the shock see Rear Shock Adjustment on page 4 17 Wheels And Tires Inspect both wheels for the following Bent loose or missing spokes Bent or crac...

Page 70: ...ons replace the wheel and tire immediately Tire Inflation CAUTION Under inflation is the most common cause of tire failure and may result in severe tire cracking tread separation blowout or unexpected...

Page 71: ...in serious personal injury Follow the manufacturer s instructions for the chain cleaner you are using below are the general guide lines 1 Remove the key from the key switch 2 Set the motorcycle on a s...

Page 72: ...d spray the inside of the chain on the inside of the links 2 Turn the wheel backwards slowly and spray the outside of the chain on the outside of the links Checking The Drive Chain 1 Remove the key fr...

Page 73: ...t after the test ride and readjust if necessary 1 Remove the key from the key switch 2 Loosen both rear motor mount Allen bolts A 4 Loosen the 13 mm jam nut C on the chain tensioner 5 Turn the adjuste...

Page 74: ...ill point too far off to one side If the vertical adjustment is off it will cause the beam to point too close to or too far ahead of the motorcycle With the headlamp on the low beam position the motor...

Page 75: ...avoid personal injury Turn off the key switch and allow the bulb to cool before changing the bulb Leave the key switch OFF until the bulb change is complete Always wear eye protection when changing a...

Page 76: ...hing to the side 5 Lift up on the spring clip and remove the headlamp bulb A 2 1 WARNING Do not touch the glass portion of the headlamp bulb Keep the headlamp bulb free of contaminants Oil from your f...

Page 77: ...placement 1 Remove the turn signal lens screw A and remove the lens 2 Push in on the bulb turn the bulb counter clockwise and then pull the bulb out 3 Insert the new bulb into the socket push in and t...

Page 78: ...using a rocking motion see image on page 5 18 2 Push in on the bulb and turn the bulb counter clockwise then pull the bulb out 3 Insert the new bulb into the socket push in and turn clockwise until i...

Page 79: ...electrical components Avoid spraying water of great force around the instrument panel Avoid using strong acidic wheel cleaners especially on spoked wheels If such products are used on hard to remove d...

Page 80: ...ing and continues to monitor the power pack This ensures that electricity is not wasted in maintaining an optimized power pack 3 To prolong the life of your power pack you should store your motorcycle...

Page 81: ...or 6 months 13 000 km 8 000 mi or 12 months 19 000 km 12 000 mi or 18 months 25 000 km 16 000 mi or 24 months 31 000 km 20 000 mi or 30 months 1 Front Brake Check operation and for fluid leakage Repla...

Page 82: ...grease Ensure main pivot bolt is properly torqued See Bolt Torque Table on page 5 2 9 8 Drive Chain Check chain slack alignment and condition Adjust and lubricate chain with chain lubricant thoroughly...

Page 83: ...30 months 12 Front Fork Check operation and for oil leakage Service rebuild if necessary Refer to the service manual for more information 9 9 9 9 9 9 13 Rear Shock Absorber Assembly Check operation an...

Page 84: ...torcycle Your CSC can accessorize the motorcycle using genuine Zero accessories A full line of Parts Accessories and Apparel can be found on the Zero Motorcycles website Fuses Whenever there is an exc...

Page 85: ...ty is considered to be melted Remove the fuse by pushing in on the plastic cap and turning counter clockwise Install the fuse by pushing in and turning clockwise For more information about the fuse la...

Page 86: ...Not Used C 10 Turn Signals Horn D 5 Instrument Panel Tail Stop Lamp A B C D 4 2 3 1 E S U F P M A S T I U C R I C D E L L O R T N O C 1 0 1 A D M r o t c a t n o C 2 0 2 A D M r e t r e v n o C C D 3...

Page 87: ...ODOMETER MILEAGE READING ITEM SERVICE ROUTINE DESCRIPTION Follow the maintenance schedules on pages 5 20 through 5 22 After a scheduled service or routine is performed record the information on the ch...

Page 88: ...5 27 NOTES...

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Page 90: ...repair it yourself If you are unable to solve an issue with your Zero S DS electric motorcycle take it to an authorized Certified Service Center CSC at your convenience If there is no CSC in your area...

Page 91: ...e Charger output was reduced due to high temperatures Check connections Operate charger at a lower ambient temperature 4 Power pack could not be trickle charged up to minimum voltage Contact CSC 5 Ove...

Page 92: ...on on the meaning of the beep sequences PATTERN WHEN MEANING SOLUTION 1 Short Key on Self Test Pass BMS OK Ready to ride 1 Trill 2 Long Key on Charger Still Plugged In Unplug charger try again 2 Long...

Page 93: ...ividual cells The BMS continuously monitors the cells and tries to keep them all in balance at the same level of charge If any of the cells are grossly out of balance the BMS will sound a Power Pack U...

Page 94: ...repaired or replaced by a CSC BMS Appendix There are other beeps which may occur under two circumstances that operators will normally never see Unlike many electronic systems the BMS essentially neve...

Page 95: ...ower pack is empty or if the BMS detects certain serious internal problems You cannot ride the motorcycle until the problem is resolved 2 Charger Disable The BMS will prevent charging if it detects ce...

Page 96: ...er Still Plugged In Power Pack Empty Too Hot Power Pack Unbalanced The Charger Disable Interlock When the charger is attached and plugged in to AC power the BMS communicates with the charger The BMS c...

Page 97: ...are balanced the charger not the BMS will sense that the power pack is full and terminate the charging cycle with a green light The BMS does have a redundant back up mechanism to prevent overcharging...

Page 98: ...t y f i r e V s n o i t c e n n o c r o e l t t o r h t d a B n o i t c e n n o c k c e h c r o d n a n o i t c a 5 t o n r o s n e s e r u t a r e p m e t r o t o M d e t c e t e d r o r o s n e s e...

Page 99: ...lure Could not pre charge motor controller Contact CSC 10 Current sensor error Problem with current sensor or connection Contact CSC 11 Board temperature sensor error Problem sensing temperature of bo...

Page 100: ...e UP ON position Press the Kill Switch ON button Charger not working A C power missing Main power cut off engaged Check A C outlet for power A C source check fuse voltage Move the main power cut off t...

Page 101: ...6 12 NOTES...

Page 102: ...nswer your questions or resolve your concerns Owner s name and address Owner s telephone number Vehicle identification number VIN Date of purchase Battery serial number An owner information chart is p...

Page 103: ...PARTS COVERED STANDARD EXTENDED Replaces 2nd Year of the Standard Warranty NO FAULT Replacement Parts are 50 of Retail Cost Unless Noted First Year Second Year Excluding Shipping and Labor Motor 35 Di...

Page 104: ...f this standard limited warranty covers parts only for these same major components Standard Warranty Exclusions This warranty does not apply to tire wear chain or sprocket condition brake pads or roto...

Page 105: ...luded from this extended warranty on off road bikes once they have been ridden This extended warranty excludes aftermarket accessory kits which may be subject to their own warranties This extended war...

Page 106: ...warranties and are not included in this no fault coverage Modifications or alterations to major components of the manufacturer s original product or its sub components void all warranties including t...

Page 107: ...product during the time the warranty service is being preformed travel loss or damage to personal property loss of revenue loss of use of the product loss of time or inconvenience Some states do not a...

Page 108: ...is responsible for learning and obeying all federal state and local laws governing the operations of an electric motorcycle Always wear a helmet knee and elbow guards goggles appropriate boots and all...

Page 109: ...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 Use the URL address below or feel free to conta...

Page 110: ...7 9 NOTES...

Page 111: ...7 10 NOTES...

Page 112: ...4 8 Beeps 4 9 BMS Appendix 6 5 Bolt Torque Table 5 2 Brake Fluid Level Inspection 5 6 Brake Pad Inspection 5 7 Brakes 4 4 5 6 Brake Fluid Level Inspection 5 6 Brake Pad Inspection 5 7 Front Brake 5 6...

Page 113: ...4 F First Time Set Up 4 1 Fork Lock 4 5 Front Brake 5 6 Front Fork Adjustment 4 15 Fuse Center Location 5 24 Fuses 5 23 G General Information 1 6 General Maintenance 5 6 Brakes 5 6 Chain 5 10 Headlam...

Page 114: ...K Key Switch Positions 4 5 L Left Side View 3 3 Limited Warranties 7 3 Location Of Important Labels 2 3 Main Power Cut Off Label 2 6 Power Pack Battery Fuse Label 2 6 Power Pack Information Label 2 4...

Page 115: ...5 Power Pack Battery Fuse Label 2 6 Power Pack And Charger 6 1 Low Power Pack Warning 6 4 Other Error Beep Patterns 6 5 Power Pack Empty 6 4 Power Pack Unbalanced 6 4 Too Hot 6 4 Power Pack Empty 6 4...

Page 116: ...ntrol Label 2 5 Throttle Disable 6 6 Tire Inflation 5 9 Tires 4 4 Transfer Of Ownership And Warranty 7 8 Transporting 1 11 Troubleshooting 6 1 Turn Signal Bulb Replacement 5 16 U Uncrating Your Motorc...

Page 117: ...INDEX 6 Z Z Force Air Induction System 2 7 Z Force Power Pack Battery Fuses 5 24 Zero Motorcycles Limited Warranties 7 3...

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