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TAKE CHARGE

™

ZERO S

™

ZERO SR

™

ZERO DS

™

2014 OWNER’S MANUAL

WWW.ZEROMOTORCYCLES.COM

2 014 OWNER’S MANUAL ZERO S / ZERO SR / ZERO DS

Table Of Contents

TOC.1

Introduction................................................... 1.1

Introduction.................................................................. 1.1

An Important Message To You From Zero Motorcycles

1.1

About This Manual .................................................... 1.1

Useful Information For Safe Riding........................... 1.2

Plug in Your Z-Force Power Pack™ ......................... 1.2

California Proposition 65........................................... 1.2

California Perchlorate Advisory................................. 1.2

Identification Numbers................................................ 1.3

Owner Information .................................................... 1.3

Power Pack Serial Number....................................... 1.4

Motor Serial Number................................................. 1.4

Key Code Number .................................................... 1.4

Vehicle Identification Number (VIN).......................... 1.4

General Information .................................................... 1.6

Technical Specifications ........................................... 1.6

Vehicle Range......................................................... 1.12

Public Charging Stations......................................... 1.13

Maximizing Your Range.......................................... 1.13

Emissions Information............................................. 1.16

Transporting............................................................ 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

Controls and Components ........................... 3.1

Controls and Components.......................................... 3.1

Motorcycle Controls .................................................. 3.2

Left Side View ........................................................... 3.4

Right Side View......................................................... 3.6

Dash Overview.......................................................... 3.8

Warning Indicator Lights ......................................... 3.10

Dash Settings.......................................................... 3.12

Smartphone Application .......................................... 3.15

Bluetooth® Pairing .................................................. 3.15

Handlebar Controls ................................................. 3.16

Performance Level Mode Button............................. 3.19

Tank Bag................................................................. 3.20

Power Tank (if equipped) ........................................ 3.21

Starting and Operating ................................. 4.1

Starting and Operating................................................ 4.1

First Time Set-Up ...................................................... 4.1

Unpacking Your Zero Motorcycle.............................. 4.2

General Operation ....................................................... 4.3

General Operation..................................................... 4.3

Key Switch/Steering Lock Positions.......................... 4.4

Power Pack ............................................................... 4.5

Operating Your Motorcycle ..................................... 4.13

Front Suspension Adjustment ................................. 4.15

Table Of Contents

TOC.2

Rear Shock Adjustment ...........................................4.17

Maintaining Your Motorcycle........................ 5.1

Maintaining Your Motorcycle ......................................5.1

Owner’s Responsibilities............................................5.1

Parts/Maintenance Items ...........................................5.1

Maintenance Schedule ..............................................5.2

Component Fasteners ...............................................5.5

Power Pack ...................................................................5.8

Power Pack................................................................5.8

General Maintenance ...................................................5.9

Brakes........................................................................5.9

Suspension ..............................................................5.12

Wheels And Tires.....................................................5.13

Tire Inflation .............................................................5.13

Drive Belt .................................................................5.14

Headlight Alignment.................................................5.16

Turn Signal Light Bulb Replacement .......................5.19

Brake/Tail LED Replacement...................................5.19

Running Light Bulb Replacement ............................5.20

Cleaning...................................................................5.21

Parking and Long Term Storage..............................5.22

Zero Motorcycles Accessories .................................5.22

Fuses .......................................................................5.22

Service Record ...........................................................5.25

Troubleshooting ............................................ 6.1

Troubleshooting .......................................................... 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 Considerations ................... 6.12

Safety Interlocks ..................................................... 6.14

Warranty and Customer Information........... 7.1

Limited Warranty Information .................................... 7.1

What Does This Limited Warranty Cover?................ 7.1

What Is The Coverage Period Of This Limited

Warranty? ................................................................. 7.1

Who Does This Limited Warranty Cover?................. 7.2

What Is Not Covered By This Limited Warranty? ..... 7.2

What Other Limitations Or Disclaimers Apply To This

Limited Warranty....................................................... 7.4

What Are Your Responsibilities As A Customer? ..... 7.5

What Will Zero Do Under This Limited Warranty? .... 7.5

How Do You Obtain Service Under This Limited

Warranty? ................................................................. 7.6

Transfer Of Ownership And Warranty....................... 7.6

Customer Information ................................................. 7.7

Customer Assistance ................................................ 7.7

Reporting Safety Defects .......................................... 7.7

Introduction

1.1

IntroductionIntroduction

An Important Message To You From Zero

Motorcycles

Congratulations and thank you for purchasing the 2014

Zero S/SR/DS electric motorcycle; we welcome you to the

community of Zero Motorcycles riders. This manual is

designed to provide you with a better understanding of the

operation, inspection, and basic maintenance

requirements of this motorcycle.

Zero continually seeks advancements in product design

d quality. Therefore, this manual contains the most

current product information available at the time of printing.

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 S/SR/DS, please

remember to hand over this manual; 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 updates and additional information about your

motorcycle, visit the Owner

Resources section of the Zero

Motorcycles website:

http://www.zeromotorcycles.com/owner-resources/

About This Manual

This manual covers the following motorcycles (standard

equipment includes belt drive, integrated charger, and

regenerative braking):

 Zero S: Street

 Integrated Z-Force™ Power Pack and Charger

 Cast W

heels

 S

treet Tires

 Zero SR: Street - Max Performance

 Integ

rated Z-Force™ Power Pack and Charger

 Cast W

heels

 S

treet Tires

 Zero DS: Dual Sport

 Integ

rated Z-Force™ Power Pack and Charger

 S

poke Wheels

 Dual Sport Tires

Locating and referencing information

A good place to locate information about the motorcycle

in the index in the back of the manual.

The terms “right” or “left” refer to the rider’s right or left

when sitting on the motorcycle.

Introduction

1.2

Useful Information For Safe Riding

This manual contains the word CAUTION to indicate

something that could hurt you or others. It also contains

the word WARNING to indicate things that could damage

your motorcycle.

CAUTION: Please read this manual carefully and

completely before operating this motorcycle. Do not

attempt to operate this motorcycle until you have attained

adequate knowledge of its controls and operating features,

and until you have been trained in safe and proper riding

techniques. Regular inspections and proper maintenance,

along with good riding skills, help you safely enjoy the

capabilities and the reliability of this motorcycle.

Disregarding the aforementioned, however, may render

the warranty invalid.

This symbol is located in various locations

on the motorcycle to inform you that

exposure to high voltage can cause shock,

burns and even death.

The high voltage components on the motorcycle 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 Power Pack™

WARNING! Proper care of the motorcycle’s power pack is

essential! When not in use, the power pack should be left

on the charger even if fully charged. Failure to do so could

damage the power pack and therefore void your power

pack warranty. See page

4.5 for other important

information regarding the power pack.

California Proposition 65

WARNING! Certain motorcycles contain or emit chemicals

known to the State of California to cause cancer and birth

defects or other reproductive harm. In addition, certain

fluids contained in vehicles and certain products of

component wear contain or emit chemicals known to the

State of California to cause cancer and birth defects or

other reproductive harm.

California Perchlorate Advisory

WARNING! Certain components of this motorcycle such

as Lithium batteries may contain Perchlorate Material.

Special handling may apply for service or end of life

disp

osal. See

www.dtsc.ca.gov

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.

Identification Numbers

1.4

Power Pack Serial Number

The Power Pack serial number is located on the upper

front left of the power pack.

Motor Serial Number

The motor serial number is stamped on the motor housing.

Key Code Number

The key code is a 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 of

the frame. Do not alter or remove this number as it is the

legal identifier for your motorcycle.

See the location of all important labels on page 2.3.

Chassis Number

The motorcycle chassis number information (A) is affixed

to the chassis column

Identification 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 ordering parts.

General Information

1.6

General Inform ation

Technical Specifications

Zero S

The Zero S specifications below apply to both the S ZF8.5

and ZF11.4 models (unless otherwise specified).

MOTOR

Type Z-Force™ 75-7 passively air-cooled,

gh-efficiency, radial flux, permanent

magnet, brushless motor.

Controller High efficiency, 420 amp, 3-phase brushless

cont

roller with re-generative deceleration

Estimated Top Speed

(max)

95 mph (153 km/h)

Estimated Top Speed

(sust

ained)

80 mph (129 km/h)

POWER SYSTEM

Type Z-Force™ Li-Ion Intelligent Power Pack

Maximum Capacity  Z

F8.5: 8.5 kWh

 Z

F11.4: 11.4 kWh

Nominal Capacity  Z

F8.5: 7.5 kWh

 Z

F11.4: 10.0 kWh

Charge Time (standard)  Z

F8.5: 6.0 hours(100% charged) /

5.5 hours (95% charged)

 Z

F11.4: 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% charged)

 ZF1

1.4 4.6 hours (100% charged) / 

4.1 hours (95% charged)

CHAdeMO Recharge

ime (0 to 95%)

1.0 hour

CHAdeMO Recharge

ime (0 to 100%)

1.5 hours

Input Standard 110 V AC or 220 V AC

Charger Type 1.3kW Integrated

Estimated Power Pack

ife to 80% (city)

 ZF8.5: 231,000 miles (372,000 km)

 ZF11.4: 308,000 miles (496,000 km)

RANGE

City (EPA UDDS)  ZF8.5

103 miles (165 km)

 ZF1

1.4 137miles (220 km)

Highway, 55 mph

(88 km/h)

 ZF8.

5 64 miles (103 km)

 ZF1

1.4 85 miles (137 km)

>Combined 

(City + 55 mph)

 ZF8.

5 79 miles (127 km)

 ZF1

1.4 105 miles (169 km)

Highway, 70 mph

12 km/h)

 ZF8.5

53 miles (84 km)

 Z

F11.4 70 miles (113 km)

>Combined (City +

70 mph)

 ZF8.

5 69 miles (112 km)

 ZF1

1.4 93 miles (149 km)

General Information

1.7

DRIVETRAIN

Transmission Clutchless Direct Drive

Final Drive

132T/28T,Poly Chain® GT® Carbon™ belt

CHASSIS/SUSPENSION/BRAKES

Front Suspension Travel 6.25 in (159 mm)

Rear Suspension Travel 6.35 in (161 mm)

Front Brakes Nissin 2 piston hydraulic

313 mm OD rotor, 4.0 mm thick

2 piston floating caliper

Rear Brakes J-Juan 1 piston hydraulic

240 mm OD rotor, 4.5 mm thick

Front Tire 110/70-17 in

Rear Tire 140/70-17 in

Front Wheel 3.00x17

Rear Wheel 3.50x17

Front Suspension 43 mm inverted, aluminum slider forks with

adju

stable compression and rebound

damping

Rear Suspension Piggy-back reservoir shock with adjustable

ring preload, compression and rebound

damping

DIMENSION

Wheel Base 55.5 in (1,410 mm)

Seat Height 31.8 in (807 mm)

Rake 24.0 degrees

Trail

3.2 in (80 mm)

WEIGHT

Frame 22 lbs (10 kg)

Curb Weight  ZF8.5 367

lbs (166 kg)

 ZF1

1.4 399 lbs (181 kg)

Carrying capacity  ZF8.5 398

lbs (181 kg)

 ZF11.4 366 lbs (166 kg)

ECONOMY

Typical Cost to Recharge  ZF8.

5 $0.96/€1.36

 ZF1

1.4 $1.28/€1.81

Equivalent Fuel

conomy, (city)

 ZF8.5 462 MPGe(0.51 L/100 km)

 ZF1

1.4 462 MPGe(0.51 L/100 km)

Equivalent Fuel

conomy (highway)

 ZF8.5 236 MPGe (1.00 L/100 km)

 ZF1

1.4 236 MPGe (1.00 L/100 km)

General Information

1.8

Zero SR

MOTOR

Type Z-Force™ 75-7 passively air-cooled,

gh-efficiency, radial flux, permanent

hi-temp magnet, brushless motor.

Controller High efficiency, 660 amp, 3-phase brushless

cont

roller with re-generative deceleration

Estimated Top Speed

(max)

102 mph (164 km/h)

Estimated Top Speed

(sust

ained)

85 mph (137 km/h)

POWER SYSTEM

Type Z-Force™ Li-Ion Intelligent Power Pack

Maximum Capacity  Z

F11.4: 11.4 kWh

 Z

F14.2: 14.2 kWh

Nominal Capacity  Z

F11.4: 10.0 kWh

 Z

F14.2: 12.5 kWh

Charge Time (standard)  Z

F11.4: 7.9 hours(100% charged) /

7.4 hours (95% charged)

 Z

F14.2: 9.9 hours (100% charged) /

9.3 hours (95% charged)

Supplemental Charger

Quick C

harge Time

(accessory)

 Z

F11.4 4.6 hours (100% charged) / 

4.1 hours (95% charged)

 Z

F14.2 5.8 hours (100% charged) / 

5.1 hours (95% charged)

CHAdeMO Recharge

ime (0 to 95%)

1.0 hour

CHAdeMO Recharge

Time (0 to 100%)

1.5 hours

Input Standard 110 V AC or 220 V AC

Charger Type 1.3kW Integrated

Estimated Power Pack

ife to 80% (city)

 ZF11.4: 308,000 miles (496,000 km)

 ZF11.4: 385,000 miles (620,000 km)

RANGE

City (EPA UDDS)  ZF1

1.4 137 miles (220 km)

 ZF14.

2 171 miles (276 km)

Highway, 55 mph

(88 km/h)

 ZF1

1.4 85 miles (137 km)

 ZF14.

2 106 miles (171 km)

>Combined 

(City + 55 mph)

 ZF1

1.4 105 miles (169 km)

 ZF14.

2 131 miles (211 km)

Highway, 70 mph

12 km/h)

 ZF11.4 70 miles (113 km)

 ZF14.

2 88 miles (141 km)

>Combined (City +

70 mph)

 ZF1

1.4 93 miles (150 km)

 ZF14.

2 116 miles (186 km)

General Information

1.9

DRIVETRAIN

Transmission Clutchless Direct Drive

Final Drive

132T/30T,Poly Chain® GT® Carbon™ belt

CHASSIS/SUSPENSION/BRAKES

Front Suspension Travel 6.25 in (159 mm)

Rear Suspension Travel 6.35 in (161 mm)

Front Brakes Nissin 2 piston hydraulic

313 mm OD rotor, 4.0 mm thick

2 piston floating caliper

Rear Brakes Nissin 2 piston hydraulic

313 mm OD rotor, 4.0 mm thick

2 piston floating caliper

Front Tire 110/70-17 in

Rear Tire 140/70-17 in

Front Wheel 3.00x17

Rear Wheel 3.50x17

Front Suspension 43 mm inverted, aluminum slider forks with

adju

stable compression and rebound

damping

Rear Suspension Piggy-back reservoir shock with adjustable

ring preload, compression and rebound

damping

DIMENSION

Wheel Base 55.4 in (1,410 mm)

Seat Height 31.8 in (807 mm)

Rake 24.0 degrees

Trail

3.2 in (80 mm)

WEIGHT

Frame 22 lbs (10 kg)

Curb Weight  ZF1

1.4 407 lbs (185 kg)

 ZF14

.2 452 lbs (205 kg)

Carrying capacity  ZF1

1.4 358 lbs (162 kg)

 ZF14.2 313 lbs (142 kg)

ECONOMY

Typical Cost to Recharge  ZF1

1.4 $1.28/€1.81

 ZF14

.2 $1.60/€2.26

Equivalent Fuel

conomy (city)

 ZF11.4 462 MPGe (0.51 L/100 km)

 ZF14

.2 462 MPGe (0.51 L/100 km)

Equivalent Fuel

conomy (highway)

 ZF11.4 236 MPGe (1.00 L/100 km)

 ZF14

.2 236 MPGe (1.00 L/100 km)

General Information

1.10

Zero DS

MOTOR

Type Z-Force™ 75-7 passively air-cooled,

gh-efficiency, radial flux, permanent

magnet, brushless motor.

Controller High efficiency, 420 amp, 3-phase brushless

cont

roller with re-generative deceleration

Estimated Top Speed

(max)

98 mph (158 km/h)

Estimated Top Speed

(sust

ained)

80 mph (129 km/h)

POWER SYSTEM

Type Z-Force™ Li-Ion Intelligent Power Pack

Maximum Capacity  Z

F8.5 8.5 kWh

 Z

F11.4 11.4 kWh

Nominal Capacity  Z

F8.5 7.5 kWh

 Z

F11.4 10.0 kWh

Charge Time (standard)  Z

F8.5 6.0 hours (100% charged)/

5.5 hours (95% charged)

 Z

F11.4 7.9 hours (100% charged)/

7.4 hours (95% charged)

Supplemental Charger

Quick C

harge Time

(accessory)

 Z

F8.5 3.6 hours (100% charged) /

3.1 hours (95% charged)

 Z

F11.4 4.6 hours (100% charged) /

4.1 hours (95% charged)

CHAdeMO Recharge

ime (0 to 95%)

1.0 hour

CHAdeMO Recharge

Time (0 to 100%)

1.5 hours

Input Standard 110 V AC or 220 V AC

Charger Type 1.3 kW Integrated

Estimated Power Pack

ife to 80% (city)

 ZF8.5 213,000 miles (343,000 km)

 ZF11.4 284,000 miles (457,000 km)

RANGE

City (EPA UDDS)  ZF8.

5 95 miles (152 km)

 ZF1

1.4 126 miles (203 km)

Highway, 55 mph

(88 km/h)

 Z

F8.5 57 miles (92 km)

 Z

F11.4 76 miles (122 km)

>Combined 

(City + 55 mph)

 ZF8.

5 71 miles (114 km)

 ZF1

1.4 95 miles (153 km)

Highway, 70 mph

12 km/h)

 ZF8.5 46 miles (74 km)

 Z

F11.4 61 miles (98 km)

>Combined (City +

70 mph)

 Z

F8.5 62 miles (99 km)

 ZF11.4 82 miles (132 km)

DRIVETRAIN

Transmission Clutchless Direct Drive

Drive System (standard) 132T / 28T, Poly Chain® GT® Carbon™ belt

General Information

1.11

CHASSIS/SUSPENSION/BRAKES

Front Suspension Travel 7 in (178 mm)

Rear Suspension Travel 7.03 in (195 mm)

Front Brakes Nissin 2 piston hydraulic 

313 mm OD rotor, 4.0 mm thick

2 piston floating caliper

Rear Brakes J-Juan 1 piston hydraulic

240 mm OD rotor, 4.5 mm thick

Front Tire 100/90-19 in

Rear Tire 130/80-17 in

Front Wheel 19 x 2.15 in

Rear Wheel 17 x 3.0 in

Front Suspension 43 mm inverted forks with adjustable

mpression 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 mm)

Rake 26.5 degrees

Trail 4.6 in (117 mm)

WEIGHT

Frame 22 lbs(10 kg)

Curb Weight  ZF8.5 372

lbs (169 kg)

 ZF1

1.4 404 lbs (183 kg)

Carrying Capacity  ZF8.5 393

lbs (178 kg)

 ZF11.4 361 lbs (164 kg)

ECONOMY

Typical Cost to Charge  ZF8.

5 $0.96/€1.36

 ZF1

1.4 $1.28/€1.81

Equivalent Fuel

conomy, City (EPA

UDDS)

 ZF8.

5 425 MPGe (.55 L/100 km)

 ZF1

1.4 425 MPGe (.55 L/100 km)

Equivalent Fuel

conomy (highway

70 mph)

 ZF8.

5 206 MPGe (1.14 L/100 km)

 ZF1

1.4 206 MPGe (1.14 L/100 km)

General Information

1.12

Vehicle Range

The range of an electric vehicle is defined as the distance

the vehicle travels on a single full charge of the power

pack. Just like EPA mileage estimates on an automobile,

“your mileage may vary.” Your range results are a direct

reflection of your riding habits. The more conservative you

ride the better range you can expect from your Zero

S/SR/DS motorcycle.

Some of the factors which affect range include speed,

accele

ration, number of starts and stops, ambient air

temperature, as well as changes in elevation. The

combination of these factors, as you travel from one point

to another, defines your trip profile. In addition, tire

pressure and payload are important considerations.

We suggest that you ride conservativel

y when you first get

your Zero S/SR/DS motorcycle, and get to know your

motorcycle and your commute. Once you become familiar

with the range 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 envelope. Those

individuals with relatively short commutes can expect to

ride quite aggressively and reach their destination with

energy to spare.

Reported motorcycle range values are measured using

two di

fferent types of industry standard test procedures:

1. “City (EPA UDDS)”: This test procedure uses a duty

cycle known as the “Universal Dynamometer Driving

Schedule (UDDS)”, which was developed by the U.S.

Environmental Protection Agency (EPA) in order to

simulate city-type riding.

2. “Highway”: This test procedure uses two separate

const

ant speeds of 55 mph and 70 mph to simulate

highway riding.

Both of these test procedures are run on a single charge,

n order to report the associated measured range values.

Range values labeled “Combined” are based on a

calculation that assumes a duty cycle comprised of 50%

City / 50% Highway.

See technical specification charts on page 1.6 through

page

1.10 for these ranges.

General Information

1.13

Public Charging Stations

There are more public charging stations coming online

every day and there may be some in your area. You can

charge from a public charging station with either the

optional J1772 S/SR/DS Zero motorcycle accessory or

CHAdeMO Zero motorcycle accessory. These stations are

often available at a variety of locations including shopping

centers, city parking lots, airports, hotels, government

offices, and other businesses. We recommend that you

search the internet for locations in your area. For example,

search for “charging stations.”

CHAdeMO Charger

Your Zero motorcycle can utilize a quick charging

CHAdeMO charger

system. A CHAdeMO charger can

cha

rge your motorcycle in about 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 difference

between electric and gas is that energy consumption is

averaged over a shorter distance on an electric

motorcycle. Electric motorcycles are designed for

convenient daily recharges versus less frequent and less

convenient trips to the gas station. As a result, the same

electric motorcycle often yields different ranges from one

full recharge to the next.

How to Predict the Range

To generally predict how an electric motorcycle’s range will

be af

fected, you can use the four factors:

 route

 rider

 w

eather

 motorcycle

By considering each of these factors, you can use

specifica

tions such as ‘city range’ as standards to estimate

what the motorcycle’s real world range will be under the

your particular usage case.

General Information

1.14

General Information

1.15

General Information

1.16

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. It also has no exhaust or evaporative

emissions. Because the Zero S/SR/DS runs solely on

electricity, it 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 efficiency, and can help

solve the serious 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

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

General Information

1.17

Transporting

When the front fork is compressed, the built up pressure

must be released to help prevent fork seal leaks. There is

a 3 mm Allen “bleed” screw located just in front of the

rebound adjuster on each fork leg. This “bleed” screw (A)

is used to release the built up pressure. Loosen the screw

slowly, but do not remove. Once all the air is out, tighten

the bleed screw.

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 riding.

It is recommended that the motorcycle be tied-down using

ratchet straps. Place the ratchet straps around a frame

contact point. Soft straps must be used to prevent

scratches or other damage.

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.

Notes

1.18

General Safety Precautions

2.1

Safety InformationGeneral Safety Precautions

General Safety Precautions

 This is a performance motorcycle and should be

treated with extreme caution.

 Proper safety

gear, including a regionally approved

helmet, riding boots, gloves, and protective clothing

should be worn while riding to reduce the risk of

potential injury. We highly recommend the use of full

height riding boots since the vast majority of motorcycle

injuries are leg and foot injuries. It is not recommended

to ride without the correct protective clothing; this

applies to even short journeys, and to every season of

the year.

 Rea

d all additional warnings and product instructions in

this owner’s manual, as well as safety labels, before

operating your electric motorcycle.

 Never pe

rmit a guest to ride your electric motorcycle

without proper instruction.

 Never use al

cohol or mind-altering drugs before

operating your electric motorcycle.

 Persons unw

illing or unable to take responsibility for

their actions should not use this motorcycle. You

assume all responsibility while operating your

motorcycle. The seller assumes no liability for misuse

or operator negligence.

 Prio

r to each use the rider must check everything in the

“every ride” column of the maintenance schedule on

page

5.2, and the charge level of the power pack as

indicated on the dash display charge indicator.

 Y

our safety depends in part on the good mechanical

condition of the motorcycle. Be sure to follow the

maintenance schedule and adjustment requirements

contained in this manual. Be sure you understand the

importance of checking all items thoroughly before

riding.

 Modifications

to the motorcycle may render the vehicle

unsafe and may cause severe personal injury. Zero

Motorcycles cannot be held liable for non-approved

modifications.

 Be

very careful when loading or adding accessories to

your motorcycle. Large, bulky, or heavy items may

adversely affect the handling and performance of your

motorcycle.

General Safety Precautions

2.2

Important Operating Information

Several operating considerations are listed below:

 Always tur

n the key switch and motor stop switch to the

OFF position when not actively riding. It is very easy to

forget that the motorcycle is powered up because it is

silent. An accident can occur if the motorcycle is left

powered up while getting on or off the motorcycle.

 T

urn the motor stop switch OFF when backing up or

pushing the motorcycle while dismounted.

 Use

the rear brake when you are stopped on an incline.

Do not hold the motorcycle using partial throttle or

damage to the motor may occur.

 T

he power pack should be plugged in when storing the

motorcycle for extended periods of time.

 Ke

ep 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.

The power pack must be charged within 24 hours if fully

ischarged, and must be charged within 90 days if

stored fully charged. Zero recommends you plug in

your power pack after 90 days even if it is fully charged.

Please leave your power pack plugged in whenever

possible. You should also use the supplied cable as it is

designed for use with your motorcycle’s electrical

components

WARNING! Cha

rge the Zero power pack with the

motorcycle’s on-board charger or the approved Zero

accessory charger.

 The power pack does not require, or tolerate, deep

discharging. To get the most power pack life, recharge

each power pack immediately after each ride. Leaving

a power pack in a discharged state will cause damage.

 Fa

ilure to follow power pack storage and charging

instructions as described in this Zero Motorcycles

Owner’s Manual may void the warranty of your Zero

motorcycle. These guidelines have been rigorously

tested to ensure maximum power pack efficiency and

service.

Location of Important Labels

2.3

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

B. VIN label (European Union) - certification

label

C. VIN label (North America) - certification label shown

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.

Location of Important Labels

2.5

High Voltage Warning Label

Affixed to battery

Notes

2.6

Controls and Components

3.1

Controls and ComponentsControls and Components

THIS PAGE INTENTIONALLY LEFT BLANK

Controls and Components

3.2

Motorcycle Controls

Controls and Components

3.3

A. Mirrors

This motorcycle is equipped

with convex mirrors. A

convex mirror has a curved surface. Convex mirrors

offer a greater field of view than a similar flat mirror.

However, the greater field of view makes objects

seem further away than they really are. Care must be

used when judging the distance of objects seen in

these mirrors.

B. Key S

witch/Steering Lock

For description and operation see

“Key

Switch/Steering Lock Positions”, on page 4-4

C. Dash Overview

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. F

ront Brake Fluid Reservoir

For description and operation see “Brakes”, on

page 5-9.

F. Right Handlebar Control

For description and operation see

“Handlebar

Controls”, on page 3-16.

G. Fr

ont Brake Lever

For description and operation see

“Handlebar

Controls”, on page 3-16.

H. Th

rottle Control

For description and operation see“Handlebar

Controls”, on page 3-16.

I. Motor Stop Switch

For description and operation see

“Handlebar

Controls”, on page 3-16.

J. L

eft Handlebar Control

For description and operation see

“Handlebar

Controls”, on page 3-16.

Controls and Components

3.4

Left Side View

Controls and Components

3.5

A. Headlight

 Fo

r headlight operation, see “Handlebar Controls”, on

page 3-16.

 Fo

r headlight bulb replacement, see “Headlight Bulb

Replacement”, on page 5-17.

 Fo

r headlight alignment, see“Headlight Alignment”,

on page 5-16.

B. Fron

t Turn Signal

 For turn signal operation, see “Handlebar Controls”,

on page 3-16.

 Fo

r turn signal light bulb replacement, see “Turn

Signal Light Bulb Replacement”, on page 5-19.

C. AC Cha

rger Power Connection

For description and operation, see “Power Pack”, on

page 4-5.

D. Brake/Tail Light

For brake/tail light bulb replacement, see

“Brake/Tail

LED Replacement”, on page 5-19.

E. Re

ar Turn Signal

For turn signal operation, see

“Handlebar Controls”,

on page 3-16.

F. Kick

stand

The kickstand swings out from the side and supports

the motorcycle when parked. The key switch should

be in the OFF position when parked.

G. Kicks

tand Switch

This switch is a safety feature

that prevents motor

operation when the kickstand is down. If the kickstand

were down when riding it could contact the ground

causing you to lose control of the motorcycle and

cause personal injury.

WARNING! Park only on a flat firm surface otherwise the

motorcycle could fall over causing damage.

H. Integrated Power Pack Charger

For description and operation, see

“Power Pack”, on

page 4-5.

Controls and Components

3.6

Right Side View

Controls and Components

3.7

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. Power Pack

For description and operation see

“Power Pack”, on

page 4-5.

D. Re

ar Brake Pedal

The rear brake pedal controls the rear brake when the

dal is pressed. When braking, the throttle should be

in the closed position. The brake light illuminates

when the rear brake pedal is applied.

E. Br

ushless Motor Controller

Precisely “meters” the flow of electricity from the

wer pack to the motor according to the action of the

throttle and surrounding conditions.

F. Dr

ive Belt Tension Adjuster

See

“Checking Drive Belt Tension”, on page 5-14 for

additional information.

Controls and Components

3.8

Dash Overview

Controls and Components

3.9

A. Adjust Button (ADJ)

See

“Dash Settings”, on page 3-12.

B. Select Button (SEL)

See

“Dash Settings”, on page 3-12.

C. Cha

rge Indicator

This indicator and readout displays the amount of

energy remaining in the power pack, similar to the fuel

gauge on a gasoline powered vehicle.

D. Remain

ing Charge Time Indicator

This area displays the amount of time left for the

power pack to reach full charge.

E. Clock

The clock displays time in standard (AM/PM) or 24

ur mode.See

“Setting the Clock”, on page 3-13

F. Speedometer

The speedometer is a digital display in either

kil

ometers per hour (km/h) or miles per hour (mph).

See

“Unit Display - Speed”, on page 3-14

G. Odometer

The odometer displays the total distance the

motorcycle has

been ridden in kilometers or miles.

H. Per

formance Modes

This area displays which performance riding mode

(ECO, SPORT, a

nd CUSTOM) has been selected by

the rider using the performance level mode button

located on the right handlebar control assembly. See

“Performance Level Mode Button”, on page 3-19

I. Output Meter

The OUT

PUT meter indicates the amount of Torque

applied to the rear wheel and the Power (energy)

being used while riding.

J. Re

gen Meter

The regenerative (REGEN)

meter indicates the

amount of Torque on the rear wheel and the Power

(energy) feeding back into the battery of the

motorcycle during the regenerative braking process.

K. Display

s A&B

Displays A&B can be customized

to display functions

which include Trip odometers, Range, Errors, RPM,

Trip Average, Lifetime Average, and Temperature. All

are accessible by using the ADJ and SEL buttons.

See

“Dash Settings”, on page 3-12.

L. Blu

etooth® Indicator

This indicator displays when an active Bluetooth®

equipped smartphone is paired with the motorcycle.

For Pairing instructions, see

“Bluetooth® Pairing”, on

page 3-15

Controls and Components

3.10

Warning Indicator Lights

Controls and Components

3.11

A. Left Indicator Turn Signal

An arrow on the lower dash flashes green

in the same direction as selected by the

turn signal switch. This arrow remains on

until the turn signal request has been canceled.

B. System Warning Indicator

If a fault has been detected, count the

number of times the red LED flashes. See

the table on

“System Warning Indicator”,

on page 6-2

C. Temperature Lamp

This flashes in the event that you exceed

the motorcycle’s performance capabilities.

The temperature warning lamp indicates

the temperature of the motor, controller temperature,

or the battery 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, see

“Troubleshooting

Your Motorcycle”, on page 6-1.

E. Charging Indicator

Flashes slowly when the motorcycle is

accepting a charge. The indicator flashes

rapidly when a charging error is detected.

The indicator is solid green when the battery is

completely charged.

F. High Be

Indicator

When the headlight high beam is on, this

indicator illuminates blue, and remains on

unti

l the high beam is turned off.

G. Right Turn Signal Indicator

An arrow on the lower dash flashes green

in the same direction as selected by the

turn signal switch. This remains on until

the turn signal request has been canceled.

Controls and Components

3.12

Dash Settings

The displays on the dash can be customized to your

personal preferences by using the ADJ (Adjust) and SEL

(Select) buttons.

A. Adjust Button (ADJ)

By momentarily pressing or holding the ADJ button

you can reset fields and toggle through the trip menus

and display options.

B. Select Button (SEL)

By momentarily pressing or holding the SEL bu

you can reset or select fields in Display A and Display

B, change the time, and change the display units.

Note: Once a feature is selected, it will stop flashing after

15 secon

s if no further button press is detected, and the

dash will return to its normal operating mode.

Displays A&B

Display A

To select Display A with the dash in its normal operating

mode

, momentarily press the SEL button once. Press the

ADJ button to toggle through the following fields:

 Trip 1 Odometer - Displays individual trip mileage and

is reset by pressing and holding the ADJ button for 2

seconds.

Note: Trip 1 is reset each time the battery is recharged

to 100%.

 Range - Displays remaining battery power based on

learned riding style and usage.

 Errors - Displays 4-digit error codes for dealer use.

 RPM - Displays motor RPM.

Controls and Components

3.13

Display B

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.

 T

rip AV - Displays the average energy usage during

dura

tion of Trip 1 in watt hours (Wh), per mile (mi), or

kilometer (km), depending on the currently selected

display unit.

Note: The Trip AV is reset each time the battery is

recharged to 100%

 Temp - Displays the temperature of the motor, battery,

and controller in Fahrenheit (F) or Celsius (C).

Note: The temperature 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 (Wh), per mile (mi),

or kilometer (km), depending on the currently selected

display unit.

Setting the Clock

To set the clock with the dash in its normal operating

mode, press and hold the SEL button for 5 seconds, then

momentarily press the SEL button once more. The clock

display will start to flash.

 Hours - Press and release the ADJ bu

tton to increase

the hour setting.

 Minutes - Press and release the SEL button once

select the minute display, then press and release the

ADJ button to increase the minute setting.

 Standard or 24 Hour Mode - Press and release the SEL

butt

on to select the time format, then press the ADJ

button to select P (am/pm mode) or 24:00 (24 hour

mode).

Controls and Components

3.14

Unit Display - Speed

To change the units that speed is shown in:

1. With the dash in its normal operating mode press and

hold the SEL button for 5 seconds.

2. Momentarily press the ADJ

button to select English

(MPH) or metric (km/h).

3. Momentarily press the SEL butt

on 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

hold th

e SEL button for 5 seconds.

2. Momentarily press the SEL button 4 times, the Te

icon on the lower dash will start to flash.

3. Press the ADJ butto

n to toggle between F or C on the

display.

4. Momentarily press the SEL button to re

turn to normal

operating mode.

Controls and Components

3.15

Smartphone Application

You can download a smartphone application that lets you

perform the following tasks related to your motorcycle:

 Adju

st the CUSTOM mode for performance gains

 Coll

ect and email logs to Zero support staff

 Examine

the precise State of Charge (SOC) of your

motorcycle

 Examine

real time power usage

The Smartphone application is avai

lable for free at both

the Apple iTunes store and Google Play store. iTunes® is

a registered trademark of Apple. Google Play® store is a

registered trademark of Google.

Bluetooth® Pairing

The following steps must be taken to properly pair a

Bluetooth®-equipped smartphone with your motorcycle.

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 button on the right handlebar

for a minimum of

5 seconds until the Bluetooth®

symbol on the dash begins to blink, then you may

release the Mode button.

3. Your motorcycle will be discoverable with the

Bluetooth® ID

of ZeroMotorcyclesXXXXX (XXXXX

refers to the last 5 digits of the motorcycle’s VIN).

 For iOS

devices, go to the Settings application on

your smartphone and locate the Bluetooth® menu

and pair with your motorcycle

 For Andro

id devices, go to the Settings tab in your

Zero Android application and choose the button with

the Bluetooth® symbol

Note: When the Bluetooth® indicator on the dash

display is solid, your motorcycle and smart phone are

paired over Bluetooth®.

Controls and Components

3.16

Handlebar Controls

Controls and Components

3.17

A. Flash-to-Pass

When the headlight is in the low beam position, push

the flas

h-to-pass switch and the high beam illuminates

and stays illuminated until the switch is released.

When released, this switch defaults back to the low

beam position. The high beam indicator also

illuminates.

B. Head

light High/Low Beam Switch

When the switch is pushed, the headlight

changes from low beam to high beam. It

stays in the selected position until it is

switched back. When in high beam position, the high

beam indicator on the lower dash illuminates.

C. Fron

t Brake Lever

he front brake lever controls th

e front brake when the

lever is squeezed. When braking, the throttle should

be in the closed position. The brake light also

illuminates.

D. Throttle Control

wist the throttle in a counter-clockwise rotation (A) to

energize the motor and start the motorcycle in a

forward

direction. Release the throttle and it snaps

back to the closed position (B), de-energizing the

motor, and regenerative braking begins.

When the motorcycle is moving and the throttle

con

rol is in the fully closed position, the regenerative

braking feature activates. Regenerative braking takes

some of the energy from the moving motorcycle and

turns it back into electrical energy. This energy is then

stored back into the power pack, contributing to

increased energy efficiency. A slight drag is felt when

the regenerative braking is activated. If you want to

coast without the regenerative braking, hold the

throttle just off of the fully closed position.

Controls and Components

3.18

E. Motor Stop Switch

When the top of the switch (A) is pressed, it cuts off

power

to the motor controller. The motor controller

remains in this state until the bottom portion of the

switch (B) is pressed. The switch does not turn off all

electrical circuits, just the operation of the motor.

F. Performance Level Mode Button

The performance level button (A) toggl

es between

ECO, SPORT, and CUSTOM modes.(refer to

“Performance Level Mode Button”, on page 3-19)

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 signal

indicator on the lower dash illuminates.

Always signal your turns and other maneuvers as

quire

d by law. Unlike an automobile, the turn signals

must always be canceled manually on the motorcycle.

Push in on the switch and it returns to the center, or,

OFF position.

H. Ho

rn Button

hen the key is in the ON position, the horn (A)

sounds whe

n the button is pressed. Electric vehicles

run quietly; the horn can be used to warn pedestrians

or other motorists of your presence.

Controls and Components

3.19

Performance Level Mode Button

The performance level mode button (A) toggles between

ECO, SPORT, and CUSTOM modes. You can switch

between performance modes while riding but the change

will not be executed until the throttle is returned to the

closed position.

The ECO sele

ction reduces the acceleration and top

speed of the 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 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).

Those who take advantage of the ECO position

are likely

to see a slight increase in range and experience greater

regenerative braking.

Controls and Components

3.20

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 motorcyc

le, secure the tank

bag with the lock (above the tank bag). At high speeds the

bag could eject, if is not secured.

Controls and Components

3.21

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.

Notes

3.22

Starting and Operating

4.1

Starting and Opera tingStarting and Opera ting

First Time Set-Up

If your motorcycle was direct-shipped you will need to

perform the following:

1. Remove the motorcycle from its shipping crate. See

Unp

acking 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).

4. Check the tire pressure and adjust to proper

specifica

tions. See

“Tire Inflation”, on page 5.13.

5. Inspect the hydraulic brake system. Follow the

hydrau

lic 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.

6. Make sure the motorcycle key switch is OFF

, then twist

the throttle to make sure its rotation is smooth, and it

returns correctly.

7. Inspect bolts and make sure they are tight. See

page

5.9 for general maintenance information. Double

check the fork, wheel, and brake bolts.

8. Insert the key in the key swi

tch and turn the key to the

ON position. The gauge performs a self test sweep.

The charge indicator should read fully charged.

Starting and Operating

4.2

Unpacking Your Zero Motorcycle

Although unpacking your Zero motorcycle can be done by

a single person, it is recommended to have a second

person to help lift and remove your motorcycle from the

crate base.

Outer Box Cover

 Cu

t and remove the two outer box retention straps.

 Un

screw stabilizer bar bolts, one on each side of outer

box.

 Open

box top and remove inner cardboard end

reinforcement sleeves.

 Un

screw stabilizer bar from handlebar end and remove.

 Un

screw lower crate cover retaining screws and

washers.

 L

ift or cut outer box away from motorcycle.

Inner Assembly

 Carefully remove plastic cover

from motorcycle.

 L

ocate small parts box below motorcycle and put to the

side. (This box contains important documentation,

owner’s manual, keys, etc.).

 R

emove the tie down straps from crate base.

 Carefully lift rear portion of the motorcycle over the

swingarm standoff and off crate base.

 Care

fully lift front wheel out of crate base.

 Dep

loy kickstand, lean motorcycle and inspect in

accordance with delivery inspection sheet.

Recycling

Your Zero Motorcycles shipping crate and p

ackaging

materials were designed to be completely recycled. Please

cut down and recycle all cardboard, plastic, and wood

materials in appropriate receptacles.

The tie down straps that accompanied your motorcycle

can be reused as regular tie down straps.

General Operation

4.3

General Operatio n

General Operation

This section describes several items you should examine

before operation.

Pre-Ride Inspection

Before operating your Zero motorcycle, check the

following to make sure the motorcycle is secure and intact:

 Power Pack. Make sure the charge indicator on the

lower dash is indicating a charged power pack. We

suggest you recharge before use. Always keep the

charger cord with the motorcycle.

 Drive Be

lt. Check the belt tension and condition.

Adjust if necessary. See “Drive Belt”, on page 5.14.

 Bra

kes. Squeeze the brake 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.

 Th

rottle. With the key switch in the OFF position, apply

the throttle and release to verify that the throttle is

smooth and returns correctly.

 Ti

res. Check both tires for condition and tread depth.

Check cold tire pressure frequently. Check for damage

and alignment. Maintain correct tire pressure as

specified on page

5.13. Replace the tires when the

tread height is 0.08 in (2 mm) or less.

CAUTION: Under-inflation is a common cause of tire

failure and may result in severe tire cracking, tread

separation, “blowout,” or unexpected loss of motorcycle

control causing serious injury or death. Inspect tires

regularly to ensure proper inflation levels.

 Electrical System. Check for correct function of the

headlight, turn signals, and the brake/tail lights.

 Pr

otective Covers. Confirm protective covers for

power pack diagnostic connector, Quick Charge

connector, and onboard charging connector are

installed correctly.

General Operation

4.4

Key Switch/Steering Lock Positions

This is a three-position switch that is located on the fork in

front of the handlebar. The switch positions are as follows:

 Steering Lock (A)

 OFF (B)

 ON (C)

The key should be removed from the motorcycle when

rked 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 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.

3. Remove the key.

To unlock the steering lock

1. Install the key and turn clockwise.

2. Remove the key.

General Operation

4.5

OFF Position

This position is used to turn the motorcycle OFF, disabling

the electrical system.

ON Position

This position is used for operating the motorcycle.

In this

position the following sequence occurs:

 Lights turn ON

 Dash display turns ON

Power Pack

The battery is located within the power pack and requires

no special break in period.

The 2014 Zero S/SR/DS leverages the 201

3’s battery cell

chemistry, configuration, and enhanced reliability. Not only

does the Z-Force® technology enable you to go longer

distances (range may vary depending on riding type and

conditions), it is also designed to last the life of the

motorcycle. 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 onboard

charge

r is connected to a 120 V AC or a 240 V AC supply.

The normal recharging time of the power pack to a 100%

charge is usually less than 6 hours for the ZF8.5 and 7.9

hours for ZF11.4 in mild ambient temperatures. Out of the

normal temperature range, charging and run-time times

will vary. The power pack should not be used outside of the

range of 23°F to 140°F (-5°C to 60°C); the Battery

Management System (BMS) turns off the power controller

outside of this range.

Note: The Battery will not charge if below 0°C or 32°F.

It is required that you leave the motorcycl

e on the charger

if you expect it to sit in storage or unused for over 30 days.

General Operation

4.6

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 90 days, even if fully charged. Please

leave your Zero motorcycle plugged in whenever possible.

Battery Management System (BMS)

Every power pack contains a Battery Management System

(BMS) which monitors the condition of the cells, and

optimizes the charging process to provide the

highest-performance, longest-range, and longest life for

the power pack.

The BMS safeguards the power pack by means of safety

interlock

s. These interlocks turn off or control certain

operations that could damage the power pack. See “Safety

Interlocks”, on page 6.14 for more information.

The BMS also monitors the power pack for a host of

prede

fined conditions, and then takes actions according to

those conditions. See,

“Battery Management System”, on

page 6.6 and “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 as you charge, ride, and store your

motorcycle.

Add On Electrical Equipment

WARNING! Do no

t add electrical components to your

motorcycle unless approved by an authorized Zero

Motorcycles dealer. Some add-on electrical components

can damage your motorcycle, prevent other components

from working as they should, and/or dramatically reduce

the range and/or life expectancy of the power pack.

Power Pack Charger

Keep your power pack connected to the charger when

your

motorcycle is sitting in storage or if it will be sitting

unused for more than 90 days. 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 90 days, even if fully

charged. Please leave your Zero motorcycle plugged in

whenever possible.

WARNING! On

ly charge the Zero power pack with the

Zero charger. The charger is located under the power

pack.

General Operation

4.7

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. Once fully charged, the charger

will check the status of the power pack once every 72

hours to ensure that it maintains a full charge. When

fully charged, a green light illuminates on the charger.

Should the charger not read that the power pack is full,

it continues 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 power pack is charged, check the charge indicator

on the dash display prior to riding.

 If th

e power pack terminates the charge before the

charge

r reaches the state previously mentioned, then

the charger continues to cycle and tops off the power

pack until the power pack is removed from the charger,

or the charger reaches the complete state previously

noted.

The onboard charger LED indicator (A) is visible through

the front

of the battery housing. A circular lens displays the

colored LED’s status of the charge.

When charging the motorcycle, the LEDs flash from left to

right, then the LEDs display how much of the battery (on a

score of 1 to 4) is charged. Next the LEDs cycle from left to

right once more. For example, if 3 of the 4 LEDs are

illuminated, the battery is 3/4 charged. Refer to

“Battery

Management System”, on page 6.6 for more information.

General Operation

4.8

Charging the Power Pack

WARNING! Charge the Zero power pack with the Zero

charger.

It is possible for lithium ion cells to overheat and fail.

Note: Charge the Zero Power pack in a location that is

well-ve

ntilated and away from combustible materials. If

charging your Zero motorcycle outdoors, avoid charging in

the rain.

The maximum power pack internal charging temperature is

131

°F

(55°C). If the power pack’s internal temperature is

over 131°F (55°C), it will not accept a charge until it is

moved to a cooler location. Also, if the power pack has just

been run hard, it may internally be above 131°F (55°C)

even if the ambient temperature is lower.

If you experience a power pack that will not take a charge,

you should

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 less.

The maximum charging temperature cutoff is a power pack

longevity

feature. Charging at higher temperatures can

shorten the life of the power pack.

Note: Frequent top off charging is good for the power

ck’s life span, so do not hesitate to charge frequently.

To charge using the standard charger:

1. Plug the supplied power cord (A) into the onboard

charger connector. Always keep the power cord with

the motorcycle.

2. Always connect the charger 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 current. The voltage does not

change the amount of time that the motorcycle takes to

charge.

General Operation

4.9

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. The charging icon (A) flashes as the battery is being

charged. Once charging is complete, the icon stays

illuminated

4. Charging a fully discharged power pack to 100% takes

about:

 ZF8.5 6 hours

 ZF11.4 7.9 hours

te: The charging icon is solid green when fully charged

and

plugged into the charger.

General Operation

4.10

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.

The accessory charging connector is located above the

r. For more information on how to connect additional

chargers, refer to the quick charger’s owner’s manual.

A. AC Power Cord

B. AC Power

Cord Connection

C. Power Pack Charger

D. Charger LED Indicators

E. Connector (to motorcycle)

General Operation

4.11

To charge using the Quick Charger

1. Ensure that the key switch is in the OFF position.

2. Locate the accessory charging connector (above the

motor) and remove the protective cover.

3. Connect the power pack charger to the power pack

connecto

4. Always connect the charger 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 current. The voltage does not

change the amount of time that the motorcycle takes to

charge.

5. Connect the off board accessory charger. See

“Quick

Charging (Off Board Accessory Charger)”, on

page 4.10.

6. When the power pack is fully charged, disconnect the

charger(s) and rein

stall the protective cover.

General Operation

4.12

Quick Charger LED Indicators

A. Ammeter

The Ammeter LED is an amber indicator that indicates

the amoun

t of current output and should gradually

ramp down from “IIIIII” to “I”.

B. 80% Charg

The 80% Charge LED is an amber indicator. If it is on

solid,

the bulk charge phase is complete, 80%

charged. Charger is now in absorption phase. If the

indicator is flashing, there are two issues that can

cause this to occur:

 The charger and BMS are balancing.

 The BMS is cutting off the charge because one or

cells have reached maximum voltage.

C. 100% Charge

The 100% Charge LED is a green indicator. If it is on

lid, 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

he AC ON LED is an amber indicator. If it is on solid,

the AC

power is good. If it is flashing, the AC voltage

is low. Check for proper voltage, and if an extension

cord is being used, verify that it is the correct length.

Maximum length is 25 ft. (7.6 m) 12 AWG.

E. Fa

ult

he Fault LED is a red indicator which indicates there

a charger error. If it is flashing, reset the charger

and see

“Troubleshooting”, on page 6.1.

CHAdeMO Charger

Your Zero motorcycle can utilize an optional qui

ck charging

CHAdeMO charger system. A CHAdeMO charger can

charge your motorcycle in about one hour

. For additional

information contact your Zero Motorcycles dealer.

General Operation

4.13

Operating Your Motorcycle

This section describes how to safely operate your

motorcycle.

Starting

1. Turn the key switch to the ON position.

2. Verify that the charge indicator reads fully charged.

3. Press the motor stop switch to the ON position.

4. With the kickstand up, twist the throttle toward

you

(counter-clockwise) to increase speed. When the

throttle is twisted away from you (clockwise), the speed

decreases.

Braking

On the right handlebar is the hand operated brake lever.

he brake lever controls the front brake when the lever is

squeezed. On the right lower side, next to the foot peg, is

the foot operated brake pedal. This pedal controls the rear

brake. When braking, the throttle should be in the closed

position.

CAUTION: If you ap

ply the front or rear brake hard

enough, it is possible to lock the wheels. This could cause

you to lose control of the motorcycle and could lead to

serious injury or death. Progressive use of the brakes

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 safe emergency stops.

Stopping Your Motorcycle

To stop your motorcycle:

1. With the throttle in the closed position press the motor

stop switch to the OFF position. This switch can also be

used in an emergency to shut the motor off.

2. Turn the key switch to the OFF position and remove the

y. 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.

Temperature Indicator

Zero Motorcycles has developed the most advanced

passively air-cooled electric powertrain for your Zero

motorcycle, delivering an unsurpassed level of simplicity,

power/energy density, low weight and ease of

maintenance. However, this passively air-cooled

pow

ertrain cannot be operated indefinitely at high power /

high rpm without reaching its thermal limitations. Hence,

your Zero motorcycle has a sophisticated thermal

management strategy to ensure the long term

performance and durability of its powertrain.

General Operation

4.14

The red temperature indicator light (A) on your Zero

motorcycle’s lower dash has two informational stages.

 Stage 1, is presented by flashing this indicator and

advises you that

the bike is about to enter its thermal

strategy. To avoid encountering an enforced power

reduction, you can choose to slow down a bit until the

indicator stops flashing.

 S

tage 2, if temperature continues to bu

ild, the indicator

light will go solid, letting you know that the thermal

strategy is now being applied and that your

motorcycle’s power will be reduced accordingly. If you

encounter the strategy while trying to maintain a high

vehicle speed, the effect 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

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 in

dicator

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

speed/power until your Zero can maintain its maximum

allowable thermal state; but no harm whatsoever will result

from this, since this is exactly how the strategy is meant to

function.

General Operation

4.15

Front Suspension Adjustment

A shock has two main actions: compression when the

shock gets loaded, and rebound when the shock returns

back to full length. Compression damping is the

adjustment that determines how fast or slow the fork

compresses. Rebound damping is the adjustment that

determines how fast or slow the fork rebounds.

Bleed Screw

The 3 mm Allen M5 screw (A) at the top of the fork leg is

the “bleed” screw. The bleed screw serves two purposes:

1. Transporting your motorcycle. See

“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 screw (B) on the top of both fork legs. Next

to the screw are the letters “S-F,” meaning Slow and Fast.

The adjuster has 18 stages of adjustment. This determines

how quickly the fork returns to its extended position after

being compressed.

 Turning the rebound adjuster screw clockwise slows

the

rebound speed down making it better for larger,

rolling terrain or bumps.

 Turning the rebound adjuster screw counter-clockwise

ncreases the rebound speed making it better for

smaller, rougher bumps. Adjust each fork leg evenly.

General Operation

4.16

Compression Damping

The compression damping is adjusted by turning a screw

on the bottom of each fork leg. There is a rubber dust

cover protecting the jam nut (A) securing the screw (B).

The adjuster has 12 stages of adjustment.

 Turn the adjuster clockwise for slower compression.

 To speed up compression, turn the adjuster

unter-clockwise.

Start with 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 consecutive bumps)

while compression 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 rubber dust cover

after the adjustment.

Note: Adjusters should never be forced completely “Fast”

r “Slow”; always leave one click of adjustment in either

direction.

Factory Supplied Front Suspension Settings

The following information will allow you to adjust the front

susp

ension back to the factory settings the motorcycle was

originally supplied with.

S & SR Models

ADJUSTMENT SETTING

Front Fork Compression 10 clicks out from fully closed

Front Fork Rebound 10 clicks out from fully closed

DS Models

ADJUSTMENT SETTING

Front Fork Compression 9 clicks out from fully closed

Front Fork Rebound 10 clicks out from fully closed

General Operation

4.17

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 it

s vertical travel. Heavier riders require stiffer

spring rates. A good approximation of your rear spring

requirements can be found by measuring the rear

suspension’s sag. This measurement quickly determines if

your rear spring is approximately correct for your 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 the ground.

2. Measure vertically from the rear axle to

the rear fender.

Mark this spot as it is used for other measurements.

3. Record this measurement (this is the measurement

referred to as M1).

4. Remove the motorcycle from the stand.

5. Wearing your normal riding apparel, sit on the

motorcycle.

6. Have an assistant hold the motorcycle up, your feet

should

be on both pegs.

7. Bounce the suspension a couple of times.

8. Have a second assistant take a measurement using the

locations as in step 2.

9. Record this measurement (this is the measurement

refe

rred to as M2).

General Operation

4.18

10.Subtract the second measurement (M2) from the first

measurement (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, the spring

pre-load should be adjusted.

MODEL SAG

S & SR 1.77 in (45 mm)

DS 2.36 in (60 mm)

General Operation

4.19

Spring Pre-load Adjustment

1. Clean any dirt or debris from the threads of the shock

near

the lock ring (A).

2. Using a lock ring wrench loosen the lock nut (A).

3. For measurements less than the specified value,

decreas

e the pre-load on the spring by turning the

spring nut (B) counter-clockwise on the shock. If more

than the 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 adjustment. Printed on the knob is

S-F, meaning Slow and Fast. The rebound adjuster knob

controls how slow or fast the shock returns to its extended

position after being compressed. Turning the knob

clockwise, or S direction, is good for big impacts.

Turning the knob counter-clockwise, or F dire

ction, is good

for smaller and more frequent impacts.

General Operation

4.20

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. Start

with 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 consecutive bumps)

while compression that is set too fast causes the shock to

bottom out harshly. If the shock is bottoming out, turn the

adjuster one click at a time until the bottom out stops.

Note: Adjusters should never be forced completely “Fast”

or “Sl

w”; always leave one click of adjustment in either

direction.

General Operation

4.21

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 7 mm

DS Model

ADJUSTMENT SETTING

Rear Shock Compression 14 clicks out from fully closed

Rear Shock Rebound 4 clicks out from fully closed

Rear Shock Spring Preload 7 mm

Notes

4.22

Maintaining Your Motorcycle

5.1

Maintaining Your MotorcycleMaintaining Your Motorcycle

Owner’s Responsibilities

Listed below are the responsibilities afforded to the owner:

 This owner’s manual should be considered a

perman

ent part of this motorcycle and should remain

with it even if the motorcycle is subsequently sold.

 Perform rout

ine care and maintenance of your electric

motorcycle as detailed in this owner’s manual.

 Use only Zero approved p

arts and Zero Motorcycles

accessories.

 The operator is responsible for learning and obeying all

coun

try, federal, state, and local laws governing the

operations of an electric motorcycle.

 Al

ways wear a regionally approved helmet, goggles,

app

ropriate boots, and all other appropriate safety

equipment when operating an electric motorcycle.

Parts/Maintenance Items

The proper replacement parts, fluids, and lubricants to use

are listed in the table below.

PART NUMBER

Headlight Bulb H4 (55/60 watt)

Turn Signal Light Bulb (amber) RY10W (10 watt)

Brake/Tail Light Bulb LED (replace the entire unit)

Front Running Light Bulb W3W (3 watt)

Brake Fluid DOT 4

Maintaining Your Motorcycle

5.2

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.

# ITEM ROUTINE EVERY

RIDE

INITIAL INITIAL ODOMETER MILEAGE READING

600 mi

(1K km)

1 month

4K mi

(7K km)

6 months

8K mi

(13K km)

12 months

12K mi

(19K km)

18 months

16K mi

(25K km)

24 months

20K mi

(31K km)

30 months

1 Brake Fluid

ront and

rear)

Check brake fluid level. Add

bra

ke fluid as necessary.

      

Replace brake fluid (every 12

mont

hs).

 

2 Front Brake Check operation, and for fluid

leakag

e. Replace brake pads if

necessary.

      

3 Rear Brake Check operation, and for fluid

leakag

e. Replace brake pads if

necessary.

      

4 Wheels Check run-out, and for damage.

Repla

ce if necessary.

    

5 Tires - Check tread depth, and for

dama

ge. Replace if necessary. 

- Check air pressure. See page

5-9

. Correct if necessary.

     

6 Wheel

earings

Check bearings for smooth

operation. Replace if necessary.

     

Maintaining Your Motorcycle

5.3

7 Drive Belt - Check belt slack and condition.

- Replace a worn/damaged belt.

- Check for cracking and/or

eplace the belt every 40K km

(25K mi)



8 Steering

earings

- Check all chassis fittings and

fasteners.

- Correct if necessary.

    Repack 

9 Chassis

Fast

eners

- Check all chassis

    

10 Front Brake

Lever P

ivot

Shaft

- Apply silicon grease lightly.

- Check operation and for oil

eakage.

- Service/rebuild if necessary.

     

11 Front Fork - Check operation and for oil

eakage. 

- Service/rebuild if necessary.

     

12 Rear Shock

Absorber

sembly

- Check operation and for oil

leakage. Replace if necessary      

13 Throttle Grip - Check operation and free play.

     

14 Kickstand

vots

- Check operation. 

- Apply silicon grease lightly.

    

# ITEM ROUTINE EVERY

RIDE

INITIAL

INITIAL ODOMETER MILEAGE READING

600 mi

(1K km)

1 month

4K mi

(7K km)

6 months

8K mi

(13K km)

12 months

12K mi

(19K km)

18 months

16K mi

(25K km)

24 months

20K mi

(31K km)

30 months

Maintaining Your Motorcycle

5.4

Note: From 24,000 mi (37,000 km) or 36 months, repeat the maintenance intervals starting from 8,000 mi (13,000) or 12

months.

15 Kickstand

Switch

Check operation and replace if

necessary.

     

# ITEM ROUTINE EVERY

RIDE

NITIAL INITIAL ODOMETER MILEAGE READING

600 mi

(1K km)

1 month

4K mi

(7K km)

6 months

8K mi

(13K km)

12 months

12K mi

(19K km)

18 months

16K mi

(25K km)

24 months

20K mi

(31K km)

30 months

Maintaining Your Motorcycle

5.5

Component Fasteners

Periodically check and tighten the following fasteners on your motorcycle.

Torque Table

LOCATION ITEM TORQUE NOTES

A Headlight bolts 8 lb ft (11 Nm) Use LOCTITE® 242® (or equivalent)

B Handlebar clamp mount bolts 19 lb ft (26 Nm) -

C Rear shock mount bolts 40 lb ft (54 Nm) -

D Seat retaining bolts 16 lb ft (22 Nm) -

E Rear sprocket to wheel, 4 bolts 26 lb ft (35 Nm) Use LOCTITE® 242® (or equivalent)

F Rear brake caliper mount bolts 34 lb ft (46 Nm) Use LOCTITE® 242® (or equivalent)

G Controller heat sink to frame bolts (rear) 19 lb ft (26 Nm) -

H Controller heat sink 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 axle pinch bolts 9 lb ft (12 Nm) Use LOCTITE® 242® (or equivalent)

L Rear brake pedal pivot bolt 34 lb ft (46 Nm) Use LOCTITE® 242® (or equivalent)

M Rear brake master cylinder to frame bolts 9 lb ft (12 Nm) Use LOCTITE® 242® (or equivalent)

N Rear axle slider retaining bolts 19 lb ft (26 Nm) Use LOCTITE® 242® (or equivalent)

O Rear axle nut 75 lb ft (102 Nm) Use LOCTITE® 242® (or equivalent)

P Motor mount bolts (rear) 20 lb ft (27 Nm) -

Q Motor mount bolts (front) 20 lb ft (27 Nm) -

R Front caliper mount bolts 19 lb ft (26 Nm) Use LOCTITE® 242® (or equivalent)

S Front axle end bolts 19 lb ft (26 Nm) Use LOCTITE® 242® (or equivalent)

Maintaining Your Motorcycle

5.6

Left Side of Motorcycle

Refer to Torque table on page 5.5.

Maintaining Your Motorcycle

5.7

Right Side of Motorcycle

Refer to Torque table on page 5.5.

Power Pack

5.8

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.

Zero recommends you plug in your Zero motorcycle after 7

days, even if fully charged. Please leave your Zero

motorcycle plugged in whenever possible.

1. 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

eat. The lithium ion cells should not get above 160°F

(71°C). Do not store in a hot trailer or leave the power

pack in direct sunlight.

3. Only an authorized service agent is qualified to have

ccess to the power pack.

4. Dispose of the power pack according to your state and

ocal laws. It is encouraged that the power pack be

recycled rather than disposed of in landfills.

5. Please contact Zero at s

upport@zeromotorcycles.com

or locate a recycling center in your area.

General Maintenance

5.9

General Maintena nce

Brakes

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.

Front Brake Pads

An example of the front brake pads is shown below.

Rear Brake Pads

An example of the rear brake pads is shown below.

General Maintenance

5.10

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.

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 sealed container.

Front Brake

Inspect the level of the front

brake fluid through the sight

glass (C). If the fluid level is

visibly below the low level

indicator (B), brake fluid must

be added. Clean any dirt or

debris from the cover (A)

before opening the reservoir.

Note: The motorcycle should

be in an

upright position prior

to checking fluid level.

1. Remove the two screws (A) securing the cover onto the

reservoir.

2. Add new DOT 4 brake fluid.

3. Inspect the cover seal, ensuring that it is free of any

wear

or damage and that it is positioned correctly.

4. Install the cover and tighten the screws.

General Maintenance

5.11

Rear Brake

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.

Inspect the level of the rear 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. Clean any dirt or debris from the cap and reservoir

opening (A) before opening the reservoir.

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.

General Maintenance

5.12

Brake Pad Inspection

The brake pads must be inspected when specified in the

maintenance schedule. See the Maintenance Schedule on

page

5.2 for additional information. Visually inspect the

brakes by looking at the remaining brake pad material

through the sides of the brake caliper. Replace the brake

pads if either pad’s thickness is 0.053 in (1.35 mm) or less.

If the brake pads (A) are worn, replace both brake pads

immediately.

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 Adjustment on

page

4.15.

Rear

CAUTION: The shock abso

rber assembly contains highly

pressurized gas.

 Do not attempt to tamper with or open the cylinder or

shock.

 Do not subject the shock to high temperature or open

flame.

ARNING! Doing either of

the above actions can cause

the cylinder or shock to explode causing personal injury or

death.

For maintenance, see Maintenance Schedule on page 5.2.

To adjust the fork, see Suspension Adjustment on

page 4.15.

General Maintenance

5.13

Wheels And Tires

Inspect both wheels for the following:

 Bent, loose, or missing spokes (DS only)

 Bent or cracked rims

 Impact marks on the rims

Inspect both tires for the following:

 Cuts, cracks, splits, or missing tread lugs

in the tread or

sidewall area

 Bumps or bulges within the tire body

 Uneven tire tread wear. Wear on one side of the tire

tre

ad or flat spots in the tire tread indicate a problem

with the tire or motorcycle.

 Exposed tire thread or cords

If ei

ther of the wheels or tires 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 cracking, tread

separation, “blowout,” or unexpected loss of motorcycle

control, causing serious injury or death.

Tire pressure should be checked and adjusted to the

proper inflation levels before each ride. Tire pressure

should be checked using an accurate gauge when the tires

are cold. This means that the tires have not been ridden on

for at least 3 hours. Always replace the valve stem cap

when finished adjusting tire pressures.

MODEL FRONT REAR

S & SR 207 kPa (30 PSI) 207 kPa (30 PSI)

DS 200 kPa (29 PSI) 186 kPa (27 PSI)

General Maintenance

5.14

Drive Belt

The drive belt provides low maintenance and quiet

operation with minimal stretch. Keep dirt, grease, oil, and

debris off the belt and sprockets.The drive belt tension

should be checked and adjusted at the intervals specified

in the Maintenance Schedule. For maintenance

information, see the Maintenance Schedule on page

5.2.

Clean the belt with mild soap and water when washing

your motorcycle. Towel dry and inspect for the following:

 Cu

ts or unusual wear patterns.

 Da

mage to the center of the belt.

 Out

side edge beveling. Some beveling is common but it

indicates that sprockets are misaligned.

 Out

side ribbed surface for signs of stone puncture.

 Insid

e (tooth portion) of belt for exposed tensile cords

normally covered by nylon layer and polyethylene layer.

This condition will result in belt failure and indicates

worn sprocket teeth.

 Sig

ns of puncture or cracking at the base of the belt

teeth.

If any of the above conditions are foun

d, the belt should be

replaced.

Checking Drive Belt Tension

Proper belt tension is essential for optimum operation of

the dr

ive system.

Lack of belt tension can lead to “ratcheting.” The teeth of

the belt slide over the teeth of the rear sprocket. This

causes an unpleasant sound; the ratcheting can also

cause damage to the carbon tensile cords. If ratcheting

has occurred you should replace the belt before the next

time you ride.

Too much tension can increase the wear of your drive

system

and the system can drag.

The tension is checked by using a Tension Tester.

The Tension Tester has a plastic measurement arm,

ocated in a slot. Along this slot there is a measuring scale.

The point of intersection of the measurement arm and the

measuring scale shows the tension of the belt. There is a

button (clicking pad) on the upper side of the Tension

Tester, where you can secure your finger with a rubber

band holder. A spring is located underneath this clicking

pad. If a certain pressure is applied to the spring, it makes

a clicking sound.

General Maintenance

5.15

1. Remove the key from the key switch.

2. Press the Tension Tester steadily to the middle of the

upper

side of the belt. The “lip” will lead the tester on to

the belt.

3. Slowly increase the pressure on the tester, until you

hear

a clicking sound. Do not increase the pressure

after the tester has clicked.

4. Remove the tester carefully from the belt. Avoid rough

movement

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

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.

Note: Belt tension will increase slightly when motor

mount bolts are fully torqued.

5. Tighten left and right jam nuts (C) to secure the belt.

6. Tighten the axle nut (A).

7. Test ride the motorcycle.

8. Recheck the belt for proper adjustment after the test

and readjust, if necessary.

General Maintenance

5.16

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. The headlight 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

perpendicular to the ground, and the operator sitting on the

motorcycle, verify the beam alignment. The motorcycle is

shipped with the headlight at a 0.5-2.5% dip.

The adjustment screw (A) is located on the back upper

right

corner of the headlamp. To adjust the headlight, turn

the screw until the correct beam alignment is achieved.

General Maintenance

5.17

Headlight Bulb Replacement

CAUTION: Halogen bulbs contain gas under pressure.

Handling a bulb improperly could cause it to shatter into

flying glass fragments, which 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

eye protection when changing a halogen

bulb.

 Avoid touching the glass.

o replace the bulb:

1. Working from behind the headlight, disconnect the

head

light bulb connector (A) and rubber cover (B).

General Maintenance

5.18

2. Remove the headlight bulb retainer (A) by turning it

counter-clockwise.

3. Remove the headlight bulb by pulling it straight out.

WARNING! Do not touch the glass portion of the headlight

bulb. Keep the headlight 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

with alcohol.

4. Install the headlight bulb into the lens.

5. Install the headlight bulb retainer and turn it clockwise

until

it locks into position.

6. Install the headlight bulb rubber cover.

7. Connect the headlight bulb connector.

General Maintenance

5.19

Turn Signal Light Bulb Replacement

1. Remove the turn signal lens screw (A) and remove the

lens.

2. Push in on the bulb, turn the bulb counterclockwise,

and the

n pull the bulb out.

3. Insert the new bulb into the socket, push in and turn

clockwise until it stop

4. Install the lens and screw; tighten the screw. Do not

over-tight

en the screw.

Brake/Tail LED Replacement

The brake/tail LED (A) is not serviceable. Please contact

your Zero Motorcycle dealer for replacement.

General Maintenance

5.20

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

to the headlight.

General Maintenance

5.21

Cleaning

WARNING! Improper cleaning can damage electrical

components, cowlings, panels, and other plastic parts. Do

not use high pressure water or steam cleaners; they can

cause water intrusion of bearing, seals, and electrical

components. Avoid spraying water of great force around

the dash unit, quick charge connector, power pack, or

controller.

To prolong the life of your motorcycle it should be washed

riodically. Regular cleaning is an important factor in

maintaining the value of your motorcycle. It also ensures

that safety related parts remain in full working order.

If tar, bugs, or other similar deposits have accumulated,

cle

an them off as soon as possible.

CAUTION: Af

ter cleaning and before starting your journey,

always test the brakes.

Washing

WARNING! Do not use any harsh

chemical products on

plastic parts. Be sure to avoid using cloths or sponges

which have been in contact with strong abrasive cleaning

products, solvent or thinner, fuel (gasoline), rust removers

or inhibitors, brake fluid, antifreeze, or electrolyte.

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 a clean

soft cloth, mild detergent, and plenty of water.

2. Use care when cleaning the plastic parts (dash,

fen

ders, and side panels), which can scratch easier

than the other parts of your motorcycle.

3. After washing, rinse your motorcycle

thoroughly with

plenty of clean water to remove any detergent residue.

4. Dry your motorcycle with a chamois or a soft, dry towel.

5. After cleaning, inspect for damage, wear or leaks.

After washing the motorcycle, allow all of the electrical

component

s to dry prior to operation. If the motorcycle is

ridden after being washed, apply both brakes several

times in order to remove any moisture from the brake

pads.

Wheels and tires

Avoid using strong acidic wheel cleaners, especially on

spoked

wheels. If such products are used on

hard-to-remove dirt, do not leave the cleaner on the

affected area any longer than instructed. Also thoroughly

rinse the area off with water, immediately dry it, and then

apply a corrosion protection spray.

Do not use products such as tire dressings on tires as this

will

deteriorate traction.

General Maintenance

5.22

Parking and Long Term Storage

 It is recommended to always leave the power pack

plugged in. The Zero S/SR/DS charger is designed to

maintain a balanced and complete charge at all times

without wasting any electricity.

 Over

extended periods of time the power pack is

checked every 72 hours to ensure that the cells are

balanced and that the power pack is full.

 T

o prolong the life of your power pack you should store

your motorcycle in a cool area. Storing your motorcycle

in a hot area will cause your power pack’s life to be

shortened.

 If,

for some reason, your motorcycle was not plugged in

for several days, you should always charge it up before

riding.

For more information on the power pack and the electrical

sys

tem 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!

Zero Motorcycles Accessories

Zero motorcycle accessories are designed to complement

and function with other systems on your motorcycle. Your

dealer 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 excessive amount of current flowing

through a circuit the fusible element will melt and create an

open or incomplete circuit. Fuses are a one-time protection

device and must be replaced each time the circuit is

overloaded. Replace the fuse with one of equal current

and voltage rating. If the fuse melts repeatedly, have the

electrical system inspected by your dealer.

General Maintenance

5.23

12 Volt Fuse Center

The 12 volt fuse center is located underneath the seat.

The fuse center (see arrow) has a protective cover that

must first be removed to gain access to the fuses. To

remove the cover, squeeze the tabs together and lift off the

cover.

To access the 12 volt fuse

center:

1. Remove two bolts securing the seat to the m

otorcycle

frame. Refer to Component Fasteners, page 5.5.

2. Pull the seat rearward to gain access to the fuse center.

3. Squeeze the tabs (A) on the fuse center to remove the

cover.

4. Replace the fuse(s).

The 12-volt fuse values are listed below:

FUSE RATING CIRCUITS CONTROLLED

1 10A Headlight

2 10A Accessory Port

3 10A Flash Lights, Turn Signals, Horn, Brake/Tail Light

4 5A Running Lights

General Maintenance

5.24

High Voltage Fuse Center

The high voltage fuse center sits in front of the low voltage

fuse center (in a cluster of four fuses).

To access the high 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 voltage fuse values are listed below:

FUSE RATING CIRCUITS CONTROLLED

1 ABC20A Charger

2 ABC4A Main Bike Board/Controller

3 ABC4A DC/DC Converter

4 ATM30 Quick Charger

Service 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 DESCRIPTION

Notes

5.26

Troubleshooting

6.1

TroubleshootingTroubleshooting

Electric Motorcycle Precautions

Your Zero motorcycle has high voltage components. The high

voltage used by these components is dangerous and can

cause personal injury, severe burns, electric shock and even

fatal injury unless appropriate precautions are taken.

Always observe and obey the instructions on labels attached to

components on the vehicle - they are there for your safety.

Do not touch, attempt to remove or replace any high voltage

parts, wiring (identified by the orange outer sleeving) or

connectors. If the motorcycle is involved in an accident do not

touch any high voltage wiring connectors or the components

connected to the wiring. If a motorcycle fire occurs, extinguish

visible flame with a Class D power-type fire extinguisher. After

flame has extinguished, douse with a water-based fire

extinguisher.

CAUTION! Y

our motorcycle uses high 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

attached to the motorcycle.

CAUTION!

The motorcycles high voltage system has no user

serviceable parts. Disassembling, removing or replacing high

voltage components, cables or connectors can cause severe

burns or electric shock that may result in serious injury or

death. High voltage cables are colored orange for easy

identification (see First Responder Information illustration at the

back of this manual).

Troubleshooting Your Motorcycle

All of the motorcycles are carefully inspected before they

are delivered. Even after the motorcycles are inspected,

some technical issues can occur. The following information

offers a guide to help you to identify an issue, and if

possible, repair it yourself. If you are unable to solve an

issue with your Zero S/SR/DS electric motorcycle, take it to

an authorized dealer at your convenience. If there is no

dealer in your area call Zero Motorcycles Customer

Service.

Troubleshooting

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 to the issue.

Troubleshooting

6.3

NUMBER OF RED FLASHES CAUSE SOLUTION

Motor Stop Switch Disabled or Kickstand

Switch Disabled

Motor stop switch is in the OFF position. Press the

motor stop

switch ON button. Kickstand is down.

Raise kickstand.

2 Indicator Always ON Contact Zero or your dealer.

Self-Test Failed Unplug charger.

Charger Connected

Throttle is ON or throttle/connection is bad. Verify

throt

tle action and/or check connection.

High Throttle Disable

Could not pre-charge motor controller. Contact your

dealer

Low Power Pack Disable Charge Power Pack Before Riding.

Contactor Error Contact Zero or your dealer.

Controller Area Network (CAN) Error Contact Zero or your dealer.

Battery Management System (BMS)

Throttle Disable

Contact Zero or your dealer.

Throttle Out of Range

Bad throttle or connections. Verify throttle

action and/or check connection.

Motor Temperature Sensor Out of Range

Bad motor temperature sensor or connections.

Replac

e temperature sensor and/or check

connections.

Troubleshooting

6.4

12 MBB Voltage Error Contact Zero or your dealer.

Board Temperature Warning

Board may have overheated. Let the motorcycle

cool

down.

Current Sensor Error

Problem with current sensor or

connection. Contact your dealer.

Welded Contactor Contact Zero or your dealer.

High Current Disable

Turn the ignition OFF and ON. If problem persists

cont

act Zero or your dealer.

Temperature Protection Error

Turn the ignition OFF and allow to cool off and then

start. If problem persists contact Zero or your

dealer.

Throttle Output Error

Turn the ignition OFF and ON. If problem persists

cont

act Zero or your dealer.

Kickstand Error

Bad kickstand switch or connection. Replace

kickstand

switch and/or check connection.

Miscellaneous Error Contact Zero or your dealer.

NUMBER OF RED FLASHES CAUSE SOLUTION

Troubleshooting

6.5

General Troubleshooting

SYMPTOM POTENTIAL CAUSE POTENTIAL SOLUTION

Motorcycle does not turn on Power Pack not charged. Key not properly engaged.

Motor sto

p switch turned OFF. Fault code set.

Charge Power Pack. Recheck key in ignition, turn OFF/ON

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.

Charger not working A/C power missing fault code set Check A/C outlet for power, A/C source check fuse/voltage.

See Charge F

ault Code chart on page

6.8 or see

Understanding BMS Flash Code Patterns on page

6.8.

Handlebars wobbly (shimmy) Incorrect tire pressure Inflate to correct tire pressure. See page

5.13.

Deformed front tire Replace/balance front tire with the same tire supplied from the

fact

ory.

Bald tire (excess wear) Replace/balance tire with the same tire supplied from the

fact

ory.

Loose headset bearings Inspect the headset for wear or damage, replace any worn or

damaged p

arts. Tighten the headset pre-load.

Troubleshooting

6.6

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. The window is located on the front of the

power pack (behind the front wheel). See the next page for

the meanings of these patterns.

Troubleshooting

6.7

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 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 Not Set Contact Zero or the Dealer

 50 ms 1 sec Self-Test Failed Contact Zero or the Dealer

 50 ms 250 ms Waiting for UART Input Contact Zero or the Dealer

sec = seconds

ms = milliseconds

Troubleshooting

6.8

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 4 GREEN ON OFF MEANING SOLUTION

    1 sec 5 sec Charge Complete Unplug Charger

Charging

 250 ms 25% Continue Charging

  250 ms 50% Continue Charging

   250 ms 75% Continue Charging

    250 ms 100% Continue Charging

Balancing

 500 ms

Power Pack Unbalanced Let the Power Pack Cool Down

  500 ms

Temperature Disable

  100 ms 500 ms To o H ot Let the Power Pack Cool Down

sec = seconds

ms = milliseconds

Troubleshooting

6.9

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 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 Remaining Charge Soon

    5 sec 1 sec 100% of Power Remaining OK

sec = seconds

ms = milliseconds

Troubleshooting

6.10

Power Pack Empty

If the power pack is completely empty, an error-beep

sounds and the BMS disables the throttle. You cannot ride

the motorcycle until you recharge the power pack. If the

Power Pack Empty error-beep still sounds after two hours

of charging time, contact your dealer. Your power pack

may need to be repaired or replaced.

Power Pack Full (High Power Pack-Voltage)

If the BMS detects that th

e power pack is already full, it

disables any further charging to prevent damage to the

power pack.

This is not an error-condition; it is the result of a successful

charging cycle. There is no self-test flash code which

reports this condition.

During an ordinary charging cycle, when the cells are

balanced, the charger (not the BMS) senses that the

power pack is full and terminates the charging cycle with a

“green light.” The BMS does have a redundant back-up

mechanism to prevent overcharging of the power pack. If

the charger fails to terminate a charging-cycle when the

power pack is full, the BMS will terminate charging itself to

prevent damage.

Power Pack Too Hot

The power pack contains internal te

mperature sensors. If

the BMS measures excessive internal temperatures, it

flashes an error code and disables the throttle. You cannot

ride the motorcycle until the power pack cools down. Place

the motorcycle in a cool, well-ventilated location and wait a

few minutes before riding again. If the Too Hot error code

still flashes after the power pack has had time to cool

down, contact your dealer. Your power pack may need to

be repaired or replaced.

Power Pack Unbalanced

The power pack contains many individual cells. The BMS

ntinuously 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 flashes a Power

Pack Unbalanced error code and disables the throttle. You

cannot ride the motorcycle until the problem is resolved.

The solution to the problem is to plug in the charger and

llow the power pack to charge for 72 hours. This allows

the BMS to re-balance the cells in the power pack. If the

Power Pack Unbalanced error code still flashes after the

power pack has spent more than 72 hours charging,

contact your dealer. Your power pack may need to be

repaired or replaced.

Troubleshooting

6.11

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.

Troubleshooting

6.12

Cold and Hot Weather Considerations

Cold Weather

Cold Weather operation of the motorcycle has no

permanent impact on its battery pack/cells; however, the

rider may see a reduction in range due to the effect cold

temperature has on the amount of energy the pack/cells

can release. The colder the weather, the greater the effect;

so that, as compared to operation in 80°F (27°C) ambient,

at 30°F(-1°C) ambient the rider could experience a

temporary reduction in range of up to 30%.

In extreme cold weather the motorcycle may also

experi

ence a temporary reduction in power and,

correspondingly, achieved top speed.

It is not recommended that the motorcycle be ridden while

its battery temperature is below 23°F(-5°C). If it is, its

battery needs to be put on the charger at a temperature

above 32°F (0°C) as soon as the ride is concluded. It is

worth noting that the Battery Management System (BMS)

will not 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

arage is acceptable, as long as:

1. the coldest temperature in the garage does not fall

below -31°F (-35°C)

2. the battery is left on the charger continuously

3. the battery is initially topped off at a temperature above

°F(0°C)

Storage temperatures below -31°F(-35°C) may result in

ccelerated permanent decay of the battery performance,

and hence it is not recommended. Above this temperature,

working as a system with the BMS, the charger will ensure

the battery survives winter storage with no permanent

damage, even if the temperatures dip well below freezing

for weeks at a time. Note that, to prevent battery damage,

the BMS will prevent the charger from charging the battery

at a temperature below 32°F(0°C). Again, as long as the

battery was initially topped off by the charger above

32°F(0°C) and remains on the charger through the winter

at temperatures above -31°F (-35°C), the system will

guard the battery from damage.

Troubleshooting

6.13

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

red

uces its charge current to the battery, increasing charge

time accordingly; the hotter the ambient temperature, the

greater the effect. Above a battery temperature of 131°F

(55°C), the BMS will no longer allow charging.

Note: Storing the motorcycle or its battery

in direct sunlight

in ambient temperatures above 105°F (41°C) may result in

accelerated permanent decay of battery performance, and

hence it is not recommended.

Troubleshooting

6.14

Safety Interlocks

If the BMS detects a serious internal fault, it can take either

or both of two actions to prevent damage to the power

pack:

 Throttle Disable. The BMS disables the throttle if the

power pack is empty, or if the BMS detects certain

serious internal problems. You cannot ride the

motorcycle until the problem is resolved.

 Ch

arger Disable. The BMS prevents charging if it

detects certain serious internal problems - even if the

power pack is connected to a charger and plugged in to

AC power. The power pack cannot be charged until the

problem is resolved.

Throttle Disable Inter

lock

The BMS communicates with the main motorcycle control

module. The BMS can send a signal to the main

motorcycle controller 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 throttle is disabled while

riding, the motorcycle will

cease to provide power, and the operator must pull over to

a safe location.

All conditions which would cause the BMS to disable the

throttle are also signaled by a flash code pattern at

self-test. If you suspect that the BMS has disabled the

throttle control on your motorcycle, turn the key switch

OFF and back ON again to enter self-test mode. The flash

code pattern from the BMS reports any of the error

conditions which would cause the BMS to disable the

throttle.

Each of these conditions, the

associated self-test flash

code pattern, and the suggested remedies are discussed

in Understanding BMS Flash Code Patterns on page

6.8.

 Power

Pack Empty

 T

oo Hot

 Power Pack Unbalanced

Troubleshooting

6.15

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.

There are two conditions that

cause the BMS to disable

charging:

1. Too hot

The BMS detects an internal power pack temperature

above 131°F (55°C).

2. Too cold

The BMS detects an internal power pack temperature

bel

ow 32°F(0°C).

Notes

6.16

Limited Warranty Information

7.1

Warranty and Customer Inform ationLimited Warranty Information

What Does This Limited Warranty Cover?

Zero Motorcycles Inc. ("Zero") warrants that all factory

manufactured 2014 Zero S/DS/SR motorcycles are free

from defects in material and workmanship during the

period of this Limited Warranty.

This Limited Warranty covers p

arts, including the motor,

motor controller, frame, swing arm, fork, rear shock, brake

assemblies, wheels and electrical sub-assemblies, and

approved Zero accessories installed at the time of

purchase by an authorized Zero dealer.

This Limited Warranty also covers the following items,

collectively referred to as “Power Packs”:

 The Z-Force® Power Tank accessory that may be

mounted in a Zero S/DS/SR model motorcycle. Should

the Z-Force® Power Tank be purchased after the initial

“in service date” of the host Zero motorcycle, the

Z-Force® Power Tank’s warranty duration will match

the remaining Power Pack warranty from the host Zero

motorcycle.

 ZF8.5

and ZF11.4 Z-Force® Li-Ion Power Packs

installed on the Zero S/DS/SR motorcycle.

This Limited Warranty covers all components of the Power

Packs that are included as a part 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 duration of this Limited Warranty for 2014 Zero

S/DS/SR motorcycles, not including the Power Packs, is a

period of 2 years from the original “in service date.”

Note: The “in service date” is the date that the authorized

dea

ler performs a pre-delivery inspection (“PDI”) and

delivers the motorcycle to the customer. In the event these

events occur on different dates, the later date shall be the

“in service date.”

The duration of this Limited Warranty for the Power Packs

ot including the Power Pack's outer case) is:

 Up to 5 years or 100,000 miles, whichever occurs first,

from the “in service date” of the host 2014 Zero

S/DS/SR motorcycle for the Z-Force® Power Tank

accessory. If purchased after the host Power Pack

warranty has expired, the Power Tank will receive the

standard warranty of 1 year from date of purchase.

 5

years or 100,000 miles, whichever occurs first, from

the “in service date” for the ZF8.5 and ZF11.4 Z-Force®

Li-Ion Power Packs on the Zero S/DS/SR motorcycle.

The Power Pack's outer case is not covered under the

Power Pack Limited W

arranty duration terms above.

Instead, the Power Pack’s outer case is covered for a

period of 2 years from its “in service date.”

Limited Warranty Information

7.2

Who Does This Limited Warranty Cover?

This Limited Warranty applies to all original owners who

submit the warranty registration card within the required

time period as printed on the registration card.

This Limited Warranty may only be transferred to new

owners with payment of a $50 processing fee and

submission of a new registration card by the new owner.

See

“Transfer Of Ownership And Warranty”, on page 7-6.

What Is Not Covered By This Limited

Warranty?

Due to the battery chemistry, there is a normal, expected

reduction in range/capacity that Power Packs can yield

over time and usage. Depending on use and storage

conditions, Power Packs will degrade during the duration

of this Limited Warranty period. Zero will only repair or

replace pursuant to this Limited Warranty a Power Pack

that exhibits a nominal storage capacity reduction of

greater than 20% of the published nominal capacity, as

measured by an authorized Zero dealer. To check the

capacity of a Power Pack, an authorized Zero dealer can

perform a battery management system log data extraction,

which will confirm if a reduction 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 conditions.” For purposes of this exclusion, the

following definitions apply:

 “Normal op

erating conditions” require routine care and

maintenance of the 2014 Zero S/DS/SR motorcycle

and Power Packs as described in this Owner's Manual.

 “Prope

r use” means only the use of a motorcycle in the

manner intended for a rider and passenger on a 2014

Zero S/DS/SR with proper safety equipment as

described in this Owner's Manual, in accordance with

local regulations.

 “Prope

r use” also means charging the Power Pack after

each use and storing it in a fully charged state, or

recharging it every 30 days, or keeping it on the

charger when in storage or not in regular use.

In addition, this Limited Warranty does not cover:

 Th

e cost of parts and labor involved in any routine care

and maintenance and/or the replacement of parts due

to normal wear and tear, use, or deterioration, including

but not limited to: tires, brake pads and rotors, fork

seals, grips, foot pegs, and the seat;

 Th

e replacement of fluids, unless their replacement is a

necessary part of warranty service on a covered

component;

 Wh

eels on off-road bikes once they have been ridden

Limited Warranty Information

7.3

 Any cosmetic concerns that arise as a result of

environmental conditions, owner abuse, misuse, lack of

routine care and maintenance, and/or improper use;

 Part

s or components damaged by use or operation

under abnormal circumstances or contrary to the

requirements described in this Owner's Manual.

 Zer

o motorcycles and Power Packs used for racing or

other competitive events;

 Zer

o motorcycles and Power Packs misused or

improperly operated;

 Damag

e, malfunctions, or performance problems

caused by modifications or alterations to 2014 Zero

S/DS/SR motorcycles and/or Power Packs – including

modifications or alterations performed by an authorized

Zero dealer – that cause the Zero motorcycle or Power

Pack to fail;

 Damag

e, malfunctions, or performance problems

caused by aftermarket accessories installed on a Zero

motorcycle or Power Pack after the “in service date,” or

caused by aftermarket accessories installed by

someone other than an authorized Zero dealer;

 Damag

e, malfunctions, or performance problems

caused 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

specifications from those set by Zero, or the use of new

or used parts not approved by Zero;

 D

amage, malfunctions, or performance problems

caused by fire, collision, accident, or improper storage;

 D

amage, malfunctions, or performance problems

caused by continued operation of the motorcycle after a

warning light, gauge reading, or other warning indicates

a mechanical or operational problem;

 Motorcycles

severely damaged or declared to be a total

loss by an insurer, or motorcycles substantially

reassembled from or repaired with parts obtained from

another used motorcycle;

 D

amage, malfunctions, or performance problems

caused by the failure to follow recommended

maintenance requirements as set forth in this Owner’s

Manual; and,

 D

amage, malfunctions, or performance problems

caused by airborne industrial pollutants (e.g., acid rain),

bird droppings, tree sap, stones, flood water,

windstorms, or other similar occurrences;

Further, this Limited Warranty does not apply to Zero

motorcycl

es or parts and accessories that are not imported

or distributed by Zero.

Limited Warranty Information

7.4

What Other Limitations Or Disclaimers Apply

To This Limited Warranty

The following additional limitations and disclaimers apply

to this Limited Warranty:

 This Limited Warranty is the only express warranty

made in connection with the sale of this Zero

Motorcycle model. Any implied warranty, including any

warranty of merchantability or warranty of fitness for a

particular purpose is limited in duration to the stated

period of this written warranty. (Some states do not

allow limitations on how long an implied warranty lasts,

so this limitation may not apply to you.)

 Z

ero does not assume – or authorize any person to

assume – any other obligation or liability on its behalf.

 T

his Limited Warranty does not cover any incidental or

consequential damages, including loss of value of the

motorcycle, lost profits or earnings, out-of-pocket

expenses for substitute transportation or lodging,

expenses associated with returning the covered

product to a authorized service facility or dealer, towing

and/or roadside assistance expenses, expenses

associated with returning the covered product back 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 consequential

damages, so this limitation or exclusion may not apply

to you. This warranty gives you specific legal rights and

you may also have other rights, which vary from state to

state.)

 Ze

ro Motorcycles reserves the right to change or

improve the design of any Zero motorcycle, Power

Pack, or any other Zero parts (collectively, “Zero

products”) at any time, without assuming any obligation

to modify any Zero products previously manufactured

or sold.

 Th

e purchaser acknowledges that there is an inherent

risk in the operation of motorcycles. This Limited

Warranty does not cover - and Zero cannot assume

responsibility for - any injury arising from the unsafe or

improper operation of Zero products, or the user’s

failure to comply with instructions, care and

maintenance requirements, warnings, and safety

precautions

 Th

e original registered owner or subsequent registered

transferee as documented on the Zero motorcycle

warranty registration form is responsible for conveying

the Owner’s Manual and all safety warnings,

instructions, and Limited Warranty if the unit is sold,

loaned, or otherwise transferred to another person.

Limited Warranty Information

7.5

What Are Your Responsibilities As A

Customer?

As the owner of a product covered by this Limited

Warranty, it is your responsibility to read and understand

this Owner's Manual, this Limited Warranty, and all product

warnings before operating your Zero motorcycle. Serious

injury or death can result from improper operation or failure

to observe warnings and safety instructions on any

motorcycle.

Further, it is also your responsibility to:

 Perform al

l recommended and necessary routine care

and maintenance and engage in proper use of your

Zero motorcycle and Power Pack as detailed in this

Owner's Manual.

 Lea

rn and obey all federal, state, and local laws

governing the operations of a motorcycle, generally,

and an electric motorcycle, specifically.

 At al

l times when operating a Zero motorcycle wear

proper safety equipment and clothing, including but not

limited to helmet, goggles, and appropriate boots.

What Will Zero Do Under This Limited

Warranty?

During the duration of this Limited Warranty, an authorized

Zero dealer will repair or replace (at Zero’s discretion),

without charge, any 2014 Zero S/DS/SR motorcycle,

Power Packs, or parts that are covered by this Limited

Warranty and found by Zero or an authorized Zero dealer

to be defective in factory materials or workmanship.

Limited Warranty Information

7.6

How Do You Obtain Service Under This

Limited Warranty?

Warranty services may be obtained by contacting your

local Zero Motorcycle dealer. Please refer to the dealer

locator on our website (

www.zeromotorcycles.com/locator)

for your nearest location.

In the event that a dealer is not in

your state, province, or

country, you can contact Zero Motorcycles Inc. directly at

+1 (888) 841-8088 (Monda

y-Friday, 8am to 5pm Pacific

Time) or via e-mail at support@zeromotorcycles.com.

In any written or telephonic communication, please state

the specific nature of any circumstances leading to the

problem.

North America and Canada:

Zero Motorcycles Inc.

380 El Pueblo Road

Scotts Valley, CA 95066

USA

Europe:

Zero Motorcycles BV

Fluorietweg 12D

Alkmaar, 1812 RR

(U.S. and International Patents and Trademarks Pending)

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. Use the

email address below or feel free to contact the Zero

Motorcycles Customer Service department for assistance.

Zero Motorcycles Inc.

380 El Pueblo Road

Scotts Valley, CA 95066

USA

Phone: +1 (888) 841-8085

Monday-Friday 8am to 5pm (Pacific Time)

E-mail:

support@zeromotorcycles.com

Customer Information

7.7

Customer In formation

Customer Assistance

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

 V

ehicle identification number (VIN)

 Date of

purchase

 Motor serial number (if visible)

An owner information chart is provided on page

1-3 to

record this information.

Zero Motorcycles Inc. can be contacted as follows:

Zero Motorcycles Inc.

380 El Pueblo Road

Scotts Valley, CA 95066

USA

Phone: +1 (888

) 841-8085

Monday-Friday 8am to 5pm (Pacific Time)

E-mail:

support@zeromotorcycles.com (24 hours)

For 24 hour updates and additional information about your

motorcycle, visit the Owner

Resources 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 injury or death, you should

immediately inform the National Highway Traffic Safety

Administration (NHTSA) in addition to notifying Zero

Motorcycles Inc.

If NHTSA receives similar complaints, it may open an

investigation, and if it finds that a safety defect exists in a

group of vehicles, it may order a recall and remedy

campaign. 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

ll-free at:

1-888-327-4236 (TTY: 1-800-424-9153); go to 

http://www.safercar.gov; or write to:

Administrator

National Highway Traffic Safety

1200 New Jersey Avenue SE

Washington, DC 20590

You can also obtain other information about motor vehicle

safety

from:

http://www.safercar.gov

Notes

7.8

Index

INDEX.1

Accessories .................................................................5.22

Brake/Tail Light Bulb Replacement .............................5.19

Brakes ...........................................................................5.9

Brake Fluid Level Inspection...................................5.10

Brake Pad Inspection..............................................5.12

Braking....................................................................4.13

DOT 4 brake fluid....................................................5.11

Front Brake .............................................................5.10

Rear Brake..............................................................5.11

Charging

CHAdeMO Charger........................................1.13, 4.12

Charging the Power Pack..............................................4.8

Cleaning Your Motorcycle ...........................................5.21

Contact information

NHTSA......................................................................7.7

Dash Settings ..............................................................3.12

Drive Belt .....................................................................5.14

Checking Drive Belt Tension...................................5.14

Emissions Information .................................................1.16

First Time Set-Up...........................................................4.1

Fuses ...........................................................................5.22

High Voltage Fuse Center.......................................5.24

General Operation .........................................................4.3

Key Switch/Steering Lock Positions..........................4.4

Pre-Ride Inspection...................................................4.3

General Safety Precautions...........................................2.1

General Troubleshooting ...............................................6.5

Headlight

Alignment ................................................................5.16

Bulb Replacement...................................................5.17

Important Operating Information....................................2.2

Inspection

Pre-Ride ....................................................................4.3

Instrument Panel.................................................. 3.8

, 3.10

Index

INDEX.2

Keys

Replacement Code Number ..................................... 1.4

Location Of Important Labels ........................................ 2.3

Maintenance Schedule.................................................. 5.2

Maximizing Range....................................................... 1.13

Motor Serial Number .....................................................1.4

Operating Your Motorcycle.......................................... 4.13

Braking....................................................................4.13

Stopping..................................................................4.13

Owner Information Record ............................................ 1.3

Owner’s Responsibilities ............................................... 5.1

Parking ........................................................................5.22

Parts/Maintenance Items............................................... 5.1

Performance 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

Quick Charging............................................................4.10

Reporting safety defects................................................7.7

Safe Riding Information.................................................1.2

Safety Interlocks ..........................................................6.14

Serial Number

Motor.........................................................................1.4

Power Pack...............................................................1.4

Smartphone Application ..............................................3.15

State of Charge (SOC) ................................................3.15

Storage

Long Term...............................................................5.22

Suspension

Front........................................................................5.12

Rear ........................................................................5.12

Suspension Adjustment...............................................4.15

Front Fork Adjustment ............................................4.16

Rear Shock Adjustment ..........................................4.17

Index

INDEX.3

Suspension settings

Front (Factory) ........................................................4.16

Rear (Factory).........................................................4.21

Technical Specifications

Zero DS Technical Specifications ....................1.8, 1.10

Zero S Technical Specifications................................1.6

Tire Inflation.................................................................5.13

Transporting ................................................................1.17

Troubleshooting

Battery Management System (BMS).........................6.6

Charge Mode ............................................................6.8

Run Mode .................................................................6.9

Turn Signal Light Bulb Replacement ...........................5.19

Unpacking Your Zero Motorcycle ..................................4.2

Recycling ..................................................................4.2

Vehicle Identification Number (VIN)

Location ....................................................................1.4

Understanding Your VIN Number .............................1.5

Vehicle Range .............................................................1.12

Warning Lights..................................................... 3.8, 3.10

Warranty

Coverage...................................................................7.1

Exclusions .................................................................7.2

Transfer Of Ownership And Warranty.......................7.6

Wheels And Tires ........................................................5.13

Notes

INDEX.4

First Responder Information - High Voltage Components Locations

TAKE CHARGE

™

ZERO S

™

ZERO SR

™

ZERO DS

™

2014 OWNER’S MANUAL

WWW.ZEROMOTORCYCLES.COM

2 014 OWNER’S MANUAL ZERO S / ZERO SR / ZERO DS

Zero S Handleiding

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