Zero FX 2016 User manual

2016 ZERO FX / ZERO FXS
TORCYCLES.COM
ZERO FX™
ZERO FX S™
2016
Y
C
YY
L
E
S
.
CO
M
88-08467.03
OWNER’S MANUAL
OWNER’S MANUAL
Zero Owner's Manual (FX and FXS).book Page 1 Thursday, April 5, 2018 12:01 PM

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Table Of Contents
TOC.1
Introduction.................................................... 1.1
Introduction.................................................................. 1.1
An Important Message 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
Emissions Information............................................... 1.6
Vehicle Range........................................................... 1.6
Maximizing Your Range............................................ 1.7
Transporting............................................................ 1.10
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
General Operation........................................................4.1
General Operation .....................................................4.1
Key Switch/Steering Lock Positions...........................4.2
Operating Your Motorcycle........................................4.4
ABS (Anti-lock Brake System)...................................4.6
Front Suspension Adjustment....................................4.9
Rear Shock Adjustment...........................................4.13
Charging and Power Pack Information........ 5.1
Power Pack and Charging...........................................5.1
Power Pack................................................................5.1
Power Pack Swapping...............................................5.3
On-Board Power Pack Charger.................................5.4
Charging the Power Pack..........................................5.5
Quick Charging (Off-Board Accessory Charger)........5.7
Public Charging Stations..........................................5.11
Add On Electrical Equipment...................................5.11
Maintaining Your Motorcycle....................... 6.1
Maintaining Your Motorcycle ..................................... 6.1
Owner’s Responsibilities........................................... 6.1
Parts/Maintenance Items.......................................... 6.2
Service History.......................................................... 6.2
Scheduled Maintenance ........................................... 6.2
Component Fasteners .............................................. 6.6
Power Pack .................................................................. 6.9
Power Pack............................................................... 6.9
General Maintenance ................................................ 6.10
Brakes..................................................................... 6.10
Suspension............................................................. 6.13
Wheels And Tires.................................................... 6.13
Tire Inflation............................................................ 6.14
Drive Belt ................................................................ 6.14
Drive Chain (Optional) ............................................ 6.17
Headlight Alignment................................................ 6.20
Turn Signal Light Bulb Replacement ...................... 6.22
Brake/Tail Light Bulb Replacement......................... 6.23
Running Light Bulb Replacement ........................... 6.23
Cleaning.................................................................. 6.25
Parking and Long Term Storage............................. 6.26
Zero Motorcycles Accessories................................ 6.26
Fuses...................................................................... 6.27
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Table Of Contents
TOC.3
Troubleshooting............................................. 7.1
Troubleshooting .......................................................... 7.1
Electric Motorcycle Precautions................................ 7.1
Troubleshooting Your Motorcycle ............................. 7.1
System Warning Indicator......................................... 7.2
Dash Error Codes ..................................................... 7.5
General Troubleshooting .......................................... 7.8
Battery Management System.................................... 7.9
Cold and Hot Weather Considerations.................... 7.15
Safety Interlocks ..................................................... 7.16
Technical Specifications............................... 8.1
Specifications.............................................................. 8.1
Zero FX..................................................................... 8.1
Zero FXS................................................................... 8.3
Warranty and Customer Information ........... 9.1
Limited Warranty Information .................................... 9.1
Who Is The Warrantor?............................................. 9.1
Who Does This Limited Warranty Cover?................. 9.1
What Does This Limited Warranty Cover?................ 9.1
What Is The Coverage Period Of This Limited
Warranty? ................................................................. 9.2
What Is Not Covered By This Limited Warranty?...... 9.3
What Other Limitations Or Disclaimers Apply To
This Limited Warranty............................................... 9.5
What Are Your Responsibilities As A Customer? ..... 9.6
What Will Zero Motorcycles Do Under This Limited
Warranty?..................................................................9.7
How Does This Limited Warranty Relate To State
Law?..........................................................................9.7
How Do You Obtain Service Under This Limited
Warranty?..................................................................9.8
Transfer Of Ownership And Warranty.......................9.9
Customer Information............................................... 9.10
Customer Assistance..............................................9.10
Reporting Safety Defects........................................9.11
Maintenance Record ................................... 10.1
Maintenance Record.................................................. 10.1
Service History........................................................10.1
Index
First Responder Information - High Voltage
Components Locations
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Introduction
1.1
IntroductionIntroduction
An Important Message From Zero Motorcycles
Congratulations and thank you for purchasing the 2016
Zero FX or Zero FXS 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/FXS, 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 the following motorcycles (standard
features and equipment include Integrated Z-Force®
Power Pack and charger, belt drive (optional chain drive),
and regenerative braking):
•Zero FX: All Terrain
•Cast or Wire Wheels
21-inch Diameter Front Wheel
18-inch Diameter Rear Wheel
•Dual Sport Tires
•Zero FXS: Supermoto
•Cast Wheels (17-inch diameter)
•Street Tires
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 WARNING to indicate
something that could hurt you or others. It also contains
the word CAUTION 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, help 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 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 5-1 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
front left of the power pack.
Motor Serial Number
The motor serial number is stamped on the right hand side
of 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 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 is affixed to
the head tube.
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Identification Numbers
1.5
VIN Breakdown
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 Motorcycles or ordering parts.
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General Information
1.6
General Information
Emissions Information
The Zero FX/FXS 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 FX/FXS 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.
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
FX/FXS 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 FX/FXS 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.
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General Information
1.7
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 (89 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 on page 8.1 through
page 8.3 for these ranges.
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
1.8
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General Information
1.9
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General Information
1.10
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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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, eye protection, 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 assumes 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 6.2, 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.
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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.
•Plug your motorcycle into an AC power source to
recharge it after each use. Once recharged, disconnect
from the AC power source. Leaving your motorcycle
unplugged between charges will maximize the
long-term health of the power pack. You should also
use the supplied cable as it is designed for use with
your motorcycle’s electrical components.
•While unplugged with the key in the OFF position, the
motorcycle’s electronics will consume a very small
amount of power and the power pack will drain
extremely slowly. If you don’t ride for an extended
period of time (30 days or more), you may want to plug
the motorcycle into an AC power source to charge it for
a few hours prior to your next ride.
CAUTION: Charge the Zero power pack with the
motorcycle’s on-board charger or the approved Zero
accessory charger.
•The power pack does not require nor benefit from 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.
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Location of Important Labels
2.3
Location of Important Labels
Location of Important Labels
The vehicle could contain the following information for both North American and European models:
A. VIN label (European Union) - certification label
B. VIN label (North America) - certification label shown C. VECI (Vehicle Emission Control Information) label
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Location of Important Labels
2.4
High Voltage Warning Labels
Located near the motor Located on frame if only one battery is installed
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