Zero Motorcycles S 2009, Owner'S Manual

Page 1: ...ZERO MOTORCYCLES 2009 S DS OWNER S MANUAL...

Page 2: ......

Page 3: ...re while this manual contains the most current product information available at the time of printing there may be minor discrepancies between your motorcycle and this manual If you have any questions...

Page 4: ...2009 ZERO S DS OWNER S MANUAL 2...

Page 5: ...harger Led Indicators 21 Maintenance and Repair 21 Power Pack Care and Technical Information 22 Bolt Torque Table 23 Maintenance Schedule 24 General Maintenance 24 Motor Maintenance 24 Suspension 24 W...

Page 6: ...2009 ZERO S DS OWNER S MANUAL 4...

Page 7: ...that allows for using freeways or highways for a few miles when necessary You can expect to achieve 40 miles of average range under normal use stop and go city traffic with a maximum range of 60 miles...

Page 8: ...ck warning to the rider in the form of a rapid acceleration deceleration pulsing of the motorcycle At this point it is strongly recommended that you reduce your speed and consider finding a safe area...

Page 9: ...unable to take responsibility for their actions should not use this motorcycle You assume all responsibility while operating your motorcycle The seller will assume no liability for misuse or operator...

Page 10: ...S DS connected to the charger when your motorcycle is sitting in storage or if it will be sitting unused for more than 7 days 6 Always firmly apply the rear brake while turning the master switch on o...

Page 11: ...2009 ZERO S DS OWNER S MANUAL 9 1 EPA Label Shown Actual Size LOCATION OF IMPORTANT LABELS 1 SAFETY INFORMATION...

Page 12: ...2009 ZERO S DS OWNER S MANUAL 10...

Page 13: ...l Module 3 Front Brake Lever 4 Key Switch 5 Right Handlebar Control Module 6 Front Brake Fluid Reservoir and Master Cylinder 7 Mirrors 8 Warning Indicator CONTROLS AND COMPONENTS MOTORCYCLE CONTROLS 2...

Page 14: ...Headlight 2 Tail Light Brake Light License Plate Light 3 On Board Power Connection 4 Kickstand Sidestand 5 Main Power Coupling 6 Sidestand Switch 7 Onboard Charger CONTROLS AND COMPONENTS LEFT VIEW 4...

Page 15: ...ERO S DS OWNER S MANUAL 13 1 Drive Chain 2 Rear Brake Fluid Reservoir 3 Rear Brake Master Cylinder 4 Chain Tensioner 5 Rear Brake Pedal 6 Zero S DS Power Pack RIGHT VIEW 4 1 3 2 5 6 CONTROLS AND COMPO...

Page 16: ...10 1 2 4 5 6 3 7 8 9 8 Shown Actual Size 1 Main Power Indicator 2 Energy Gauge 3 Speedometer 4 Odometer 5 Trip Odometer 6 Warning Indicator 7 High Beam Indicator 8 Turn Signal Indicator 9 Select Adju...

Page 17: ...ZERO S DS OWNER S MANUAL 15 20 30 40 50 60 70 80 90 100 1 10 120 10 1 Headlight Hi Low Beam Selector 2 Turn Signal Switch 3 Horn 4 High Beam Flasher LEFT HANDLEBAR CONTROLS 1 4 2 3 CONTROLS AND COMPON...

Page 18: ...009 ZERO S DS OWNER S MANUAL 16 20 30 0 90 100 1 10 120 10 1 Motor Stop Switch Kill Switch 2 Front Brake Lever 3 Throttle CONTROLS AND COMPONENTS RIGHT HANDLEBAR CONTROLS CONTROLS AND COMPONENTS 1 2 3...

Page 19: ...raulic line from the reservoirs to the calipers and verify that there are no leaks or damage to the brake lines Verify that the brakes function properly 7 Make sure the motorcycle is off then twist th...

Page 20: ...riding in dusty or wet areas BRAKE Squeeze the brake lever and push the motorcycle to see if it rolls You should be able to lock up the wheels up completely using the brakes Check for sufficient brake...

Page 21: ...AWG cord no longer than 25ft 7 5 m 5 AVOID connecting the Zero S DS motorcycle charger and another device to a single 15A 20A circuit or the circuit may become overloaded 6 Charging a fully discharged...

Page 22: ...6 for 11 seconds if no battery is connected 80 Charge Amber Solid Flashing Bulk charge phase complete 80 charged In Absorption phase With no battery connected indicates algorithm selected by number o...

Page 23: ...nced and complete charge at all times without wasting any electricity 2 Over extended periods of time the power pack is checked every 72 hours to ensure that the cells are balanced and that the power...

Page 24: ...threadlocker D Shock mount bolts 13 15 N m Use grease E Rear axle bolts 18 20 N m Use grease F Motor mount bolt 30 N m Use anti sieze paste G Rear Caliper mount bolts 11 13 N m Use grease H Triple cla...

Page 25: ...eel Bearings Check bearings for smooth operation Replace if necessary 7 Swingarm Pivot Bearings Check bearing assemblies for looseness Moderately repack with lithium grease Ensure main pivot bolt is p...

Page 26: ...s preload and rebound damping adjustments Preload is altered by loosening the lock ring on the spring and turning the adjuster to either compress or decompress the spring Rebound damping is adjusted u...

Page 27: ...or mounting bolts Do not over tighten the motor mounting bolts since the motor adapter plate is aluminum A worn chain will damage the sprockets so it is advisable to replace the chain before it is too...

Page 28: ...2009 ZERO S DS OWNER S MANUAL 26...

Page 29: ...pounds 36 3 kg Total weight 270 pounds 122 5 kg ECONOMY Typical cost to recharge Less than 01 per mile or kilometer MOTOR Type Brushed permanent magnetic electric Top Speed 55 mph 90 kph POWER SYSTEM...

Page 30: ...patterns and their meanings SAFETY INTERLOCKS The BMS can disable the bike s throttle control if the pack is fully discharged or in case of other errors The BMS can also disable charging under certain...

Page 31: ...ycle and your commute Once you become familiar with the range versus performance of your motorcycle then you can adjust your driving characteristics if you so desire This applies mainly to drivers wit...

Page 32: ...l warming and energy security problems facing the country and the world EMISSIONS The Zero S and DS do not require any gasoline and as a result do not get miles per gallon For the sake of emissions co...

Page 33: ...d be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold 2 Read and understand the owner s manual and all product warnings before opera...

Page 34: ...2009 ZERO S DS OWNER S MANUAL 32...

Page 35: ...power for 15 seconds 3 Charge Timeout caused by battery pack not reaching required voltage Charger output was reduced due to high temperatures Check connections Operate charger at a lower ambient temp...

Page 36: ...tle You cannot ride the bike until the pack cools down Place the bike in a cool well ventilated location and wait a few minutes before riding again If the Too Hot error beep still sounds after the pac...

Page 37: ...ed off or b The throttle control is disabled for any reason which includes the pack being completely empty The Low Pack warning beep will sound when you can still ride the bike but the remaining range...

Page 38: ...BMS can send a signal to the main bike controller requesting that the throttle control on the bike be disabled When the throttle control is disabled the drivetrain will not deliver power to the rear...

Page 39: ...is also reported by an error beep pattern after BMS self test when the bike is turned on See Understanding Beep Sequences page 34 for a description of the Too Hot error beep and the remedies PACK FULL...

Page 40: ...result with a beep pattern Note that this sanity check and the resulting beep patterns is different from the key on self test The sanity test and the beeps happen immediately when the board is first...

Page 41: ...up ON position page 12 item 5 Flip Kill Switch to the ON position page 16 item 1 Charger not working A C power missing Main power coupling not engaged Check A C outlet for power A C source check fuse...

Page 42: ...2009 ZERO S DS OWNER S MANUAL 40...

Page 43: ...s and electrical sub assemblies The second year of this limited warranty covers parts only for these same major components Should the EXTENDED WARRANTY be purchased the coverage level from the first y...

Page 44: ...the above limitation or exclusion may not apply to you Zero Motorcycles Inc reserves the right to change or improve the design of any electric motorcycle product without assuming any obligation to mo...

Page 45: ......

Page 46: ......

Page 47: ...TES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU This warranty gives you specific legal rights and you also...

Page 48: ......

Page 49: ......

Page 50: ......