Zero DS 2014, Owner'S Manual

Page 1: ...ZERO S ZERO SR ZERO DS 2014 OWNER S MANUAL...

Page 2: ......

Page 3: ...1 17 Safety Information 2 1 General Safety Precautions 2 1 General Safety Precautions 2 1 Important Operating Information 2 2 Location of Important Labels 2 3 Location of Important Labels 2 3 Control...

Page 4: ...ting 6 1 Electric Motorcycle Precautions 6 1 Troubleshooting Your Motorcycle 6 1 System Warning Indicator 6 2 General Troubleshooting 6 5 Battery Management System 6 6 Cold and Hot Weather Considerati...

Page 5: ...it is by law an important part of the vehicle If you have any questions concerning the operation or maintenance of your motorcycle please contact Zero at support zeromotorcycles com For 24 hour update...

Page 6: ...cle should be serviced by technicians with special training High voltage cable or wiring has an orange covering Do not probe tamper with cut or modify high voltage cable or wiring Plug in Your Z Force...

Page 7: ...Identification Numbers 1 3 Identification Numbers Owner Information Record information pertaining to your motorcycle here When contacting your dealer you may need to provide this information...

Page 8: ...5 digit number used to create duplicate keys This number is located on a tag that accompanies the original keys Vehicle Identification Number VIN The VIN is a 17 digit number stamped on the head tube...

Page 9: ...ation Numbers 1 5 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 orderi...

Page 10: ...dard ZF8 5 6 0 hours 100 charged 5 5 hours 95 charged ZF11 4 7 9 hours 100 charged 7 4 hours 95 charged Supplemental Charger Quick Charge Time accessory ZF8 5 3 6 hours 100 charged 3 1 hours 95 charge...

Page 11: ...on 43 mm inverted aluminum slider forks with adjustable compression and rebound damping Rear Suspension Piggy back reservoir shock with adjustable spring preload compression and rebound damping DIMENS...

Page 12: ...00 charged 9 3 hours 95 charged Supplemental Charger Quick Charge Time accessory ZF11 4 4 6 hours 100 charged 4 1 hours 95 charged ZF14 2 5 8 hours 100 charged 5 1 hours 95 charged CHAdeMO Recharge Ti...

Page 13: ...nt Suspension 43 mm inverted aluminum slider forks with adjustable compression and rebound damping Rear Suspension Piggy back reservoir shock with adjustable spring preload compression and rebound dam...

Page 14: ...Quick Charge Time accessory ZF8 5 3 6 hours 100 charged 3 1 hours 95 charged ZF11 4 4 6 hours 100 charged 4 1 hours 95 charged CHAdeMO Recharge Time 0 to 95 1 0 hour CHAdeMO Recharge Time 0 to 100 1...

Page 15: ...ompression and rebound damping Rear Suspension Piggy back reservoir shock with adjustable spring preload compression and rebound damping DIMENSION Wheel Base 56 2 in 1 427 mm Seat Height 33 2 in 843 m...

Page 16: ...versus performance of your motorcycle then you can adjust your riding characteristics if you so desire This applies mainly to riders with trip profiles which are at the edge of the performance envelo...

Page 17: ...ut one hour For additional information contact your Zero Motorcycles dealer Maximizing Your Range Range varies in electric motorcycles similarly to how it varies in gas motorcycles However the big dif...

Page 18: ...General Information 1 14...

Page 19: ...General Information 1 15...

Page 20: ...is the only kind of vehicle which actually gets cleaner in terms of air pollution each year as the electricity grid gets cleaner and more renewable Zero Emissions Vehicles ZEV s offer greater efficie...

Page 21: ...ew The fork must be fully extended most likely on a stand or balanced on the kickstand with the front tire in the air then the air can be bled and capped Ensure that the screw is tightened before ridi...

Page 22: ...Notes 1 18...

Page 23: ...drugs before operating your electric motorcycle Persons unwilling or unable to take responsibility for their actions should not use this motorcycle You assume all responsibility while operating your...

Page 24: ...l be sitting unused for more than 30 days The power pack must be charged within 24 hours if fully discharged and must be charged within 90 days if stored fully charged Zero recommends you plug in your...

Page 25: ...on of Important Labels The vehicle could contain the following information for both North American and European models A VECI Vehicle Emission Control Information label B VIN label European Union cert...

Page 26: ...Location of Important Labels 2 4 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 2 5 High Voltage Warning Label Affixed to battery...

Page 28: ...Notes 2 6...

Page 29: ...Controls and Components 3 1 Controls and Components Controls and Components THIS PAGE INTENTIONALLY LEFT BLANK...

Page 30: ...Controls and Components 3 2 Motorcycle Controls...

Page 31: ...For description and operation see Dash Overview on page 3 8 D Cavity for Accessory 12 Volt Socket Location for Zero dealer installed 12 volt accessory socket E Front Brake Fluid Reservoir For descrip...

Page 32: ...Controls and Components 3 4 Left Side View...

Page 33: ...light bulb replacement see Brake Tail LED Replacement on page 5 19 E Rear Turn Signal For turn signal operation see Handlebar Controls on page 3 16 F Kickstand The kickstand swings out from the side...

Page 34: ...Controls and Components 3 6 Right Side View...

Page 35: ...see Power Pack on page 4 5 D Rear Brake Pedal The rear brake pedal controls the rear brake when the pedal is pressed When braking the throttle should be in the closed position The brake light illumina...

Page 36: ...Controls and Components 3 8 Dash Overview...

Page 37: ...a displays which performance riding mode ECO SPORT and CUSTOM has been selected by the rider using the performance level mode button located on the right handlebar control assembly See Performance Lev...

Page 38: ...Controls and Components 3 10 Warning Indicator Lights...

Page 39: ...y over under temperature See Temperature Indicator on page 4 13 for more information D Armed Indicator Indicates the motorcycle is live or ready to move if the throttle is actuated For troubleshooting...

Page 40: ...Note Once a feature is selected it will stop flashing after 15 seconds if no further button press is detected and the dash will return to its normal operating mode Displays A B Display A To select Di...

Page 41: ...erature may not read accurately during the first 5 miles of a ride while the application is calibrating itself Life AV Displays the average energy usage over the life of the motorcycle in watt hours W...

Page 42: ...rily press the SEL button to return to normal operating mode Unit Display Temperature To change the units that the temperature display is shown 1 With the dash in its normal operating mode press and h...

Page 43: ...cle 1 Ensure that the motorcycle is not Armed The motorcycle must be keyed ON the kickstand must be in the down position and the run switch must be in the Stop position 2 Press and hold the Mode butto...

Page 44: ...Controls and Components 3 16 Handlebar Controls...

Page 45: ...king the throttle should be in the closed position The brake light also illuminates D Throttle Control Twist the throttle in a counter clockwise rotation A to energize the motor and start the motorcyc...

Page 46: ...9 G Turn Signal Switch When the turn signal switch is pushed in the left or right position the corresponding front and rear turn signals flash When the turn signal switch is ON the corresponding turn...

Page 47: ...motorcycle It is an ideal mode for when you want softer acceleration This position is also good for newer riders and for extending range The SPORT selection causes the motorcycle to accelerate at a si...

Page 48: ...le 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 b...

Page 49: ...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 whi...

Page 50: ...Notes 3 22...

Page 51: ...roper specifications See Tire Inflation on page 5 13 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...

Page 52: ...rcycle Inner Assembly Carefully remove plastic cover from motorcycle Locate small parts box below motorcycle and put to the side This box contains important documentation owner s manual keys etc Remov...

Page 53: ...lying the brakes Throttle With the key switch in the OFF position apply the throttle and release to verify that the throttle is smooth and returns correctly Tires Check both tires for condition and tr...

Page 54: ...d to prevent theft The key can be removed in either the OFF or steering lock position Steering Lock Using the steering lock when parked prevents unauthorized use and helps prevent theft To operate the...

Page 55: ...e The integrated onboard charger minimizes charge time and can work in parallel with Zero s quick charge accessories to cut charge times by as much as 70 The charging time will remain the same if the...

Page 56: ...nd Cold and Hot Weather Considerations on page 6 12 for further information The BMS is sealed inside the power pack As a rider you don t need to think much about the BMS it just silently does its job...

Page 57: ...sure that the power pack is charged check the charge indicator on the dash display prior to riding If the power pack terminates the charge before the charger reaches the state previously mentioned the...

Page 58: ...ld ensure the internal temperature is below 131 F 55 C If the power pack was recently run and it will not take a charge the power pack should cool and begin taking a charge in around 30 minutes or les...

Page 59: ...s draw as much as 12 amps from the 120 V AC circuit when charging 3 The charging icon A flashes as the battery is being charged Once charging is complete the icon stays illuminated 4 Charging a fully...

Page 60: ...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 The accessory charging connector i...

Page 61: ...harger to a GROUNDED outlet When using an extension cord avoid excessive voltage drops by using a grounded 3 wire 12 AWG cord no longer than 7 6 m 25 ft The charger can be used on 120 V AC or 240 V AC...

Page 62: ...it is on solid the charging is complete and the charger will enter maintenance mode If it is flashing the absorption phase is complete and the charger is in finish phase D AC ON The AC ON LED is an am...

Page 63: ...s should bring the Zero motorcycle to a complete stop without locking the wheels Your Zero motorcycle is a light weight performance product and therefore practice is strongly recommended to perfect sa...

Page 64: ...ct of the strategy will be that your motorcycle will be gradually slowed down to the point that the top speed of the bike is sustainable from a thermal standpoint If you encounter the strategy due to...

Page 65: ...Transporting on page 1 17 2 Bleeding the fork Bleed the fork regularly let any excess air out after each ride Rebound Damping The rebound damping is adjusted by turning the slotted brass adjuster scre...

Page 66: ...that is set too fast will cause the fork to bottom out harshly If the fork is bottoming out turn the adjuster one click at a time until the bottom out stops Adjust each fork leg evenly Replace the rub...

Page 67: ...weight This adjustment is a recommended guideline personal riding preference may vary from the specifications given To Check the Sag value 1 Support your motorcycle on a stand with the rear wheel off...

Page 68: ...ent M1 Example Measurement Operator Value M1 23 62 in 600 mm M2 21 65 in 550 mm Sag 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...

Page 69: ...specified value increase the pre load on the spring by turning the spring nut B clockwise on the shock Rebound Adjustment The rebound adjuster knob A is at the bottom of the shock It has 8 stages of a...

Page 70: ...a middle setting and fine tune the compression from there Proper compression allows the tire to track the ground over consecutive bumps Compression that is set too slow will pack up feel harsh over co...

Page 71: ...otorcycle 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: ...roved parts and Zero Motorcycles accessories The operator is responsible for learning and obeying all country federal state and local laws governing the operations of an electric motorcycle Always wea...

Page 74: ...EAGE READING 600 mi 1K km or 1 month 4K mi 7K km or 6 months 8K mi 13K km or 12 months 12K mi 19K km or 18 months 16K mi 25K km or 24 months 20K mi 31K km or 30 months 1 Front Brake Check operation an...

Page 75: ...k operation and for oil leakage Service rebuild if necessary 11 Front Fork Check operation and for oil leakage Service rebuild if necessary 12 Rear Shock Absorber Assembly Check operation and for oil...

Page 76: ...from 8 000 mi 13 000 or 12 months 15 Kickstand Switch Check operation and replace if necessary ITEM ROUTINE EVERY RIDE INITIAL INITIAL ODOMETER MILEAGE READING 600 mi 1K km or 1 month 4K mi 7K km or...

Page 77: ...k to frame front 19 lb ft 26 Nm I Main pivot bolt nut swingarm 75 lb ft 102 Nm J Upper Lower triple clamps pinch bolts 15 lb ft 20 Nm upper 17 lb ft 23 Nm lower Use LOCTITE 242 or equivalent K Front a...

Page 78: ...Maintaining Your Motorcycle 5 6 Left Side of Motorcycle Refer to Torque table on page 5 5...

Page 79: ...Maintaining Your Motorcycle 5 7 Right Side of Motorcycle Refer to Torque table on page 5 5...

Page 80: ...The power pack is a lithium ion power system While it does require charging it does not require maintenance 2 The power pack should be kept away from excessive heat The lithium ion cells should not ge...

Page 81: ...d 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 Front Brake Pads An example...

Page 82: ...e hydraulic system for leaks Use only new DOT 4 brake fluid from a sealed container Front Brake LOWER A B C Inspect the level of the front brake fluid through the sight glass B If the fluid level is v...

Page 83: ...brake fluid through the reservoir housing If the fluid level is visibly below the low minimum MIN indicator C brake fluid must be added until level reaches the upper MAX indicator B Do not overfill Cl...

Page 84: ...y The brake rotor should also be checked for thickness The minimum thickness is 0 15 in 3 85 mm Suspension Front For maintenance see Maintenance Schedule on page 5 2 To adjust the fork see Suspension...

Page 85: ...ires are found to have any of the above conditions replace the wheel and tire immediately Tire Inflation CAUTION Under inflation is a common cause of tire failure and may result in severe tire crackin...

Page 86: ...t the base of the belt teeth If any of the above conditions are found the belt should be replaced Checking Drive Belt Tension Proper belt tension is essential for optimum operation of the drive system...

Page 87: ...he belt Avoid rough movements of the tester as this would change the results of the measurement The measurement should be in the range of 20 30 kg Drive Belt Adjustment Procedure 1 Remove key from the...

Page 88: ...ght can be adjusted vertically If the vertical adjustment is off it causes the beam to point too close to or too far ahead of the motorcycle With the headlight on the low beam position the motorcycle...

Page 89: ...could result in serious injury To help avoid injury Turn the key switch OFF and allow the bulb to cool before changing the bulb Leave the key switch OFF until the bulb change is complete Always wear e...

Page 90: ...adlight bulb free of contaminants Oil from your fingers or contaminants will shorten the life of the bulb Thoroughly clean any fingerprints or contaminants from the bulb using a clean cloth moistened...

Page 91: ...turn the bulb counterclockwise and then pull the bulb out 3 Insert the new bulb into the socket push in and turn clockwise until it stops 4 Install the lens and screw tighten the screw Do not over tig...

Page 92: ...eplacement 1 Working from behind the headlight remove the bulb socket A from the headlight by squeezing the metal clip A 2 Pull the old bulb straight out from the socket 3 Push the new bulb into the s...

Page 93: ...Note We recommend the use of a garden hose to wash your motorcycle High pressure washers like those at coin operated car washes can damage certain parts 1 Gently wash your motorcycle with a sponge or...

Page 94: ...r 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 dangero...

Page 95: ...ver To access the 12 volt fuse center 1 Remove two bolts securing the seat to the motorcycle frame Refer to Component Fasteners page 5 5 2 Pull the seat rearward to gain access to the fuse center 3 Sq...

Page 96: ...h voltage fuse center 1 Remove the two bolts securing the seat to the motorcycle frame 2 Pull the seat rearward to gain access to the fuse center 3 Unscrew the fuse s cover 4 Replace the fuse The high...

Page 97: ...ce Record 5 25 Service Record Follow the maintenance schedules on page 5 2 After a scheduled service or routine is performed record the information on the chart below DATE ITEM SERVICE ROUTINE DESCRIP...

Page 98: ...Notes 5 26...

Page 99: ...gh voltage System components can be hot to touch during and after starting and when the motorcycle is shut off Be careful of both the high voltage and the high temperature Obey all labels that are att...

Page 100: ...ng 6 2 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...

Page 101: ...action and or check connection 5 High Throttle Disable Could not pre charge motor controller Contact your dealer 6 Low Power Pack Disable Charge Power Pack Before Riding 7 Contactor Error Contact Zero...

Page 102: ...16 High Current Disable Turn the ignition OFF and ON If problem persists contact Zero or your dealer 17 Temperature Protection Error Turn the ignition OFF and allow to cool off and then restart If pr...

Page 103: ...7 Charger not working A C power missing fault code set Check A C outlet for power A C source check fuse voltage See Charge Fault Code chart on page 6 8 or see Understanding BMS Flash Code Patterns on...

Page 104: ...wer 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 The window is located on...

Page 105: ...GREEN 3 GREEN 4 GREEN ON OFF MEANING SOLUTION 50 ms 5 sec Healthy BMS OK 50 ms 5 ms Isolation Fault Contact Zero or the Dealer 50 ms 60 sec Pack Low Charge power pack 50 ms 1 sec Number of Cell Packs...

Page 106: ...l flash depending on the power pack s state of charge 1 RED 2 GREEN 3 GREEN 4 GREEN ON OFF MEANING SOLUTION 1 sec 5 sec Charge Complete Unplug Charger Charging 250 ms 25 Continue Charging 250 ms 50 Co...

Page 107: ...key is in the ON position 1 RED 2 GREEN 3 GREEN 4 GREEN ON OFF MEANING SOLUTION 5 sec 1 sec 25 of Power Remaining Charge Soon 5 sec 1 sec 50 of Power Remaining Charge Soon 5 sec 1 sec 75 of Power Rema...

Page 108: ...itself to prevent damage Power Pack Too Hot The power pack contains internal temperature sensors If the BMS measures excessive internal temperatures it flashes an error code and disables the throttle...

Page 109: ...tterns 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...

Page 110: ...allow the battery to be discharged below 22 F 30 C which is the absolute lowest discharge temperature prescribed by the cell manufacturer Storage of the motorcycle for the winter in a non heated gara...

Page 111: ...tery In hot temperatures greater than 110 F 43 C the charger reduces its charge current to the battery increasing charge time accordingly the hotter the ambient temperature the greater the effect Abov...

Page 112: ...r requesting that the throttle control on the motorcycle be disabled When the throttle control is disabled the motor will not deliver power to the rear wheel and the motorcycle cannot be ridden If the...

Page 113: ...charger requesting that charging terminates immediately When the charger is disabled the indicator lights on the charger displays that charging has stopped There are two conditions that cause the BMS...

Page 114: ...Notes 6 16...

Page 115: ...rt of the Z Force Power Pack or Power Tank including the battery integrated battery management system internal wiring and internal structures What Is The Coverage Period Of This Limited Warranty The d...

Page 116: ...tion is within expected norms Further this Limited Warranty only covers 2014 Zero S DS SR motorcycles or Power Packs Power Tanks that are operated according to proper use and under normal operating co...

Page 117: ...by the improper repair of the motorcycle installation of any parts or accessories not sold or approved by Zero the installation and use of any parties or accessories that alter the motorcycle s speci...

Page 118: ...to its owner mechanic s travel time or communication charges loss or damage to personal property loss or time or inconvenience Some states do not allow the exclusion or limitation of incidental or co...

Page 119: ...roper use of your Zero motorcycle and Power Pack as detailed in this Owner s Manual Learn and obey all federal state and local laws governing the operations of a motorcycle generally and an electric m...

Page 120: ...Canada Zero Motorcycles Inc 380 El Pueblo Road Scotts Valley CA 95066 USA Europe Zero Motorcycles BV Fluorietweg 12D Alkmaar 1812 RR NL U S and International Patents and Trademarks Pending Transfer O...

Page 121: ...urces section of the Zero Motorcycles website www zeromotorcycles com owner resources Reporting Safety Defects If you believe that your vehicle has a defect which could cause a crash or could cause in...

Page 122: ...Notes 7 8...

Page 123: ...Motorcycle 5 21 Contact information NHTSA 7 7 D Dash Settings 3 12 Drive Belt 5 14 Checking Drive Belt Tension 5 14 E Emissions Information 1 16 F First Time Set Up 4 1 Fuses 5 22 High Voltage Fuse Ce...

Page 124: ...mance Level Mode Button 3 19 ECO Position 3 19 SPORT Position 3 19 Power Pack 5 8 Plug in Your Z Force Power Pack 1 2 Serial Number 1 4 Pre Ride Inspection 4 3 Public Charging Stations 1 13 Q Quick Ch...

Page 125: ...ing 1 17 Troubleshooting Battery Management System BMS 6 6 Charge Mode 6 8 Run Mode 6 9 Turn Signal Light Bulb Replacement 5 19 U Unpacking Your Zero Motorcycle 4 2 Recycling 4 2 V Vehicle Identificat...

Page 126: ...Notes INDEX 4...

Page 127: ...ould result in serious injury or death High voltage cables and components may remain energized for up to 10 seconds after disabling DO NOT CUT DO NOT CUT COLORED COLORED ZONES ZONES WARNING WARNING ZO...

Page 128: ...TAKE CHARGE WWW ZEROMOTORCYCLES COM...