Zero Motorcycles XU 2012 User manual

ZERO X ™
ZERO MX ™
ZERO XU™
2012 Owner’s Manual

TOC-1
Introduction................................................................. 1-1
An Important Message To You From Zero.........1-1
Introduction............................................................1-1
Index ..............................................................1-2
Useful Information For Safe Riding ............1-2
Plug In Your Z-Force Power Pack™...................1-2
Owner Information ................................................1-3
Power Pack Serial Number.................................1-4
Key Code Number ...............................................1-4
Motor Serial Number............................................1-4
Motor Identification................................................1-4
Identification Numbers .........................................1-5
VIN/PIN Breakdown ......................................1-6
General Information .............................................1-7
Zero X Street Legal
Technical Specifications ...............................1-7
Zero MX Dirt
Technical Specifications ...............................1-9
Zero XU Street Legal
Technical Specifications .............................1-11
Vehicle Range ....................................................1-13
Optimizing Your Range By Adapting
Your Riding Style ................................................1-14
Public Charging Stations ...................................1-14
Emissions Information.......................................1-14
Transporting........................................................1-15
Safety Information .....................................................2-1
General Safety Precautions .................................2-1
Important Operating Information..................2-2
Location Of Important Labels ......................2-3
Throttle And Speed Control Label ...............2-4
Anti-Tamper Control Label (Europe Only) ..2-5
Controls And Components .......................................3-1
Motorcycle Controls (MX Dirt) ..............................3-1
Motorcycle Controls (X/XU Street Legal).............3-3
Right Side View (MX Dirt) ....................................3-5
Right Side View (X Street Legal) ........................3-7
Right Side View (XU Street Legal) .....................3-9
Table Of Contents

TOC-2
Power Pack...........................................................5-5
General Maintenance ...........................................5-6
Motor (MX) .....................................................5-6
Brakes ...........................................................5-6
Suspension ...................................................5-8
Wheels And Tires .........................................5-8
Tire Inflation ..................................................5-9
Drive Belt .......................................................5-9
Drive Chain .................................................5-12
Headlight Alignment....................................5-15
Headlight Bulb Replacement.....................5-16
Turn Signal Light Bulb Replacement .......5-18
Brake/Tail Light Bulb Replacement...........5-19
Running Light Bulb Replacement.............5-20
Cleaning ......................................................5-21
Parking And Long Term Storage.......................5-22
Maintenance Schedule.......................................5-23
Parts/Maintenance Items ...................................5-29
Accessories ........................................................5-29
Fuses ..................................................................5-29
Instrument Panel (MX Dirt) ................................3-11
Performance Level Switch (MX Dirt) .................3-12
Instrument Panel (X/XU Street Legal)...............3-13
Indicators .....................................................3-14
Performance Level Switch ..................................3-15
XU Street Legal...........................................3-15
X Street Legal .............................................3-16
Handlebar Controls (MX Dirt) ............................3-17
Handlebar Controls (X/XU Street Legal) ..........3-19
Starting And Operating .............................................4-1
First Time Set-Up.................................................4-1
Unpacking Your Zero Motorcycle .................4-2
General Operation ................................................4-4
Pre-Ride Inspection......................................4-4
Key Switch/Steering Lock Positions ............4-5
Power Pack ...................................................4-6
Operating Your Motorcycle..............................4-20
Suspension Adjustment .............................4-21
Maintaining Your Motorcycle ....................................5-1
Owner’s Responsibilities ....................................5-1
Bolt Torque Table .................................................5-2

TOC-3
Troubleshooting ..........................................................6-1
Power Pack And Charger ....................................6-1
Battery Management System .......................6-3
Understanding BMS Flash Code
Patterns .........................................................6-4
Safety Interlocks..........................................6-10
Temperature Indicator.................................6-14
General Troubleshooting ...........................6-17
Warranty/Customer Assistance ............................... 7-1
Customer Assistance...........................................7-1
Warranty Information ............................................7-2
Zero Motorcycles Warranties ...............................7-2
Standard Warranty.........................................7-2
Disclaimers Applicable to Standard
Warranty.........................................................7-4
Proper Use.................................................... 7-5
Purchaser’s Responsibilities.......................7-5
Warranty Procedures ....................................7-5
Transfer Of Ownership And Warranty ..........7-6

TOC-4
NOTES

1-1
Introduction
Introduction
This manual covers the following motorcycles:
•Zero MX Dirt
- Chain Drive
- Off Road Tires
- Stand-alone Charger
•Zero X Street Legal
- Chain Drive
- Dual Sport Tires
- Stand-alone Charger
- Lights
•Zero XU Street Legal
- Belt Drive
- Street Tires
- Integrated Charger
- Lights
- Regenerative Braking
Congratulations and thank you for purchasing the
2012 Zero 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, 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 Motorcycles
For 24 hour updates and additonal information about
your motorcycle, visit the owners resources section of
the Zero Motorcycles website:
www.zeromotorcycles.com/owner-resources/

1-2
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.
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 the above may render the warranty
invalid.
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™
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 power pack warranty. See page 4-6 for other
important information about the power pack.
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 by technicians with special
training.

1-3
Owner Information
Record important information pertaining to your motorcycle here. When contacting your dealer, you may need to
provide this information.
Dealer Information Motorcycle Information
Power Pack Serial Number
Address PIN (MX)
Key Code
Date of Purchase
VIN (X/XU)
Telephone No.
E-mail
Name
Model

1-4
Power Pack Serial Number
The power pack serial number is located on top of
the power pack next to the connector 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.
Motor Serial Number
The motor serial number is stamped on the silver
metal cooling cover that wraps around the Agni motor
or on the casting band for the Motenergy brushless
motor.
Motor Identification
A. Motenergy Brushless Motor
•XU - Street Legal
B. Agni
•MX - Dirt
•X - Street Legal
BA

1-5
Identification Numbers
See Location Of Important Labels on page 2-3.
The Vehicle Identification Number (VIN) is found on
the X/XU Street Legal. The Production Identification
Number (PIN) is found on the MX Dirt. This is a
17-digit number (A) stamped on the head tube of the
frame. Do not alter or remove this as it is the legal
identifier for your motorcycle.
A

1-6
VIN/PIN Breakdown
Z2 = X/MX Platform
538
Motorcycle Type
C = 2012
Production Number
C = 11-12 MY XD/X
E = 11-12 MY XU
F = 11-12 MY XU LSM
XU2 X CA1 12345
538 = On Road
L2 = 12 MY XU-M
U2 = 12 MY XU
C2 = 12 MY XU-LSM
X2 = 12 MY MX
A1 = Type A 9kW (12.1 HP) -X
M0 = Type M 4.1 kW (5.5 HP) -XU-LSM
M2 = Type M 5.2 kW (7.0 HP) -XU
World Manufacturer Identifier
C = California
Model Line
Model Year
Plant Location
Model
Net Brake Horsepower
CC
(Europe Only)
(Canada Only)

1-7
General Information
Zero X Street Legal Technical
Specifications
**Zero chargers typically draw as much as 10 amps at 120 volts.
MOTOR
Type High Efficiency, Forced Air Cooled, Axial Flux Permanent Magnet,
Brushed Motor
Controller High Efficiency, 400 amp,
Programmable Brushed DC Controller
Estimated
Top Speed 90 km/h (56 mph)
POWER SYSTEM
Type ZF3 Z-Force™ Patented Li-Ion
Portable Intelligent Power Pack
Maximum
Capacity 3 kWh
Nominal
Capacity 2.6 kWh
Recharge Time
(standard) • 3.1 hours (100% charged)
• 2.7 hours (95% charged)
Quick Recharge
Time (optional) • 2.0 hours (100% charged)
• 1.3 hours (95% charged)
POWER SYSTEM
Input** Standard 120 V AC or 240 V AC
Charger Type 1 kW Stand-alone
Estimated Pack
Life (to 80%) City 165,000 Km (103,000 miles)
Estimated Pack
Life (to 80%) Trail 4,000 hours
DRIVETRAIN
Transmission Clutchless one speed
Drive System 13T/61T Sprockets, 420 Chain
CHASSIS/SUSPENSION/BRAKES
Front Suspension
Travel 240 mm (9.4 in)
Rear Suspension
Travel 221 mm (8.7 in)
Front Brakes 2 Piston Hydraulic, 220 x 4 mm
Rotor, Hand Actuated
Rear Brakes 1 Piston Hydraulic, 220 x 4 mm
Rotor, Foot Actuated
Brake Rotor Minimum Thickness 3.85 mm (0.15 in)

1-8
*Environmental Protection Agency (EPA) Urban Dynamometer Driving
Schedule (UDDS)
CHASSIS/SUSPENSION/BRAKES
Front Tire 100/70-19 in
Rear Tire 100/80-16 in
Front Wheel 19 x 1.85 in
Rear Wheel 16 x 2.15 in
Front Suspension 38 mm (1.5 in) inverted fork with adjustable compression and
rebound damping
Rear Suspension Direct-Link shock with adjustable spring preload, compression and
rebound damping
DIMENSIONS
Wheel Base 141 cm (55.5 in)
Seat Height
(standard) 87 cm (34.3 in)
Rake 26.4 degrees
Trail 89 mm (3.5 in)
RANGE
Trail 60-120 minutes
City(EPA UDDS)* 61 km (38 miles)
WEIGHT
Frame 6.6 kg (14.5 pounds)
GVWR 211 kg (465 pounds)
Curb Weight 98 kg (215 pounds)
Carrying Capacity 113 kg (250 pounds)
ECONOMY
Typical Cost to
Recharge $0.32
Equivalent Fuel
Economy (City)
487 MPGe
0.48 liters/100 km
(0.13 gallons/62 miles)

1-9
Zero MX Dirt Technical Specifications
**Zero chargers typically draw as much as 10 amps at 120 volts.
MOTOR
Type High Efficiency, Forced Air Cooled, Axial Flux Permanent Magnet,
Brushed Motor
Estimated
Top Speed 86 km/h (54 mph)
Controller High Efficiency, 400 amp,
programmable brushed DC Controller
POWER SYSTEM
Type ZF3 Z-Force™ Patented Li-Ion
Intelligent Portable Power Pack
Maximum
Capacity 3 kWh
Nominal
Capacity 2.6 kWh
RANGE
MX Track 40-90 minutes
Trail 60-120 minutes
DRIVETRAIN
Transmission Clutchless one speed
Drive System 13T/71T Sprockets, 420 Chain
POWER SYSTEM
Recharge Time
(standard) • 3.1 hours (100% charged)
• 2.7 hours (95% charged)
Quick Recharge
Time (optional) • 2 hours (100% charged)
• 1.3 hours (95% charged)
Input** Standard 120 V AC or 240 V AC
Charger Type 1 kW Stand-alone
Estimated Pack
Life (to 80%) • MX Track-3,000 hours • Trail-4,000 hours
DIMENSIONS
Wheel Base 141 cm (55.5 in)
Seat Height
(standard) 87 cm (34.3 in)
Rake 26.4 degrees
Trail 89 mm (3.5 in)

1-10
WEIGHT
Frame 6.6 kg (14.5 pounds)
GVWR 204 kg (450 pounds)
Curb Weight 91 kg (200 pounds)
Carrying Capacity 113 kg (250 pounds)
ECONOMY
Typical Cost to
Recharge $0.32
CHASSIS/SUSPENSION/BRAKES
Front Suspension
Travel 240 mm (9.4 in)
Rear Suspension
Travel 221 mm (8.7 in)
Front Suspension 38 mm inverted fork with adjustable compression and
rebound damping
Rear Suspension Direct-Link shock with adjustable spring preload, compression and
rebound damping
Front Brakes 2 Piston Hydraulic, 220 x 4 mm
Rotor, Foot Actuated
Rear Brakes 1 Piston Hydraulic, 220 x 4 mm
Rotor, Foot Actuated
Brake Rotor Minimum Thickness 3.85 mm (0.15 in)
Front Tire 100/70-19 in
Rear Tire 100/90-16 in
Front Wheel 19 x 1.85 in
Rear Wheel 16 x 2.15 in

1-11
Zero XU Street Legal Technical
Specifications
*Environmental Protection Agency (EPA) Urban Dynamometer Driving
Schedule (UDDS)
**Zero chargers typically draw as much as 10 amps at 120 volts.
POWER SYSTEM
Type ZF3 Z-Force™ Patented Li-Ion
Intelligent Portable Power Pack
Maximum
Capacity 3 kWh
Nominal
Capacity 2.6 kWh
Maximum
Range Up to 48 km (30 miles)
EPA UDDS*
Range (city) 58 km (42 miles)
Recharge Time
(standard) • 3.1 hours (100% charged) • 2.7 hours (95% charged)
Quick Recharge
Time (optional) • 2 hours (100% charged)
• 1.3 hours (95% charged)
Charger Type 1 kW Integrated
Estimated Pack
Life (to 80%) 182,000 Km (113,000 miles)
Input** Standard 120 V AC or 240 V AC
MOTOR
Type High Efficiency, Axial Flux Permanent Magnet Brushless Motor with
Integrated Forced Air Cooling
Controller High Efficiency, 220 amps, 3-phase Brushless Controller with Re-
Generative Deceleration
Estimated
Top Speed
(max) 105 km/h (65 mph)
Estimated
Top Speed
(sustained) 88 km/h (55 mph)
DRIVETRAIN
Transmission Clutchless one speed
Drive System 25T/132T Sprockets, Poly Chain®
GT® Carbon™ Belt

1-12
DIMENSIONS
Wheel Base 138 cm (55 in)
Seat Height
(standard) 80 cm (31.5 in)
Low Seat Height
(option) 77 cm (30.5 in)
Rake 24.7 degrees
Trail 86 mm (3.4 in)
WEIGHT
Frame 6.6 kg (14.5 pounds)
Curb Weight 100 kg (221 pounds)
GVWR 214 kg (471 pounds)
Carrying Capacity 115 kg (250 pounds)
ECONOMY
Typical Cost to
Recharge $0.32
Equivalent Fuel
Economy (City)
539 MPGe
0.44 liters/100 km
(0.11 gallons/62 miles)
Equivalent Fuel
Economy (Highway)
359 MPGe
0.66 liters/100 km
(0.17 gallons/62 miles)
CHASSIS/SUSPENSION/BRAKES
Front Suspension
Travel 135 mm (5.3 in)
Rear Suspension
Travel 141 mm (5.5 in)
Front Suspension 38 mm (1.5 in) inverted fork with adjustable compression and
rebound damping
Rear Suspension Direct-Link shock with adjustable spring preload, and rebound
damping
Front Brakes 2 Piston Hydraulic, 220 x 4 mm
Rotor, Hand Actuated
Rear Brakes 1 Piston Hydraulic, 220 x 4 mm
Rotor, Foot Actuated
Brake Rotor Minimum Thickness 3.85 mm
(0.15 in)
Front Wheel 19 x 1.85 in
Rear Wheel 16 x 2.15 in
Front Tire 90/90-19 in
Rear Tire 90/110-16 in

1-13
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 conservatively you
ride, the better range you can expect from your Zero
motorcycle.
Some of the factors which affect range include speed,
acceleration, number of starts and stops, terrain, 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 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.
Average motorcycle range is calculated using industry
standardized formulas. These ranges are separated
into four categories: City, Highway, Trail, and Track.
•“City (EPA UDDS)” Environmental Protection
Agency (EPA) Universal Dynamometer Driving
Schedule (UDDS). The City (EPA UDDS) range is
a U.S. federal test procedure to give an estimate
on how many miles an electric vehicle will go on
a single charge (X/XU).
•“Highway” range is to provide the rider an
estimate of what you can expect to achieve when
using the motorcycle for highway commuting. This
range takes into account the distanced traveled on
city roads getting to and from the highway as well
as the distance spend in highway congestion. The
average highway commute is made up of 50%
steady highway speed riding and 50% city like
riding (XU).
•“Trail” is an off road range that represents the
riding time that most riders can expect to achieve
while riding trails. The lower range represents a
more aggressive pace, while the upper range is a
more conservative rider (X/MX).
•“Track” range represents the riding time that most
riders can achieve while riding tracks. The lower
range represents a more aggressive pace, while
the upper range is a more conservative rider (MX).

1-14
Emissions Information
The Zero electric motorcycle is a 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 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.
Public Charging Stations
There are more public charging stations coming
on-line every day and there may be some in your
area. You can charge from a public charging station
with the optional J1772 Zero motorcycle accessory.
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.”
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 decrease your range.
•Coasting whenever possible makes a significant
difference; the motorcycle will coast for a long
distance (take advantage of this).
•The regenerative braking system on deceleration
(XU only) takes some of the energy from the
motor and turns it back into electrical energy. This
energy is then stored back into the power pack.
See technical specification charts on page 1-7
through 1-12 for these ranges.

1-15
A
SF
SF
A
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.
Transporting
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 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.