Zero Motorcycles ZERO SR User manual

ZERO S™
ZERO SR™
ZERO DS™
ZERO S / ZERO SR / ZERO DS
TOR CYCLES.COM
2015 OWNER’S MANUAL
2015 OWNER’S MANUAL
Zero Owner's Manual (S and DS).book Page 1 Tuesday, January 20, 2015 2:37 PM

Zero Owner's Manual (S and DS).book Page 2 Tuesday, January 20, 2015 2:37 PM

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
Front Brake Lever Adjuster ..................................... 3.20
Tank Bag.................................................................3.21
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
Zero Owner's Manual (S and DS).book Page 1 Tuesday, January 20, 2015 2:37 PM

Table Of Contents
TOC.2
ABS (Anti-lock Brake System).................................4.15
Front Suspension Adjustment..................................4.17
Rear Shock Adjustment...........................................4.21
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 ...........................................................5.26
Troubleshooting............................................ 6.1
Troubleshooting.......................................................... 6.1
Electric Motorcycle Precautions................................ 6.1
Troubleshooting Your Motorcycle............................. 6.1
System Warning Indicator......................................... 6.2
Dash Error Codes ..................................................... 6.5
General Troubleshooting .......................................... 6.8
Battery Management System.................................... 6.9
Cold and Hot Weather Considerations ................... 6.15
Safety Interlocks ..................................................... 6.16
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....................... 7.7
Customer Information................................................. 7.8
Customer Assistance................................................ 7.8
Reporting Safety Defects.......................................... 7.9
Zero Owner's Manual (S and DS).book Page 2 Tuesday, January 20, 2015 2:37 PM

Introduction
1.1
IntroductionIntroduction
An Important Message To You From Zero
Motorcycles
Congratulations and thank you for purchasing the 2015
Zero S, Zero SR, or Zero DS (S/SR/DS) electric
motorcycle; we welcome you to the community of Zero
Motorcycles riders. This manual is designed to provide
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 S/SR/DS, 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 Zero at
[email protected].
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
features and equipment include belt drive, integrated
charger, and regenerative braking):
•Zero S: Street
•Integrated Z-Force®Power Pack and Charger
•Cast Wheels
•Street Tires
•Zero SR: Street - Max Performance
•Integrated Z-Force®Power Pack and Charger
•Cast Wheels
•Street Tires
•Zero DS: Dual Sport
•Integrated Z-Force®Power Pack and Charger
•Cast Wheels
•Dual Sport Tires
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.
Zero Owner's Manual (S and DS).book Page 1 Tuesday, January 20, 2015 2:37 PM

Introduction
1.2
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.
Plug in Your Z-Force®Power Pack™
CAUTION: 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
disposal. See www.dtsc.ca.gov
Zero Owner's Manual (S and DS).book Page 2 Tuesday, January 20, 2015 2:37 PM

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.
Zero Owner's Manual (S and DS).book Page 3 Tuesday, January 20, 2015 2:37 PM

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 right hand side
of 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.
Zero Owner's Manual (S and DS).book Page 4 Tuesday, January 20, 2015 2:37 PM

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.
Zero Owner's Manual (S and DS).book Page 5 Tuesday, January 20, 2015 2:37 PM

General Information
1.6
General Information
Technical Specifications
Zero S
The Zero S specifications below apply to both the S ZF9.4
and ZF12.5 models (unless otherwise specified).
MOTOR
Type Z-Force® 75-7 passively air-cooled,
high-efficiency, radial flux permanent
magnet, brushless motor
Controller High efficiency, 420 amp, 3-phase brushless
controller with regenerative deceleration
Estimated Top Speed
(max) 98 mph (158 km/h)
Estimated Top Speed
(sustained) 80 mph (129 km/h)
POWER SYSTEM
Type Z-Force® Li-Ion Intelligent Power Pack
Maximum Capacity •ZF9.4: 9.4kWh
•ZF12.5: 12.5 kWh
Nominal Capacity •ZF9.4: 8.3kWh
•ZF12.5: 11.0 kWh
Charge Time (standard) •ZF9.4: 6.6 hours (100% charged) /
6.1 hours (95% charged)
•ZF12.5: 8.6 hours (100% charged) /
8.1 hours (95% charged)
Supplemental Charger
Quick Charge Time (with
one accessory charger)
•ZF9.4: 3.9 hours (100% charged) /
3.4 hours (95% charged)
•ZF12.5: 5.0 hours (100% charged) /
4.5 hours (95% charged)
Supplemental Charger
Quick Charge Time (with
max accessory chargers)
•ZF9.4: 1.9 hours (100% charged) /
1.4 hours (95% charged)
•ZF12.5: 2.4 hours (100% charged) /
1.9 hours (95% charged)
Input Universal 100 - 240 V AC
Charger Type 1.3 kW Integrated
Estimated Power Pack
Life to 80% (city) •ZF9.4: 254,000 miles (409,000 km)
•ZF12.5: 339,000 miles (546,000 km)
RANGE
City (EPA UDDS) • ZF9.4: 113 miles (182 km)
•ZF12.5: 151 miles (243 km)
Highway, 55 mph
(88 km/h) •ZF9.4: 70 miles (113 km)
•ZF12.5: 94 miles (151 km)
>Combined
(City + 55 mph) •ZF9.4: 87 miles (140 km)
•ZF12.5: 115 miles (185 km)
Highway, 70 mph
(113 km/h)* •ZF9.4: 58 miles (93 km)
•ZF12.5: 77 miles (124 km)
>Combined (City +
70 mph) •ZF9.4: 76 miles (122 km)
•ZF12.5: 102 miles (164 km)
* When “highway” is referenced elsewhere in this manual for range,
consider calculated highway speed as 70 mph (113 km/h).
Zero Owner's Manual (S and DS).book Page 6 Tuesday, January 20, 2015 2:37 PM