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.
Zero Owner's Manual (S and DS).book Page 2 Friday, April 26, 2013 4:55 PM

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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General Information
1.7
DRIVETRAIN
Transmission Clutchless Direct Drive
Final Drive 132T/28T,Poly Chain® GT® Carbon™ belt
CHASSIS/SUSPENSION/BRAKES
Front Suspension Travel 5.51 in (140 mm)
Rear Suspension Travel 5.85 in (149 mm)
Front Brakes Nissin 2 piston hydraulic
313 mm OD rotor, 4.0 mm thick
2 piston floating caliper
27 mm OD pistons
Rear Brakes Nissin 1 piston hydraulic
Single piston floating caliper, 25.4 mm OD
piston
Front Tire 110/70-17 in
Rear Tire 130/70-17 in
Front Wheel 3.00x17
Rear Wheel 3.50x17
Front Suspension 38 mm inverted, aluminum slider forks with
adjustable compression and rebound
damping
Rear Suspension Piggy-back reservoir shock with adjustable
spring preload, compression and rebound
damping
DIMENSION
Wheel Base 55.4 in (1,406 mm)
Seat Height 31.3 in (794 mm)
Rake 23.8 degrees
Trail 3.2 in (82 mm)
WEIGHT
Frame 19.5 lbs (8.8 kg)
Curb Weight ZF8.5 355 lbs (161 kg)
ZF11.4 387 lbs (175 kg)
Carrying capacity ZF8.5 400 lbs (181 kg)
ZF11.4 368 lbs (167 kg)
ECONOMY
Typical Cost to Recharge ZF8.5 $0.90/€1.28
ZF11.4 $1.20/€1.70
Equivalent Fuel
Economy, City (EPA
UDDS)
ZF8.5 463 MPGe(0.51 L/100 km)
ZF11.4 463 MPGe(0.51 L/100 km)
Equivalent Fuel
Economy (highway
70 mph)
ZF8.5 263 MPGe (1.00 L/100 km)
ZF11.4 263 MPGe (1.00 L/100 km)
Zero Owner's Manual (S and DS).book Page 7 Friday, April 26, 2013 4:55 PM

General Information
1.8
Zero DS
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 1.3 kW Integrated
Estimated Power Pack
Life to 80% (city) ZF8.5 213,000 miles (343,000 km)
ZF11.4 284,000 miles (457,000 km)
RANGE
City (EPA UDDS) ZF8.5 95 miles (153 km)
ZF11.4 126 miles (203 km)
Highway, 55 mph
(88 km/h) ZF8.5 57 miles (92 km)
ZF11.4 76 miles (122 km)
>Combined
(City + 55 mph) ZF8.5 71 miles (114 km)
ZF11.4 95 miles (153 km)
Highway, 70 mph
(112 km/h) ZF8.5 46 miles (74 km)
ZF11.4 61 miles (98 km)
>Combined (City +
70 mph) ZF8.5 62 miles (100 km)
ZF11.4 82 miles (132 km)
DRIVETRAIN
Transmission Clutchless Direct Drive
Drive System (standard) 132T / 28T, Poly Chain® GT® Carbon™ belt
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General Information
1.9
CHASSIS/SUSPENSION/BRAKES
Front Suspension Travel 7 in (178 mm)
Rear Suspension Travel 7.69 in (195 mm)
Front Brakes Nissin 2 piston hydraulic
313 mm OD rotor, 4.0 mm thick
2 piston floating caliper
Rear Brakes Nissin 1 piston hydraulic
221 mm OD rotor, 4.5 mm thick
Single piston floating caliper, 25.4 mm OD
piston
Front Tire 100/90-19 in
Rear Tire 130/80-17 in
Front Wheel 19 x 2.15 in
Rear Wheel 17 x 3.0 in
Front Suspension 38 mm inverted forks with adjustable
compression and rebound damping
Rear Suspension Piggy-back reservoir shock with adjustable
spring preload, compression and rebound
damping
DIMENSION
Wheel Base 56.5 in (1,435 mm)
Seat Height 34.4 in (873 mm)
Rake 26.5 degrees
Trail 4.6 in (117 mm)
WEIGHT
Frame 19.5 lbs(8.8 kg)
Curb Weight ZF8.5 363 lbs(165 kg)
ZF11.4 395 lbs(179 kg)
Carrying Capacity ZF8.5 392 lbs (178 kg)
ZF11.4 360 lbs (164 kg)
ECONOMY
Typical Cost to Charge ZF8.5 $0.90/€1.28
ZF11.4 $1.20/€1.70
Equivalent Fuel
Economy, City (EPA
UDDS)
ZF8.5 426 MPGe (.55 L/100 km)
ZF11.4 426 MPGe (.55 L/100 km)
Equivalent Fuel
Economy (highway
70 mph)
ZF8.5 205 MPGe (1.15 L/100 km)
ZF11.4 205 MPGe (1.15 L/100 km)
Zero Owner's Manual (S and DS).book Page 9 Friday, April 26, 2013 4:55 PM

General Information
1.10
Vehicle Range
The range of an electric vehicle is defined as the distance
the vehicle travels 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 S/DS
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 S/DS 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 on page 1.6 through
page 1.8 for these ranges.
Zero Owner's Manual (S and DS).book Page 10 Friday, April 26, 2013 4:55 PM

General Information
1.11
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 S/DS Zero motorcycle accessory or
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 Motorcycles 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.
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General Information
1.12
RANGE
LOW SPEED HIGH SPEED
FEWER STOPS STOP & GO
FLAT ELEVATION CHANGES
SMOOTH PAVEMENT SOFT GRAVEL
MODULATED RIDING AGGRESSIVE RIDING
STREAMLINED FULLY UPRIGHT
REDUCED CARGO HEAVIER
ROUTERIDER
ZOM0156
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General Information
1.13
RANGE
INFLATED TIRES UNDERINFLATED TIRES
LUBED CHAIN DRY CHAIN
ADJUSTED CHAIN STRETCHED CHAIN
BALANCED PACK UNBALANCED PACK
WARM WEATHER COLD WEATHER
NO WINDS HIGH HEAD WINDS
DRY ROADS SLIPPERY ROADS
WEATHERBIKE
ZOM0157
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General Information
1.14
Emissions Information
The Zero S/DS 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 S/DS 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
Zero Owner's Manual (S and DS).book Page 14 Friday, April 26, 2013 4:55 PM

General Information
1.15
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.
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Zero Owner's Manual (S and DS).book Page 15 Friday, April 26, 2013 4:55 PM

Notes
1.16
Zero Owner's Manual (S and DS).book Page 16 Friday, April 26, 2013 4:55 PM