Zero FX 2015 User manual

2015 OWNER’S MANUAL ZERO FX
TOR CYCLES.COM
ZERO FX ™
2015 OWNER’S MANUAL
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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
Unplug 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
Left Side View ...........................................................3.4
Right Side View.........................................................3.6
Dash Overview..........................................................3.8
Warning Indicator Lights .........................................3.10
Dash Settings.......................................................... 3.12
Smartphone Application..........................................3.15
Bluetooth® Pairing..................................................3.15
Handlebar Controls ................................................. 3.16
Performance Level Mode Button.............................3.19
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Table Of Contents
TOC.2
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................................................................4.6
Power Pack Charger..................................................4.9
Operating Your Motorcycle......................................4.16
ABS (Anti-lock Brake System).................................4.18
Front Suspension Adjustment..................................4.20
Rear Shock Adjustment...........................................4.24
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..............................................................5.12
Wheels and Tires.....................................................5.12
Tire Inflation.............................................................5.13
Drive Belt ................................................................ 5.14
Drive Chain (Optional) ............................................ 5.16
Headlight Alignment................................................ 5.19
Turn Signal Light Bulb Replacement ...................... 5.21
Brake/Tail Light Bulb Replacement......................... 5.22
Running Light Bulb Replacement ........................... 5.22
Cleaning.................................................................. 5.24
Parking and Long Term Storage............................. 5.25
Zero Motorcycles Accessories................................ 5.25
Fuses...................................................................... 5.26
Service Record .......................................................... 5.31
Troubleshooting............................................ 6.1
Troubleshooting.......................................................... 6.1
Electric Motorcycle Safety Precautions..................... 6.1
Troubleshooting Your Motorcycle............................. 6.1
System Warning Indicator......................................... 6.2
Dash Error Codes ..................................................... 6.5
General Troubleshooting .......................................... 6.8
Battery Management System.................................... 6.9
Cold and Hot Weather Considerations ................... 6.15
Safety Interlocks ..................................................... 6.16
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Table Of Contents
TOC.3
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.......................................... 7.8
Index
First Responder Information - High Voltage
Components Locations
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Introduction
1.1
IntroductionIntroduction
An Important Message To You From Zero
Motorcycles
Congratulations and thank you for purchasing the 2015
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 FX, please ensure
that this manual stays with the motorcycle; 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 and equipment:
•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.
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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.
WARNING! 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 only 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.
Unplug Your Z-Force®Power Pack™
CAUTION: Proper care of the motorcycle’s power pack is
essential! Once your motorcycle is charged, disconnect
the power pack from AC power. Leaving your motorcycle
unplugged will maximize long-term power pack health. See
“Power Pack”, on page 4.6 for other important information
regarding 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
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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.
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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.
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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.
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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 regenerative
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 hours (100% charged) / 7.4
hours (95% charged)
Supplemental Charger
Quick Charge Time
(accessory)
•ZF2.8: 1.9 hours (100% charged) / 1.4
hours (95% charged)
•ZF5.7: 3.4 hours (100% charged) / 2.9
hours (95% charged)
Input Standard 110 V AC or 220 V AC
Charger Type 650 W Integrated
EstimatedPowerPackLife
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
(113 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)
* When “highway” is referenced elsewhere in this manual for range,
consider calculated highway speed as 70 mph (113 km/h).
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General Information
1.7
DRIVETRAIN
Transmission Clutchless Direct Drive
Final Drive 132T/25T, Poly Chain® GT® Carbon™ belt
CHASSIS/SUSPENSION/BRAKES
Front Suspension Travel 8.60 in (218 mm)
Rear Suspension Travel 8.94 in (227 mm)
Front Brakes Bosch Gen 9 ABS, J-Juan asymmetric dual
piston floating caliper, 240 mm OD x
4.5 mm thick disc
Rear Brakes Bosch Gen 9 ABS, J-Juan single piston
floating caliper, 240 mm OD x 4.5 mm thick
disc
Front Tire Pirelli Scorpion MT-90 A/T 90/90-21 54S
Rear Tire Pirelli Scorpion MT-90 A/T 120/80-18 62S
Front Wheel 1.85 x 21 in
Rear Wheels 2.50 x 18 in
Front Suspension Showa 41 mm inverted cartridge forks, with
adjustable spring preload, compression,
and rebound damping
Rear Suspension Showa 40 mm piston, piggy-back reservoir
shock with adjustable spring preload,
compression, and rebound damping
DIMENSIONS
Wheel Base 56.6 in (1,438 mm)
Seat Height 34.7 in (881 mm)
Rake 26.7 degrees
Trail 4.1 in (104 mm)
WEIGHT
Frame 20 lbs (9.1 kg)
Curb Weight •ZF2.8: 247 lbs (112 kg)
•ZF5.7: 289 lbs (131 kg)
Carrying Capacity •ZF2.8: 383 lbs (174 kg)
•ZF5.7: 341 lbs (155 kg)
ECONOMY
Typical Cost to Recharge •ZF2.8: $ 0.32/€ 0.26
•ZF5.7: $ 0.62/€ 0.51
Equivalent Fuel Economy
(city) •472 MPGe (0.498 L/100 km)
Equivalent Fuel Economy
(highway) •ZF2.8: 202 MPGe (1.16 L/100 km)
•ZF5.7: 202 MPGe (1.16 L/100 km)
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General Information
1.8
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 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, 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.
Reported motorcycle range values are measured using
two different types of industry standard test procedures:
1. “City”: This range test is specified to determine riding
during “stop-and-go” operation typically found in urban
areas. This estimate is provided following the SAE
J2982 Riding Range Test Procedure for On-Highway
Electric Motorcycles to provide a reasonable and
consistent basis for manufacturers to inform
prospective owners of the riding range that can be
expected under specified operating conditions. Actual
range will vary based on riding conditions and habits.
2. “Highway”: This test procedure uses two separate
constant speeds of 55 mph (88 km/h) and 70 mph
(113 km/h) 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.
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General Information
1.9
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 Level 1 public charging station with your
supplied charge cord or from a Level 2 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.”
Note: Use of a Level 2 charging cord doesn’t improve
charge times unless a supplemental accessory charger is
also used.
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 your
particular usage case.
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General Information
1.10
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General Information
1.11
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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.
CAUTION: 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.
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General Information
1.13
Transporting
It is recommended that the motorcycle be tied-down using
ratchet straps while it is being transported. 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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Notes
1.14
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