Zero Motorcycles MX User manual

TOC-1
Introduction.................................................................1-1
An Important Message To You From Zero.........1-1
Introduction............................................................1-1
Index ..............................................................1-1
Useful Information For Safe Riding ............1-2
Plug In Your Power Pack ....................................1-2
Owner Information ................................................1-3
Production Identification Number (PIN) ..............1-4
PIN Location..................................................1-4
PIN Break Down ...........................................1-4
General Information ............................................. 1-6
Zero X Technical Specifications...................1-6
Zero MX Technical Specifications ................ 1-7
Vehicle Range...............................................1-9
Optimizing Your Range By Adapting
Your Riding Style...........................................1-9
Public Charging Stations .............................1-9
Emissions Information ..................................1-10
Transporting .....................................................1-10
Safety Information .....................................................2-1
General Safety Precautions .................................2-1
Important Operating Information..................2-2
Location Of Important Labels ......................2-3
Power Pack Information Label ....................2-4
Throttle And Speed Control Label ...............2-5
Controls And Components .......................................3-1
Motorcycle Controls ..............................................3-1
Right Side View....................................................3-2
Instrument Panel ..................................................3-3
Speed Control Switch...................................3-3
Main Power Indicator....................................3-4
Energy Gauge ...............................................3-4
Torque Control Switch ..................................3-4
Handlebar Controls..............................................3-5
Left Handlebar Control.................................3-6
Right Handlebar Control ..............................3-6
Table Of Contents

TOC-2
Maintenance Schedule.......................................5-13
Accessories ........................................................5-16
Fuses ..................................................................5-16
Troubleshooting ..........................................................6-1
Power Pack And Charger ....................................6-1
Understanding Beep Sequences ................6-3
Safety Interlocks............................................6-6
General Troubleshooting ............................6-11
Warranty/Customer Assistance ...............................7-1
Customer Assistance...........................................7-1
Warranty Information ............................................7-2
Zero Motorcycles Limited Warranties.....................7-3
Standard Warranty.........................................7-3
Extended Warranty ........................................7-4
No Fault Warranty.........................................7-5
Disclaimers Applicable to Standard
Warranty, Extended Warranty and
No Fault Warranty .............................................7-5
Proper Use....................................................7-6
Purchaser’s Responsibilities.......................7-7
Warranty Procedures ....................................7-7
Transfer Of Ownership And Warranty ..........7-8
Starting And Operating .............................................4-1
First Time Set-Up.................................................4-1
Uncrating Your Motorcycle ............................ 4-2
General Operation ................................................4-4
Pre-Ride Inspection......................................4-4
Key Switch Positions....................................4-5
Power Pack ...................................................4-5
Operating Your Motorcycle..............................4-15
Suspension Adjustment .............................4-16
Maintaining Your Motorcycle .................................... 5-1
Owner’s Responsibilities ....................................5-1
Bolt Torque Table .................................................5-2
Power Pack...........................................................5-5
General Maintenance ...........................................5-6
Motor ..............................................................5-6
Brakes ...........................................................5-6
Suspension ...................................................5-6
Wheels And Tires .........................................5-7
Tire Inflation ..................................................5-8
Chain .............................................................5-8
Cleaning .......................................................5-11
Parking And Long Term Storage .......................5-12

1-1
Introduction
Introduction
Index
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.
Congratulations and thank you for purchasing the
2010 Zero X/MX electric motorcycle; we welcome you
to the community of Zero Motorcycle 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
motorcycle, 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 [email protected].
An Important Message To You
From Zero

1-2
Useful Information For Safe Riding
This manual contains the word CAUTION to tell about
something that could hurt you or others. It also
contains the word WARNING to tell about 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 careful maintenance, along with good
riding skills, will help you to safely enjoy the
capabilities and the reliability of this motorcycle.
Disregarding them may render the warranty invalid.
Plug In Your 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 battery warranty. See page 4-5 for other
important information about the power pack.

1-3
CSC Information Motorcycle Information
Address
Model
Date of Purchase
PIN
Telephone No.
E-mail
Battery Serial Number
Owner Information
Record important information here pertaining to your motorcycle. When contacting your Certified Service Center
(CSC) you may need to provide this information.

1-4
A
Production Identification
Number (PIN)
A. PIN Label (Canadian version only)
PIN Break DownPIN Location
The PIN is a 17-digit number stamped on the head
tube of the frame. Do not alter or remove this as it is
the legal identifier for your motorcycle.
See Location Of Important Labels on page 2-3.

1-5
538
Motorcycle Type
2 = 168 Cell
3 = 2nd Generation
4 = 336 Cell
M = Mars
P = Perm
Z = Z Motor Force
A = Agni
05 = 0 - 50 HP
51 = 50 - 100 HP
10 = 100 + HP
9 = 2009
A = 2010
B = 2011
Production Number
S 3 91M 905 123456
Model Line
Motor Type
Model Year
Net Brake Horse Power
Dirt

1-6
General Information
Zero X Technical Specifications
MOTOR
Type Brushed permanent magnetic electric
Motor • Sport-Mars
• Extreme-Perm
Torque 67.7 N•m (50 lb ft)
Peak
Horsepower 23
Peak Electrical
Input 17,400 Watts
POWER SYSTEM
Type Patent-pending lithium ion array
Capacity 2 kwh (58 V @ 35 Ah)
Range Up to 2 hours or 64 km (40 miles)
Recharge Time Less than 2 hours
Input Standard 110 V AC or 220 V AC
DRIVETRAIN
Transmission Clutchless one speed
Drive System • Sport-12T/71T, 420 Chain
• Extreme-15T/71T, 420 Chain
CHASSIS/SUSPENSION/BRAKES
Front Suspension
Travel 200.7 mm (7.9 in)
Rear Suspension
Travel 215.9 mm (8.5 in)
Front Brakes 4 Piston Hydraulic, Stainless Rotor,
Hand Actuated
Rear Brakes 4 Piston Hydraulic, Stainless Rotor,
Hand Actuated
Front Tire 24 x 3.0 in
Rear Tire 17 x 3.5 in

1-7
Zero MX Technical Specifications
DIMENSIONS
Wheel Base 137.2 cm (54 in)
Seat Height 88.3 cm (34.8 in)
Rake 23 degrees
WEIGHT
Frame 5.9 kg (13 pounds)
Power Pack 20.9 kg (46 pounds)
Curb Weight 73.0 kg (161 pounds)
Total Wei ght w/o
Power Pack 52.2 kg (115 pounds)
ECONOMY
Typical Cost to
Recharge Less than $.01 per mile or kilometer
MOTOR
Type Brushed permanent magnetic electric
Motor • Sport-Mars
• Extreme-Perm
Torque 67.7 N•m (50 lb ft)
Peak
Horsepower 23
Peak Electrical
Input 17,400 watts
POWER SYSTEM
Type Patent-pending lithium ion array
Capacity 2 kwh (58 V @ 35 Ah)
Range Up to 2 hours or 64 km (40 miles)
Recharge Time Less than 2 hours
Input Standard 110 V AC or 220 V AC

1-8
DIMENSIONS
Wheel Base 138.4 cm (54.5 in)
Seat Height 87.1 cm (34.3 in)
Rake 24 degrees
WEIGHT
Frame 5.9 kg (13 pounds)
Power Pack 20.9 kg (46 pounds)
Curb Weight 78.0 kg (172 pounds)
Total Wei ght w/o
Power Pack 57.2 kg (126 pounds)
ECONOMY
Typical Cost to
Recharge Less than $.01 per mile or kilometer
DRIVETRAIN
Transmission Clutchless one speed
Drive System • Sport-12T/71T, 420 Chain
• Extreme-15T/71T, 420 Chain
CHASSIS/SUSPENSION/BRAKES
Front Suspension
Travel • Sport-203.2 mm (8 in)
• Extreme-228.6 mm (9 in)
Rear Suspension
Travel 215.9 mm (8.5 in)
Front Brakes 4 Piston Hydraulic, Stainless Rotor,
Hand Actuated
Rear Brakes 4 Piston Hydraulic, Stainless Rotor,
Hand Actuated
Front Tire 19 x 3.0 in
Rear Tire 17 x 3.5 in

1-9
Vehicle Range
The range of an electric vehicle is defined as the
distance the vehicle will travel 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 and conditions. The more conservative you ride
the better range you can expect from your Zero X/MX
Motorcycle.
Some of the factors which affect range include speed,
acceleration, number of starts and stops, terrian, 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 X/MX motorcycle and get to know your
motorcycle. Once you become familiar with the range
versus performance of your motorcycle, then you can
adjust your riding characteristics if you so desire.
Public Charging Stations
There are more public charging stations coming on-
line every day and there may be some in your area.
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.”
You can expect to achieve up to 2 hours of riding
time if you are riding conservatively. If you are riding
aggressively, you can expect a ride time of around 45
minutes.
Optimizing Your Range By Adapting
Your Riding Style
•Apply the throttle slowly and try to match the
motorcycle’s acceleration with your throttle
position.
•Hard acceleration will cause a voltage drop,
thereby making the energy gauge drop
significantly; the gauge should recover when you
roll off the throttle.
•Coasting whenever possible makes a significant
difference; the motorcycle will coast for a long
distance (take advantage of this).

1-10
A
SF
SF
A
Zero Emissions Vehicles (ZEVs) 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 from your Zero motorcycle. Parts and
products 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.
Transporting
(MX model only)
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.
When the fork is released, with no weight on the front
tire, the screw must be opened again to allow for
stabilization. Ensure that the screw is tightened before
riding.
Emissions Information
The Zero X/MX electric motorcycle is a zero emissions
vehicle under California (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 X/MX 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.

1-11
A
It is recommended that the motorcycle be tied-down
using ratchet straps and a fork support (A) to prevent
fork damage. Place the ratchet straps around the
frame or a solidly mounted part. 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.

1-12
NOTES

2-1
Safety Information
General Safety Precautions
1. This is a performance motorcycle and should
be treated with extreme caution.
2. Proper safety gear including a DOT 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.
3. Read all additional warnings and product
instructions in this owner’s manual, as well as
safety labels, before operating your electric
motorcycle.
4. Never carry a passenger. This motorcycle is
designed for a SINGLE RIDER ONLY.
5. Never permit a guest to ride your electric
motorcycle without proper instruction. These are
performance motorcycles and should be treated
with extreme caution.
6. Never use alcohol or mind-altering drugs before
operating your electric motorcycle.
7. 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.
8. Prior to each use the rider must check everything
in the “every ride” column of the maintenance
schedules on pages 5-13 through 5-15, and the
power pack function level as indicated on the
instrument panel energy gauge.
9. 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.

2-2
10. Modifications of the motorcycle may render the
vehicle unsafe and may cause severe personal
injury. Zero Motorcycles cannot be held liable for
non-approved modifications.
11. 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.
Important Operating Information
1. Always turn the key switch and kill 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.
2. Switch the power OFF when backing up or
pushing the motorcycle while dismounted. It is
possible to unintentionally twist the throttle,
resulting in unexpected acceleration.
3. 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.
4. The Zero X/MX power pack should be plugged in
when storing the motorcycle for extended periods
of time.
5. Keep your Zero X/MX connected to the charger
when your motorcycle is sitting in storage or if it
will be sitting unused for more than 7 days.
The power pack must be charged within 24 hours
if fully discharged, and must be charged within 60
days if stored fully charged. Zero recommends
you plug in your power pack after 7 days even if
its fully charged. Please leave your power pack
plugged in whenever possible.
WARNING: Charge the Zero power pack with the
Zero charger.
6. Always firmly apply the rear brake while turning
the key switch ON or OFF. In the event of a
malfunction, the firm application of the rear brake
will help keep the motorcycle from running away.
7. 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. See Charging The Power
Pack on page 4-12.

2-3
D
B C
A
Location Of Important Labels
A. Throttle and Speed Control Label
B. Vehicle Certification Label
C. Production Identification Number (PIN) Label.
(Canadian version only)
See Production Identification Number (PIN) on
page 1-4.
D. Power Pack Information Label
The Vehicle Certification Label contains the following
information:
•Gross Vehicle Weight Rating (GVWR)
•Gross Axle Weight Rating (GAWR) Front and Rear
•Production Identification Number (PIN)
•Rim Size
•Tire Pressures
•Manufactured Date
8. Failure to follow battery 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 battery
efficiency and service.

2-4
7
Power Pack Information Label

2-5
There is no engine braking
Throttle And Speed Control Label