Zero Motorcycles Zero S Series 2014 Owner's Manual

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[Page 1] Zero Motorcycles Zero S Series 2014

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 ...

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Table Of Contents TOC.1 Introduction................................................... 1.1 Introduction.................................................................. 1.1 An Important Message To You From Zero Motorcycles 1.1 About This Manual .....

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Table Of Contents TOC.2 Rear Shock Adjustment ...........................................4.17 Maintaining Your Motorcycle........................ 5.1 Maintaining Your Motorcycle ......................................5.1 Owner’s Responsibilities.......

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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 m...

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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 ...

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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. ...

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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 d...

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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. ...

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General Information 1.6 General Information 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, hi gh-efficiency...

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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 Niss...

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General Information 1.8 Zero SR MOTOR Type Z-Force™ 75-7 passively air-cooled, hi gh-efficiency, radial flux, permanent hi-temp magnet, brushless motor. Controller High efficiency, 660 amp, 3-phase brushless cont roller with re-generative decel...

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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 Niss...

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General Information 1.10 Zero DS MOTOR Type Z-Force™ 75-7 passively air-cooled, hi gh-efficiency, radial flux, permanent magnet, brushless motor. Controller High efficiency, 420 amp, 3-phase brushless cont roller with re-generative deceleration...

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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 ...

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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 r...

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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 motorcy...

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General Information 1.14 ...

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General Information 1.15 ...

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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...

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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...

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Notes 1.18 ...

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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,...

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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...

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Location of Important Labels 2.3 Location of Important Labels 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 la...

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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. ...

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Location of Important Labels 2.5 High Voltage Warning Label Affixed to battery ...

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Notes 2.6 ...

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Controls and Components 3.1 Controls and ComponentsControls and Components THIS PAGE INTENTIONALLY LEFT BLANK ...

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Controls and Components 3.2 Motorcycle Controls ...

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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 objec...

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Controls and Components 3.4 Left Side View ...

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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“Headligh...

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Controls and Components 3.6 Right Side View ...

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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 aux...

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Controls and Components 3.8 Dash Overview ...

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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...

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Controls and Components 3.10 Warning Indicator Lights ...

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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 Warn...

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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...

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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 t...

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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) o...

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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...

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Controls and Components 3.16 Handlebar Controls ...

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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 bac...

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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 ...

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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 thro...

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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 (...

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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, whic...

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Notes 3.22 ...

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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 mot...

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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 Cove...

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General Operation 4.3 General Operation 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...

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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 remov...

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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 O...

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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...

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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 ...

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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 fro...

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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...

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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. Us...

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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 pow...

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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 e The 80% Charge LED is an a...

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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 switc...

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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 ...

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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...

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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 adjustm...

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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...

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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 char...

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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 t...

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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 s...

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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 R...

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Notes 4.22 ...

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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 m...

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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...

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Maintaining Your Motorcycle 5.3 7 Drive Belt - Check belt slack and condition. - Replace a worn/damaged belt. - Check for cracking and/or r eplace the belt every 40K km (25K mi)  8 Steering B earings - Check all chassis fittings and fast...

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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.       # I...

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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 ...

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Maintaining Your Motorcycle 5.6 Left Side of Motorcycle Refer to Torque table on page 5.5. ...

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Maintaining Your Motorcycle 5.7 Right Side of Motorcycle Refer to Torque table on page 5.5. ...

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Power Pack 5.8 Power Pack 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 da...

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General Maintenance 5.9 General Maintenance 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 sh...

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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 imme...

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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...

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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 remainin...

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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 mis...

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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 interv...

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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, unt...

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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 a...

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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: �...

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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...

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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, p...

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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 th...

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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 elect...

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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. �...

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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 t...

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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 motor...

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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 ...

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Notes 5.26 ...

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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 ...

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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. ...