Zero 2014 FX User manual

2 014 OWNER’S MANUAL ZERO FX
ZERO FX ™
TAKE CHARGE™
WWW.ZEROMOTORCYCLES.COM
2014 OWNER’S MANUAL

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........................................................... 1.8
Public Charging Stations........................................... 1.9
Maximizing Your Range............................................ 1.9
Emissions Information............................................. 1.12
Transporting............................................................ 1.13
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
Side View .................................................................. 3.4
Dash Overview.......................................................... 3.6
Warning Indicator Lights ........................................... 3.8
Dash Settings.......................................................... 3.10
Smartphone Application .......................................... 3.13
Bluetooth® Pairing .................................................. 3.13
Handlebar Controls ................................................. 3.14
Performance Level Mode Button............................. 3.17
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
Power Pack Charger ................................................. 4.8
Operating Your Motorcycle ..................................... 4.14
Front Suspension Adjustment ................................. 4.16
Rear Shock Adjustment .......................................... 4.18

Table Of Contents
TOC.2
Maintenance ................................................... 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 ..............................................................5.11
Wheels and Tires.....................................................5.12
Tire Inflation .............................................................5.12
Drive Belt .................................................................5.13
Drive Chain (Optional) .............................................5.15
Headlight Alignment.................................................5.18
Turn Signal Light Bulb Replacement .......................5.20
Brake/Tail Light Bulb Replacement..........................5.21
Running Light Bulb Replacement ............................5.21
Cleaning...................................................................5.23
Parking and Long Term Storage..............................5.24
Zero Motorcycles Accessories.................................5.24
Fuses .......................................................................5.24
Service Record ...........................................................5.27
Troubleshooting ............................................ 6.1
Troubleshooting ...........................................................6.1
Electric Motorcycle Safety Precautions..................... 6.1
Troubleshooting Your Motorcycle ............................. 6.1
System Warning Indicator......................................... 6.2
General Troubleshooting .......................................... 6.5
Battery Management System.................................... 6.6
Cold and Hot Weather Considerations ................... 6.12
Safety Interlocks ..................................................... 6.14
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....................... 7.6
Customer Information ................................................. 7.7
Customer Assistance ................................................ 7.7
Reporting Safety Defects .......................................... 7.7

Introduction
1.1
IntroductionIntroduction
An Important Message To You From Zero
Motorcycles
Congratulations and thank you for purchasing the 2014
Zero FX 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].
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 Zero FX motorcycles with the following
features:
Belt Drive / optional Chain Drive
Dual Sport Tires
Regenerative Braking
Integrated Charger
Lights
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.

Introduction
1.2
Useful Information For Safe Riding
This manual contains the word CAUTION to indicate
something that could hurt you or others. It also contains
the word WARNING to indicate 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 proper maintenance,
along with good riding skills, will help you to 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 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™
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 “Power Pack”, on page 4-5 for other
important information about 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

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.

Identification Numbers
1.4
Power Pack Serial Number
The Power Pack serial number is located on the upper
right rear of the power pack.
Motor Serial Number
The motor serial number is stamped on 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 (A). Do not alter or remove this as it is the legal
identifier for your motorcycle.
See the location of all important labels on page 2-3.

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.

General Information
1.6
General Information
Technical Specifications
Zero FX
The Zero FX specifications below apply to both the ZF2.8
and ZF5.7 models (unless otherwise specified).
MOTOR
Type Z-Force 75-5 passively air-cooled, high
efficiency, radial flux, permanent magnet,
brushless motor
Controller High efficiency, 420 amp, 3-phase
brushless controller with re-generative
deceleration
Estimated Top Speed
(max)
85 mph (137 km/h)
Estimated Top Speed
(sustained)
70 mph (113 km/h)
POWER SYSTEM
Type Z-Force™ Li-Ion Intelligent Modular
Maximum Capacity ZF2.8: 2.8 kWh
ZF5.7: 5.7 kWh
Nominal Capacity ZF2.8: 2.5 kWh
ZF5.7: 5.0 kWh
Charge Time (standard) ZF2.8: 4.1 hours(100% charged)/3.7
hours (95% charged)
ZF5.7: 7.8 (100% charged)/7.4 (95%
charged)
Supplemental Charger
Quick Charge Time
(accessory)
ZF2.8 1.9 hours (100% charged)/1.4
hours (95% charged)
ZF5.7 3.3 hours (100% charged)/2.8
hours (95% charged)
CHAdeMo Recharge Time
(0 to 95%)
1.0 hour
CHAdeMo Recharge Time
(0 to 100%)
1.5 hours
Input Standard 110 V AC or 220 V AC
Charger Type 1.3 kW Integrated
Estimated Power Pack Life
to 80% (city)
ZF2.8: 79,000 miles (127,000 km)
ZF5.7: 158,000 miles (254,000 km)
RANGE
City (EPA UDDS)  ZF2.8 35 miles (56 km)
ZF5.7 70 miles (113 km)
Highway, 55 mph
(88 km/h)
ZF2.8 22 miles (35 km)
ZF5.7 44 miles (71 km)
>Combined 
(City + 55 mph)
ZF2.8 27 miles (43 km)
ZF5.7 54 miles (87 km)
Highway, 70 mph
(112 km/h)
ZF2.8 15 miles (24 km)
ZF5.7 30 miles (48 km)
>Combined 
(City + 70 mph)
ZF2.8 21 miles (34 km)
ZF5.7 42 miles (68 km)

General Information
1.7
DRIVETRAIN
Transmission Clutchless Direct Drive
Final Drive 132T/25T, Poly Chain® GT® Carbon™
(belt)
CHASSIS/SUSPENSION/BRAKES
Front Suspension Travel 9.05 in (230 mm)
Rear Suspension Travel 8.94 in (227 mm)
Front Brakes Nissin 2 piston hydraulic
240 mm OD rotor, 4.5 mm thick
2 piston floating caliper
Rear Brakes J-Juan 1 piston hydraulic
240 mm OD rotor, 4.5 mm thick
Single floating caliper
Front Tire 3.00-21 in (90/90-21)
Rear Tire 4.10-18 in (110/90-18)
Front Wheel 1.60x21 in
Rear Wheels 2.15x18 in
Front Suspension 38mm OD steel stanchions, 48mm OD
outer tube clamping diameter. Inverted
forks with adjusted compression and
rebound damping
Rear Suspension Piggyback reservoir shock with adjustable
spring preload, compression, and rebound
DIMENSIONS
Wheel Base 56.6 in (1,438 mm)
Seat Height 34.7 in (881 mm)
Rake 26.3 degrees
Trail 4.45 in (114 mm)
WEIGHT
Frame 19.5 lbs (8.8 kg)
Curb Weight ZF2.8 238 lbs (108 kg)
ZF5.7 280 lbs (127 kg)
Carrying Capacity ZF2.8 382 lbs (173 kg)
ZF5.7 340 lbs (154 kg)
ECONOMY
Typical Cost to Recharge ZF 2.8: $ 0.3/€ 0.43
ZF 5.7: $ 0.6/€ 0.85
Equivalent Fuel Economy
(city)
472 MPGe (0.498 L/100 km)
Equivalent Fuel Economy
(highway)
ZF 2.8: 202 MPGe (1.16 L/100 km)
ZF 5.7: 202 MPGe (1.16 L/100 km)

General Information
1.8
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. The more conservative 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, ambient air
temperature 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
and your commute. Once you become familiar with the
range versus performance of your motorcycle, then you
can adjust your riding characteristics if you so desire. This
applies mainly to riders with trip profiles which are at the
edge of the performance envelope. Those individuals with
relatively short commutes can expect to ride quite
aggressively and reach their destination with energy to
spare.
Reported motorcycle range values are measured using
two different types of industry standard test procedures:
1. “City (EPA UDDS)”: This test procedure uses a duty
cycle known as the “Universal Dynamometer Driving
Schedule (UDDS)”, which was developed by the U.S.
Environmental Protection Agency (EPA) in order to
simulate city-type riding.
2. “Highway”: This test procedure uses two separate
constant speeds of 55 mph and 70 mph to simulate
highway riding.
Both of these test procedures are run on a single charge,
in order to report the associated measured range values.
Range values labeled “Combined” are based on a
calculation that assumes a duty cycle comprised of 50%
City / 50% Highway.
See technical specification charts beginning on page 1-6
for these ranges.

General Information
1.9
Public Charging Stations
There are more public charging stations coming online
every day and there may be some in your area. You can
charge from a public charging station with either the
optional J1772 Zero Motorcycle accessory or a CHAdeMO
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.”
CHAdeMO Charger
Your Zero Motorcycle can utilize a quick charging
CHAdeMO charger system. A CHAdeMO charger can
charge your motorcycle in about one hour. For additional
information contact your Zero Motorcycle dealer.
Maximizing Your Range
Range varies in electric motorcycles similarly to how it
varies in gas motorcycles. However, the big difference
between electric and gas is that energy consumption is
averaged over a shorter distance on an electric
motorcycle. Electric motorcycles are designed for
convenient daily recharges versus less frequent and less
convenient trips to the gas station. As a result, the same
electric motorcycle often yields different ranges from one
full recharge to the next.
How to Predict the Range
To generally predict how an electric motorcycle’s range will
be affected, you can use the four factors:
route
rider
weather
motorcycle
By considering each of these factors, you can use
specifications such as ‘city range’ as standards to estimate
what the motorcycle’s real world range will be under the
your particular usage case.

General Information
1.10

General Information
1.11

General Information
1.12
Emissions Information
The Zero electric motorcycle is a true freeway capable
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
Motorcycle 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. Zero Emissions Vehicles (ZEV’s) 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.

General Information
1.13
Transporting
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.
The fork must be fully extended (most likely on a stand or
balanced on the kickstand with the front tire in the air) then
the air can be bled and capped. Ensure that the screw is
tightened before riding.
It is recommended that the motorcycle be tied-down using
ratchet straps. Place the ratchet straps around a frame
contact point. 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.

Notes
1.14

General Safety Precautions
2.1
Safety InformationGeneral Safety Precautions
General Safety Precautions
This is a performance motorcycle and should be
treated with extreme caution.
Proper safety gear, including a regionally 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.
Read all additional warnings and product instructions in
this owner’s manual, as well as safety labels, before
operating your electric motorcycle.
Never permit a guest to ride your electric motorcycle
without proper instruction.
Never use alcohol or mind-altering drugs before
operating your electric motorcycle.
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.
Prior to each use the rider must check everything in the
“every ride” column of the maintenance schedule on
page 5-2, and the charge level of the power pack as
indicated on the dash display charge indicator.
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.
Modifications to the motorcycle may render the vehicle
unsafe and may cause severe personal injury. Zero
Motorcycles cannot be held liable for non-approved
modifications.
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.

General Safety Precautions
2.2
Important Operating Information
Several operating considerations are listed below:
Always turn the key switch and motor stop 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.
Turn the motor stop switch OFF when backing up or
pushing the motorcycle while dismounted.
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.
The power pack should be plugged in when storing the
motorcycle for extended periods of time.
Keep your Zero connected to the charger when your
motorcycle is sitting in storage or if it will be sitting
unused for more than 30 days.
The power pack must be charged within 24 hours if fully
discharged, and must be charged within 90 days if
stored fully charged. Zero recommends you plug in
your power pack after 30 days even if it is fully charged.
Please leave your power pack plugged in whenever
possible.
WARNING! Charge the Zero power pack with the Zero
charger.
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.
Failure to follow power pack 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 power pack efficiency and
service.