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