Zero DS 2013 User manual

2013 OWNER’S MANUAL
ZERO S
™
ZERO DS
™
ORCYCLES.C O M
2013 OWNER’S MANUAL
Zero Owner's Manual (S and DS).book Page 1 Friday, April 26, 2013 4:55 PM

Zero Owner's Manual (S and DS).book Page 2 Friday, April 26, 2013 4:55 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
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......................................................... 1.10
Public Charging Stations......................................... 1.11
Maximizing Your Range.......................................... 1.11
Emissions Information............................................. 1.14
Transporting............................................................ 1.15
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
Instrument Panel.......................................................3.8
Performance Level Switch ......................................3.11
Handlebar Controls ................................................. 3.12
Tank Bag.................................................................3.15
Smartphone Application..........................................3.15
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
Front Suspension Adjustment................................. 4.15
Rear Shock Adjustment ..........................................4.17
Zero Owner's Manual (S and DS).book Page 1 Friday, April 26, 2013 4:55 PM

Table Of Contents
TOC.2
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 ...................................................................5.9
Power Pack................................................................5.9
General Maintenance .................................................5.10
Brakes......................................................................5.10
Suspension..............................................................5.13
Wheels And Tires.....................................................5.14
Tire Inflation.............................................................5.14
Drive Belt .................................................................5.15
Drive Chain (Optional) .............................................5.17
Headlight Alignment.................................................5.20
Turn Signal Light Bulb Replacement .......................5.23
Brake/Tail LED Replacement...................................5.23
Running Light Bulb Replacement ............................5.24
Cleaning...................................................................5.25
Parking and Long Term Storage..............................5.26
Zero Motorcycles Accessories.................................5.26
Fuses.......................................................................5.26
Service Record ...........................................................5.29
Troubleshooting............................................ 6.1
Troubleshooting.......................................................... 6.1
Electric Motorcycle Precautions................................ 6.1
Troubleshooting Your Motorcycle............................. 6.1
Battery Management System.................................... 6.2
Cold and Hot Weather Considerations ..................... 6.8
Safety Interlocks ..................................................... 6.10
System Warning Indicator....................................... 6.12
General Troubleshooting ........................................ 6.15
Warranty and Customer Information........... 7.1
Warranty Information.................................................. 7.1
Zero Motorcycles Warranties.................................... 7.1
Standard Warranty.................................................... 7.1
Standard Warranty Exclusions.................................. 7.1
Disclaimers Applicable to Standard Warranty........... 7.2
Proper Use................................................................ 7.3
Purchaser’s Responsibilities..................................... 7.3
Warranty Procedures................................................ 7.4
Transfer Of Ownership And Warranty....................... 7.5
Customer Information................................................. 7.6
Customer Assistance................................................ 7.6
Reporting Safety Defects.......................................... 7.7
Index
First Responder Information
Zero Owner's Manual (S and DS).book Page 2 Friday, April 26, 2013 4:55 PM

Introduction
1.1
IntroductionIntroduction
An Important Message To You From Zero
Motorcycles
Congratulations and thank you for purchasing the 2013
Zero S/DS 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 S/DS, 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 owners resources section of the Zero
Motorcycles website:
http://www.zeromotorcycles.com/owner-resources/
About This Manual
This manual covers the following motorcycles:
Zero S: Street
Integrated Z-Force™ Power Pack and Charger
Cast Wheels
Street Tires
Belt Drive
Integrated Charger
Regenerative Braking
Zero DS: Dual Sport
Integrated Z-Force™ Power Pack and Charger
Spoke Wheels
Dual Sport Tires
Belt Drive
Integrated Charger
Regenerative Braking
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 Friday, April 26, 2013 4:55 PM

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, helps 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 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 page 4.5 for other important
information regarding the power pack.
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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.
Dealer Information Motorcycle Information
Address Model
Key Code
Date of Purchase
VIN
Telephone No.
E-mail
Power Pack Serial Number
Name
Motor Serial Number
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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 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.
A
ZOM0089
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Identification Numbers
1.5
VIN Break Down
The following breakdown of the VIN will help understand the significance of each digit or character in case you need to
reference it when contacting Zero or ordering parts.
S = S/DS Platform
538
Motorcycle Type
M4 = 13 MY S
D4 = 13 MY DS
Z2 = 16 kW (22 HP)
D = 2013
Production Serial Number
Check Digit (Calculated)
SM4 #DZ2 12345
538 = Zero Motorcycles Inc.
World Manufacturer Identifier
C = Scotts Valley, CA, USA
Model Line
Model Year
Plant Location
A = 13 MY S
B = 13 MY DS
Model
Net Brake Horsepower
C A
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General Information
1.6
General Information
Technical Specifications
Zero S
The Zero S specifications below apply to both the S ZF8.5
and ZF11.4 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 re-generative deceleration
Estimated Top Speed
(max) 95 mph (153 km/h)
Estimated Top Speed
(sustained) 80 mph (129 km/h)
POWER SYSTEM
Type Z-Force™ Patented Li-Ion Intelligent Power
Pack
Maximum Capacity ZF8.5: 8.5 kWh
ZF11.4: 11.4 kWh
Nominal Capacity ZF8.5: 7.5 kWh
ZF11.4: 10.0 kWh
Charge Time (standard) ZF8.5: 6.0 hours(100% charged) /
5.5 hours (95% charged)
ZF11.4: 7.9 hours (100% charged) /
7.4 hours (95% charged)
Supplemental Charger
Quick Charge Time
(accessory)
ZF8.5 3.6 hours (100% charged) /
3.1 hours (95% charged)
ZF11.4 4.6 hours (100% charged) /
4.1 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 1.3kW Integrated
Estimated Power Pack
Life to 80% (city) ZF8.5: 232,000 miles (373,000 km)
ZF11.4: 309,000 miles (497,000 km)
RANGE
City (EPA UDDS) ZF8.5 103 miles (166 km)
ZF11.4 137miles (220 km)
Highway, 55 mph
(88 km/h) ZF8.5 64 miles (103 km)
ZF11.4 85 miles (137 km)
>Combined
(City + 55 mph) ZF8.5 79 miles (127 km)
ZF11.4 105 miles (169 km)
Highway, 70 mph
(112 km/h) ZF8.5 53 miles (85 km)
ZF11.4 70 miles (113 km)
>Combined (City +
70 mph) ZF8.5 70 miles (113 km)
ZF11.4 93 miles (150 km)
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