Zero Motorcycles FX 2022 User manual

MOTORCYCLES.COM
88-09683-01
ZERO FX
™
ZERO FXE
™
ZERO FXS
™
ZERO MOTORCYCLES
2022 OWNER’S MANUAL
2021 OWNER’S MANUAL ZERO FX | FXE | FXS
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Table Of Contents
TOC.1
Introduction .................................................. 1.1
Introduction .............................................................. 1.1
An Important Message From Zero .......................................1.1
California Proposition 65 .....................................................1.1
California Perchlorate Advisory ........................................... 1.1
About This Manual ...............................................................1.2
Useful Information For Safe Riding ......................................1.2
When To Charge Your Z-Force® Power Pack™ ...................1.3
Identification Numbers .............................................. 1.4
Owner Information ...............................................................1.4
Power Pack Serial Number ..................................................1.5
Motor Serial Number ...........................................................1.5
Vehicle Identification Number (VIN).....................................1.5
General Information .................................................. 1.6
Emissions Information .........................................................1.6
Vehicle Range .....................................................................1.7
Maximizing Your Range .......................................................1.8
Transporting ........................................................................1.9
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 .................................................................... 3.13
Smartphone Application.................................................... 3.16
Bluetooth® Pairing............................................................ 3.17
Handlebar Controls ........................................................... 3.18
Performance Level Mode Button ....................................... 3.21
Front Brake Lever Adjuster (FXE and FXS only) ................ 3.22
Parking Brake Operation (if equipped).............................. 3.22
Starting and Operating.................................... 4.1
General Operation ..................................................... 4.1
General Operation ............................................................... 4.1
Key Switch/Steering Lock Positions.................................... 4.2
Motorcycle Tip-Over Sensor ................................................ 4.3
Operating Your Motorcycle ................................................. 4.4
ABS (Anti-lock Braking System) .......................................... 4.6
Front Suspension Adjustment ............................................. 4.9
Rear Shock Adjustment..................................................... 4.14
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Table Of Contents
TOC.2
Charging and Power Pack Information .............. 5.1
Power Pack and Charging ......................................... 5.1
Power Pack ......................................................................... 5.1
Modular Power Pack System - Removal and Installation
(if equipped) ........................................................................ 5.3
On-Board Power Pack Charger ............................................ 5.5
Charging the Power Pack .................................................... 5.6
Quick Charging (Off-Board Accessory Charger) .................. 5.8
Public Charging Stations ................................................... 5.12
Add On Electrical Equipment ............................................ 5.12
Maintaining Your Motorcycle ........................... 6.1
Maintaining Your Motorcycle ..................................... 6.1
Owner’s Responsibilities ..................................................... 6.1
Parts/Maintenance Items..................................................... 6.2
Service History .................................................................... 6.2
Scheduled Maintenance ...................................................... 6.2
Component Fasteners ......................................................... 6.6
Power Pack............................................................... 6.9
Power Pack ......................................................................... 6.9
General Maintenance .............................................. 6.10
Brakes ............................................................................... 6.10
Parking Brake (if equipped)............................................... 6.13
Suspension........................................................................ 6.14
Wheels And Tires .............................................................. 6.14
Tire Inflation ...................................................................... 6.15
Drive Belt........................................................................... 6.16
Drive Chain (Optional)........................................................6.20
Seat Removal - FXE............................................................6.23
Side Panel - FXE ................................................................6.24
Front Panel - FXE ...............................................................6.25
Front Panel - FX/FXS..........................................................6.26
Headlight Alignment ..........................................................6.27
Headlight Bulb Replacement - FX/FXS...............................6.28
Headlight Bulb Replacement - FXE ....................................6.29
Turn Signal Light Bulb Replacement .................................6.30
Brake/Tail Light Bulb Replacement ...................................6.30
Running Light Bulb Replacement ......................................6.31
Cleaning ............................................................................6.32
Parking and Long Term Storage ........................................6.33
Zero Motorcycles Accessories ...........................................6.33
Fuses .................................................................................6.33
Troubleshooting ............................................. 7.1
Troubleshooting ........................................................7.1
Electric Motorcycle Precautions ..........................................7.1
Troubleshooting Your Motorcycle ........................................7.1
System Warning Indicator ....................................................7.2
Diagnostic Codes.................................................................7.5
General Troubleshooting .....................................................7.8
Battery Management System ...............................................7.9
Cold and Hot Weather Considerations ...............................7.15
Safety Interlocks ................................................................7.16
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Table Of Contents
TOC.3
Technical Specifications ................................ 8.1
Specifications (Europe) ............................................. 8.1
VIN Breakdown ....................................................................8.1
Zero FX ................................................................................8.2
Zero FXE (11kW)..................................................................8.4
Zero FXE .............................................................................. 8.6
Specifications (Rest Of The World) ............................ 8.8
VIN Breakdown ....................................................................8.8
Zero FX ................................................................................8.9
Zero FXE ............................................................................ 8.11
Zero FXS ............................................................................ 8.13
Warranty and Customer Information ................ 9.1
Limited Warranty Information .................................... 9.1
Who Is The Warrantor? ........................................................9.1
Who Does This Limited Warranty Cover? .............................9.1
What Does This Limited Warranty Cover? ............................ 9.1
What Is The Coverage Period Of This Limited Warranty? .... 9.2
What Is Not Covered By This Limited Warranty? .................9.3
What Other Limitations Or Disclaimers Apply To This
Limited Warranty .................................................................9.5
What Are Your Responsibilities As A Customer? ................. 9.6
What Will Zero Motorcycles Do Under This Limited
Warranty? ............................................................................9.7
How Does This Limited Warranty Relate To State Law?....... 9.7
How Do You Obtain Service Under This Limited Warranty? . 9.8
How Do I Transfer Ownership And The Limited Warranty ....9.9
Customer Information .............................................. 9.10
Customer Assistance ........................................................ 9.10
Reporting Safety Defects .................................................. 9.11
Maintenance Record ..................................... 10.1
Maintenance Record................................................ 10.1
Service History .................................................................. 10.1
Index
First Responder Information – High Voltage
Component Locations
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Introduction
1.1
IntroductionIntroduction
An Important Message From Zero
Congratulations and thank you for purchasing the 2022 Zero FX,
Zero FXE or Zero FXS 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 and
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
FX/FXE/FXS, please ensure that this manual stays with the
motorcycle; 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 your authorized Zero
Motorcycles dealer.
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/
California Proposition 65
WARNING: Operating, servicing and maintaining a
passenger vehicle or off-highway motor vehicle can
expose you to chemicals including engine exhaust, carbon
monoxide, phthalates, and lead, which are known to the State of
California to cause cancer and birth defects or other
reproductive harm. To minimize exposure, avoid breathing
exhaust, do not idle the engine except as necessary, service
your vehicle in a well-ventilated area and wear gloves or wash
your hands frequently when servicing your vehicle. For more
information go to www.P65Warnings.ca.gov/passenger-vehicle.
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 disposal.
See www.dtsc.ca.gov.
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Introduction
1.2
About This Manual
This manual covers the following motorcycles (standard features
and equipment include Integrated Z-Force® Power Pack and
charger, belt drive (optional chain drive), and regenerative
braking):
•Zero FX: Dual Sport
•Wire Wheels
21-inch Diameter Front Wheel
18-inch Diameter Rear Wheel
•Dual Sport Tires
•Zero FXS: Supermoto
•Cast Wheels (17-inch diameter)
•Street Tires
•Zero FXE
•ZF7.2 Power Pack
•LED Headlight
•Modified body panels
Locating and referencing information
A good place to locate information about the motorcycle is 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.
Useful Information For Safe Riding
This manual contains the word WARNING to indicate something
that could hurt you or others. It also contains the word CAUTION
to indicate things that could damage your motorcycle.
WARNING! 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 only 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.
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Introduction
1.3
When To Charge Your Z-Force® Power Pack™
Proper care of the motorcycle’s power pack is essential! In order
to maximize the life of your power pack(s), Zero Motorcycles has
established the following guidelines for proper charging and
operation.
•If the power pack is fully discharged, it must be charged
within 24 hours to prevent damage to the power pack.
•If you ride regularly, but your ride doesn’t require most of
your power pack’s capacity, your power pack will benefit
from not being charged to 100% unnecessarily. In hot
climates, going a few rides before recharging will prolong
your power pack’s life by limiting the amount of time it
spends parked at a high state of charge.
•If you ride infrequently, once per week or less, recharging the
evening prior to when you need to be at full charge is much
better for your power pack than charging it right after each
ride and having it sit for days between rides at a high state of
charge.
•If the power pack’s state of charge is below 30%, we
recommend you charge the power pack to at least 60% and
then disconnect the charger.
CAUTION: Never store your motorcycle at a low state of charge
(below 30% SOC). Leaving the power pack at a low state of
charge for a prolonged period could damage it and void your
warranty.
•If you ride in hot weather (>35ºC / 95ºF) or spend a majority
of your ride at freeway speeds, the power pack will benefit
from not being charged “hot”. Allowing your pack a few
hours to cool off prior to recharging will prolong its life. You
may also benefit from off-peak electricity rates by waiting
until the evening to charge.
•Once your motorcycle has been charged, we recommend
that you disconnect the charger. The power pack will go into
“hibernate mode” and self-discharge extremely slowly over
time. So, if you haven’t ridden it for a long while and need to
charge it to 100% SOC, plug it in to the charger for a few
hours prior to your ride. Unplugging the charger when not
needed ensures the best long-term health of your power
pack.
•For long term storage (>30 days) of your motorcycle, see
“Parking and Long Term Storage”, on page 6.33.
•To ensure best performance of your Zero motorcycle over its
lifetime, please be certain that the motorcycle’s firmware is
up to date. If you have questions, please contact the nearest
Zero Motorcycles dealer.
For other important information regarding the power pack, see
“Power Pack”, on page 5.1.
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Identification Numbers
1.4
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
1.5
Power Pack Serial Number
The Power Pack serial number is located in following locations.
•ZF3.6 - Rear of power pack below connector housing.
•ZF7.2 - Top right of power pack beneath retaining rail.
Motor Serial Number
The motor serial number is stamped on the right hand side of
the motor housing.
Vehicle Identification Number (VIN)
The VIN is a 17-digit number stamped on the head tube of the
frame (A). 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 is affixed to the
head tube.
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General Information
1.6
General Information
Emissions Information
The Zero FX/FXE/FXS 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
FX/FXE/FXS 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.
CAUTION: 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.
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General Information
1.7
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 conservatively you ride, the better range you
can expect from your Zero FX/FXE/FXS motorcycle.
Some of the factors which affect range include: speed,
acceleration, 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 conservatively when you first get your
Zero FX/FXE/FXS 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.
The reported motorcycle range values in this Owner’s Manual
are measured using different standards, according to the
country the Zero motorcycle is being sold.
For Zero motorcycles sold within European countries, range is
calculated using European Union regulation EU 134/2014 Annex
VII.
For Zero motorcycles sold in all other countries, range is
calculated using the following types of industry standard test
procedures:
1. “City”: This range test is specified to determine riding during
“stop-and-go” operation typically found in urban areas. This
estimate is provided following the SAE J2982 Riding Range
Test Procedure for On-Highway Electric Motorcycles to
provide a reasonable and consistent basis for manufacturers
to inform prospective owners of the riding range that can be
expected under specified operating conditions. Actual range
will vary based on riding conditions and habits.
2. “Highway”: This test procedure uses two separate constant
speeds of 55 mph (89 km/h) and 70 mph (113 km/h) to
simulate highway riding.
Both of these test procedures are run on a single charge, in
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 8.8 through
page 8.13 for these ranges.
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General Information
1.8
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
affected, you can use the four factors:
•route
•rider
•weather
•motorcycle
By considering each of these factors, you can use specifications
such as ‘city range’ as standards to estimate what the
motorcycle’s real world range will be under your particular usage
case.
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General Information
1.9
Transporting
It is recommended that the motorcycle be tied-down using
ratchet straps while it is being transported. Place the ratchet
straps around a frame contact point. Soft straps must be used
to reduce 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.
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Notes
1.10
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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,
eye protection, 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. It is not recommended to ride without the correct
protective clothing; this applies to even short journeys and to
every season of the year.
•Read all additional warnings and product instructions in this
owner’s manual, as well as safety labels, before operating
your electric motorcycle.
•Never permit a guest to ride your electric motorcycle without
proper instruction.
•Never use alcohol or mind-altering drugs before operating
your electric motorcycle.
•Persons unwilling or unable to take responsibility for their
actions should not use this motorcycle. You assume all
responsibility while operating your motorcycle. The seller
assumes no liability for misuse or operator negligence.
•Prior to each use the rider must check everything in the
“every ride” column of the maintenance schedule on
page 6.1, and the charge level of the power pack as
indicated on the dash display charge indicator.
•Your 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 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.
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General Safety Precautions
2.2
Important Operating Information
Several operating considerations are listed below:
•Always turn 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.
•Turn 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.
•If you plan on riding again the next day or the power pack’s
state of charge is less than 30%, plug your motorcycle into an
AC power source to recharge it. Always use the supplied
charging cable as it has been designed for use with your
motorcycle’s electrical components.
•While unplugged with the key in the OFF position, the
motorcycle’s electronics will consume a very small amount of
power and the power pack will drain extremely slowly. If the
motorcycle has been unused for more than 30 days, turn the
key switch to the ON position and back to OFF to exit long
term storage mode and then allow it to charge for 24 hours to
ensure optimal battery balance is restored.
CAUTION: Only charge the Zero power pack with the
motorcycle’s on-board charger or the approved Zero accessory
charger.
•The power pack does not require nor benefit from deep
discharging. Leaving a power pack in a discharged state will
cause damage. See “When To Charge Your Z-Force® Power
Pack™”, on page 1.3.
•Failure to follow power pack storage and charging
instructions as described in this 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.
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Location of Important Labels
2.3
Location of Important Labels
Location of Important Labels
The motorcycle could contain the following information for both North American and European models:
A. VIN label (North America) - certification label
B. VECI (Vehicle Emission Control Information) label
Note: Location of label varies between motorcycle models.
C. VIN label (European Union) - certification label
D. Tire and loading information label
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Location of Important Labels
2.4
High Voltage Warning Labels
Located near the motor
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