Zero Motorcycles S 2009 User manual
ZERO MOTORCYCLES
2009 S / DS OWNER`S MANUAL
2009 ZERO S / DS OWNER'S MANUAL
1
INTRODUCTION
Congratulations and thank you for purchasing the 2009 Zero S/DS electric motorcycle. This manual is designed
to provide you with a better understanding of the operation, inspection, and basic maintenance requirements of
this motorcycle. If you have any questions concerning the operation or maintenance of your motorcycle, please
Zero Motorcycles continually seeks advancements in product design and quality. Therefore, while this manual
contains the most current product information available at the time of printing, there may be minor discrepancies
between your motorcycle and this manual. If you have any questions concerning this manual, please contact
Zero Motorcycles.
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 CAREFUL
MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL HELP YOU TO SAFELY ENJOY THE
CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE.
INTRODUCTION
2009 ZERO S / DS OWNER'S MANUAL
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2009 ZERO S / DS OWNER'S MANUAL
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TABLE OF CONTENTS
1 Introduction
5 Safety Information
5 Performance Specifications
and Operator Guidelines
7 General Safety Precautions
8 Important Operating Notes
9 Location of Important Labels
11 Controls and Components
11 Motorcycle Controls
12 Left View
13 Right View
14 Instrument Cluster
15 Left Handlebar Controls
16 Right Handlebar Controls
17 Operation
17 First Time Set-Up
18 General Operation
18 ˚Basic Operation
18 ˚Z-Force Power Pack
18 ˚Drive Chain
18 ˚Brake
18 ˚Throttle
18 ˚Tires
18 ˚Electrical System
19 Re-Charging the Power Pack
20 Onboard Charger Led Indicators
21 Maintenance and Repair
21 Power Pack Care and Technical Information
22 Bolt Torque Table
23 Maintenance Schedule
24 General Maintenance
24 ˚Motor Maintenance
24 ˚Suspension
24 ˚Wheels and Tires
25 ˚Chain Lubrication and Maintenance
25 ˚Cleaning
27 Consumer Information
27 Technical Specifications
28 Battery Management System (BMS)
29 Vehicle Range
29 Public Charging Stations
30 Emissions Information
31 Reporting Safety Defects
31 Purchaser’s Responsibilities
33 Troubleshooting
33 Power Pack and Charger
34 ˚Understanding Beep Sequences
36 ˚Safety Interlocks
38 ˚BMS Appendix
39 General Troubleshooting
41 Warranty Information
TABLE OF CONTENTS
WARNING! YOU MUST LEAVE YOUR MOTORCYCLE ON
THE CHARGER IF YOU EXPECT IT TO SIT IN STORAGE
OR UNUSED FOR OVER 7 DAYS. WARNING!
2009 ZERO S / DS OWNER'S MANUAL
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2009 ZERO S / DS OWNER'S MANUAL
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SAFETY INFORMATION
PERFORMANCE SPECIFICATIONS AND OPERATION GUIDELINES
The 2009 Zero S is a multi-purpose motorcycle designed to provide many years of trouble free commuting
and riding excellence. Please read the information below to get a sense for the motorcycles’ performance abilities
and limitations.
PERFORMANCE ENVELOPE
• TheZeroShasatopspeedof55mphthatallowsforusingfreewaysorhighwaysforafewmiles
when necessary.
• Youcanexpecttoachieve40milesofaveragerange,undernormaluse(stopandgocitytrafc),witha
maximumrangeof60miles(steadyridingat25mph).Youcanexpecttoachieve30milesofrangeonthe
freeway(steadyridingat55mph).
• TheZeroShastheabilitytostart,fromastandstill,upasteep10%gradewhenfullyloaded(300lbtotal
passenger+baggageweight).Itisnotrecommendedthatyoustoponagradeofmorethan10%withafully
loaded motorcycle.
Warning system explained on following page.
SAFETY INFORMATION
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SAFETY INFORMATION
PERFORMANCE SPECIFICATIONS AND OPERATION GUIDELINES
MOTOR OVERHEATING WARNING SYSTEM
The 2009 Zero S is equipped with a motor overheating warning system. In the unlikely event that you exceed the
motorcycles’ performance capabilities it will provide you with warnings in three distinct stages:
STAGE 1: The Motor begins to reach an undesirable temperature
• Aslowblinkisclearlyseenonthedash-mountedwarningindicator
• Youcancontinuetoridewithoutperformanceinterruptions
• Youshouldreducespeed—thiswilllowerpoweroutputandthemotortemperaturetoeliminatethe
blinking warning indicator
STAGE 2: If the Motor continues to heat up
• Afastblinkisclearlyseenonthedash-mountedwarningindicator
• Thepowertothemotoroscillatesautomaticallyprovidingatactilefeedbackwarningtotheriderin
the form of a rapid acceleration/deceleration pulsing of the motorcycle
• Atthispointitisstronglyrecommendedthatyoureduceyourspeedandconsiderndingasafe
area to exit the road
• Youmaystillhavetimetobackoffthethrottletoreduceheatandeliminatetheoscillation.Doingso
will also eliminate the warning indicator.
STAGE 3: If the critical temperature threshold of the motor is reached
• Youwillnotreachthisstagewithoutknowinglyignoringtheclearwarningindicators
• Atensecondsequenceofcloseintervalsofrapidpulsingwillbevisibleonthewarningindicator
and then power to the motor will be cut
• Youmustquicklyndasafeplacetoparkthemotorcycleoffoftheroad
• Whenpowertothemotoriscutthewarningindicatorgoessolid
• Themotorshouldtakenolongerthanabout10minutestocool
• Whenthewarningindicatorturnsoffyoucansafelyoperatethemotorcycleagain
• Usethethrottlesparinglyatrsttoensurethatthemotordoesnotoverheat
SAFETY INFORMATION
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1. Thisisaperformancemotorcycleandshouldbetreatedwithextremecaution.
2. Proper safety gear including a 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.
3. Nevercarryapassenger.ThismotorcycleisdesignedforanOPERATORONLY.
4. Donotrideonwet,frozen,oilyorpittedsurfaces.Avoidpotholes,surfacecracks,andotherobstacles.
5. Priortoeachusetheridermustcheckthetirepressure,brakes,andpowerpackfunction.
6. Never use alcohol or mind-altering drugs before operating a Zero Motorcycle.
7. Never permit a guest to ride your Zero Motorcycle without proper instruction. These are performance
motorcycles and should be treated with extreme caution.
8. 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 will assume no liability for misuse
or operator negligence.
9. Read all additional warnings and product instructions in this owner’s manual and safety labels before
operating the Zero Motorcycle.
10. Yoursafetydependsinpartonthegoodmechanicalconditionofthemotorcycle.Besuretofollowthe
maintenance schedule and adjustment requirements contained in this manual. Be sure you understand the
importance of checking all items thoroughly before riding.
11. Modicationsofthemotorcyclemayrenderthevehicleunsafeandmaycauseseverepersonalinjury.
12. Beverycarefulwhenloadingoraddingaccessoriestoyourmotorcycle.Large,bulkyorheavyitemsmay
adversely affect the handling and performance of your motorcycle.
YOUR INSURANCE POLICIES MAY NOT PROVIDE COVERAGE FOR ACCIDENTS INVOLVING THE USE
OF THIS MOTORCYCLE. TO DETERMINE IF COVERAGE IS PROVIDED, YOU SHOULD CONTACT YOUR
INSURANCE COMPANY OR AGENT.
GENERAL SAFETY PRECAUTIONS
SAFETY INFORMATION
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1. Alwaysturnthekeyswitchtotheoffpositionwhennotactivelyriding.Itisveryeasytoforgetthatthe
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.
2. Switch the power off when backing up or pushing the motorcycle while dismounted. It is possible to
unintentionally twist the throttle resulting in an accident.
3. Usetherearbrakewhenyouarestoppedonanincline.Donotholdthemotorcycleusingpartialthrottleor
damage to the motor may occur.
4. TheZeroS/DSelectricmotorcycleshouldbepluggedinwhenstoringthemotorcyclefor
extendedperiodsoftime.
5. KeepyourZeroS/DSconnectedtothechargerwhenyourmotorcycleissittinginstorageorifitwillbe
sitting unused for more than 7 days.
6. Alwaysrmlyapplytherearbrakewhileturningthemasterswitchonoroff.Intheeventofamalfunction,the
rmapplicationoftherearbrakewillhelpkeepthemotorcyclefromrunningaway.
7. The Zero S/DS power pack does not require or tolerate deep discharging. To get the most Zero S/DS
power pack life, recharge each Zero S/DS power pack immediately after each ride. Leaving a Zero S/DS
power pack in a discharged state will damage the batteries. The Zero S/DS power pack is the most
expensive part of the motorcycle and misuse will void the Zero S/DS power pack warranty.
8. Operate your motorcycle only in good weather; using your motorcycle in rain, snow, or other precipitation
may result in damage to your motorcycle.
SAFETY INFORMATION IMPORTANT OPERATING NOTES
SAFETY INFORMATION
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1. EPALabel(ShownActualSize)
LOCATION OF IMPORTANT LABELS
1
SAFETY INFORMATION
2009 ZERO S / DS OWNER'S MANUAL
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2009 ZERO S / DS OWNER'S MANUAL
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1. Dash/InstrumentPanel
2. Left Handlebar Control Module
3. FrontBrakeLever
4. KeySwitch
5. RightHandlebarControlModule
6. Front Brake Fluid Reservoir and Master Cylinder
7. Mirrors
8. Warning Indicator
CONTROLS AND COMPONENTS
MOTORCYCLE CONTROLS
20
30
40
50
60
70
80
90
10 0110
120
10
1
4
3
7 7
8
2
5
6
CONTROLS AND COMPONENTS
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1. Headlight
2. Tail Light / Brake Light / License Plate Light
3. OnBoardPowerConnection
4. Kickstand/Sidestand
5. MainPowerCoupling
6. Sidestand Switch
7. Onboard Charger
CONTROLS AND COMPONENTS LEFT VIEW
467
1
2
3
5
CONTROLS AND COMPONENTS
2009 ZERO S / DS OWNER'S MANUAL
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1. DriveChain
2. Rear Brake Fluid Reservoir
3. RearBrakeMasterCylinder
4. ChainTensioner
5. RearBrakePedal
6. Zero S/DS Power Pack
RIGHT VIEW
41 3256
CONTROLS AND COMPONENTS
2009 ZERO S / DS OWNER'S MANUAL
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20
30
40
50
60
70
80
90
10 0110
120
10
1
2
4
5
6
3
7
8
9
8
Shown Actual Size
1. MainPowerIndicator
2. Energy Gauge
3. Speedometer
4. Odometer
5. TripOdometer
6. Warning Indicator
7. High Beam Indicator
8. Turn Signal Indicator
9. Select / Adjust
CONTROLS AND COMPONENTS INSTRUMENT CLUSTER
CONTROLS AND COMPONENTS
2009 ZERO S / DS OWNER'S MANUAL
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20
30
40
50
60
70
80
90
100110
120
10
1. HeadlightHi/LowBeamSelector
2. Turn Signal Switch
3. Horn
4. HighBeamFlasher
LEFT HANDLEBAR CONTROLS
1
4
2
3
CONTROLS AND COMPONENTS
2009 ZERO S / DS OWNER'S MANUAL
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20
30
40
50
60
70
80
90
100110
120
10
1. MotorStopSwitch/KillSwitch
2. Front Brake Lever
3. Throttle
CONTROLS AND COMPONENTS RIGHT HANDLEBAR CONTROLS
CONTROLS AND COMPONENTS
1
2
3
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OPERATION
FIRST TIME SET-UP
1. RemovetheZeroS/DSmotorcyclefromitscrate.Removeanyresidualpackingmaterialswithscissors.
2. The Zero S/DS has been in transit and storage. Engage the main power coupling on the Zero power pack.
(Seepage12,item5)
3. Youmustchargethepowerpackbeforeridingthemotorcycle.
4. IdentifyandinspecttheZeroS/DSwheelsandbrakesforleaksorirregularities.
5. Checkthetirepressureandadjusttoproperspecications.(Seepage23)
6. Inspect the hydraulic brake system. Follow the hydraulic line from the reservoirs to the calipers, and verify
that there are no leaks or damage to the brake lines. Verify that the brakes function properly.
7. Make sure the motorcycle is off then twist the throttle to make sure it returns correctly.
8. Inspectboltsandmakesuretheyaretight.(Seebolttorquespecicationsonpage22)Besuretodouble
check all fork and brake bolts.
9. After the motorcycle has completed charging, insert the key in the Ignition Switch, engage the rear brake
and turn the key to the “ON” position. Wait for the instrument self-test routine to complete. The Zero S/DS
energy gauge should read fully charged. Once you are prepared to ride, flip the kill switch to the “ON”
position. Your motorcycle is now on and ready to ride.
OPERATION
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OPERATION GENERAL OPERATION
BASIC OPERATION
Before operating the Zero S/DS motorcycle, check the following to make sure the motorcycle is secure
and intact.
Z-FORCE POWER PACK
Make sure the onboard energy gauge has solid bars to the top, indicating a charged Zero S/DS power pack.
Iftheenergygaugereadsbelow6bars(1/2),wesuggestyourechargebeforeuse.
DRIVE CHAIN
Check chain slack and condition. Adjust and lubricate if necessary. The drive chain must be cleaned and
lubricatedattheintervalsspeciedinthemaintenanceschedule;otherwiseitwillquicklywearout,especially
when riding in dusty or wet areas.
BRAKE
Squeeze the brake lever and push the motorcycle to see if it rolls. You should be able to lock-up the wheels up
completelyusingthebrakes.Checkforsufcientbrakeuidinthereservoir.
THROTTLE
While the motorcycle is “OFF,” apply the throttle and release to verify that the throttle is smooth and the return
works properly.
TIRES
Check both tires for condition and tread depth. Check cold tire pressure frequently. Check for damage and
alignment.Maintaincorrecttirepressureasspeciedonpage23.Replacethetireswhenthetreadheightis
2mm or less.
ELECTRICAL SYSTEM
Check correct functioning of headlamps, tail-lights, brake lights, turn indicators, control lamps and horn while the
motorcycleison.Donotafxanytypeoftintedlmorstickerstotheheadlightlens.
OPERATION
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