Zero S 2012 User manual

2012 Owner’s Manual
ZERO S™
ZERO DS™

TOC-1
Introduction ................................................................1-1
An Important Message To You From Zero ..........1-1
Introduction............................................................1-1
Index ..............................................................1-1
Useful Information For Safe Riding..............1-2
Plug in Your Z-Force Power Pack™...................1-2
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
VIN Location ..................................................1-4
VIN Break Down............................................1-5
General Information .............................................. 1-6
Zero S Technical Specifications ...................1-6
Zero DS Technical Specifications.................1-8
Vehicle Range .............................................1-10
Optimizing Your Range By Adapting Your
Riding Style..................................................1-11
Public Charging Stations.............................1-12
Emissions Information .................................1-12
Transporting .................................................1-13
Safety Information .....................................................2-1
General Safety Precautions..................................2-1
Important Operating Information...................2-2
Location Of Important Labels .......................2-3
Throttle And Speed Control Label ................2-4
Controls And Components.......................................3-1
Motorcycle Controls ..............................................3-1
Left Side View.......................................................3-3
Right Side View ....................................................3-5
Instrument Panel ...................................................3-7
Indicators .......................................................3-8
Performance Level Switch..................................3-10
Handlebar Controls .............................................3-11
Starting And Operating .............................................4-1
First Time Set-Up..................................................4-1
Unpacking Your Zero Motorcycle..................4-2
Table Of Contents

TOC-2
Parking And Long Term Storage........................5-23
Maintenance Schedule .......................................5-24
Parts/Maintenance Items ....................................5-27
Zero Motorcycle Accessories..............................5-27
Fuses ...................................................................5-27
Troubleshooting .........................................................6-1
Power Pack And Charger.....................................6-1
Battery Management System........................6-3
Safety Interlocks ..........................................6-10
Temperature Indicator .................................6-12
General Troubleshooting .............................6-17
Warranty/Customer Assistance................................7-1
Customer Assistance ............................................7-1
Warranty Information ............................................7-2
Zero Motorcycles Warranties................................7-2
Standard Warranty ........................................7-2
Disclaimers Applicable to Standard
Warranty ........................................................7-3
Proper Use ....................................................7-4
Purchaser’s Responsibilities .........................7-4
Warranty Procedures ....................................7-5
Transfer Of Ownership And Warranty ..........7-6
General Operation.................................................4-3
Pre-Ride Inspection.......................................4-3
Key Switch/Steering Lock Positions .............4-4
Power Pack ...................................................4-6
Operating Your Motorcycle..........................4-14
Suspension Adjustment .............................4-15
Maintaining Your Motorcycle ...................................5-1
Owner’s Responsibilities.......................................5-1
Bolt Torque Table ..................................................5-2
Power Pack ...........................................................5-6
General Maintenance............................................5-7
Brakes............................................................5-7
Suspension ....................................................5-9
Wheels And Tires..........................................5-9
Tire Inflation .................................................5-10
Drive Belt .....................................................5-10
Drive Chain (optional) .................................5-14
Headlight Alignment ...................................5-17
Headlight Bulb Replacement ......................5-18
Turn Signal Light Bulb Replacement .........5-20
Brake/Tail Light Bulb Replacement ............5-20
Running Light Bulb Replacement...............5-21
Cleaning.......................................................5-22

1-1
Introduction
Congratulations and thank you for purchasing the
2012 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:
www.zeromotorcycles.com/owner-resources/
Introduction
This manual covers the following motorcycles:
•Zero S: Street
- Integrated Z-Force Power Pack™ and Charger
- Cast Wheels
- Street Tires
- Belt Drive
•Zero DS: Dual Sport
- Integrated Z-Force Power Pack™ and Charger
- Spoke Wheels
- Dual Sport Tires
- Belt Drive
Index
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.
An Important Message To You
From Zero Motorcycles

1-2
Useful Information For Safe Riding
This manual contains the word CAUTION to tell about
something that could hurt you or others. It also
contains the word WARNING to tell about 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.
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 4-6 for other
important information about the power pack.
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.

1-3
Dealer Information Motorcycle Information
Address Model
Key Code
Date of Purchase
VIN
Telephone No.
E-mail
Power Pack Serial Number
Name
Motor Serial Number
Owner Information
Record important information pertaining to your motorcycle here. When contacting your dealer, you may need to
provide this information.

1-4
A
Vehicle Identification Number
(VIN)
See Location Of Important Labels on page 2-3.
VIN Location
A. VIN Stamp
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.

1-5
Z1 = S/DS Platform
538
Motorcycle Type
M3 = 12 MY S
D3 = 12 MY DS
M3 = 9.1 kW (12.2 HP)
C = 2012
Production Number
SM3 9 CM3 12345
538 = On Road
World Manufacturer Identifier
C = California
Model Line
Model Year
Plant Location
A = 11-12 MY S
B = 11-12 MY DS
Model
Net Brake Horsepower
CA
VIN Break Down
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.

1-6
General Information
Zero S Technical Specifications
*Environmental Protection Agency (EPA) Urban Dynamometer Driving
Schedule (UDDS)
**Zero chargers typically draw as much as 10 amps at 120 volts.
MOTOR
Type High efficiency, double-stator axial flux permanent magnet, brushless motor
with integrated forced air cooling
Controller High efficiency, 420 amp, 3-phase brushless controller with re-generative
deceleration
Estimated Top
Speed (max) 142 km/h (88 mph)
Estimated Top
Speed
(sustained) 121 km/h (75 mph)
POWER SYSTEM
Type Z-Force™ Patented Li-Ion Intelligent
Power Pack
Maximum
Capacity • ZF6 6.0 kWh • ZF9 9.0 kWh
Nominal
Capacity • ZF6 5.3 kWh • ZF9 7.9 kWh
Charge Time
(standard)
• ZF6 6.0 hours (100% charged)/5.3
hours (95% charged)
• ZF9 9.0 hours (100% charged)/8.0
(95% charged)
POWER SYSTEM
Quick 2X
Charger Time
(accessory)
• ZF6 3.0 hours (100% charged)/2.7
hours (95% charged)
• ZF9 4.9 hours (100% charged)/4.0
hours (95% charged)
Quick 3X
Charger Time
(accessory)
• ZF6 2.2 hours (100% charged)/1.8
hours (95% charged)
• ZF9 3.1 hours (100% charged)/2.7
hours (95% charged)
Quick 4X
Charger Time
(accessory)
• ZF6 1.6 hours (100% charged)/1.3
hours (95% charged)
• ZF9 2.4 (100% charged)/2.0 hours
(95% charged)
Input** Standard 120 V AC or 240 V AC
Charger Type 1 kW Integrated
Estimated
Power Pack Life
to 80% (city) • ZF6 330,000 km (205,000 miles)
• ZF9 495,000km (308,000 miles)
RANGE
CityEPA
UDDS* Range • ZF6 122 km (76 miles) • ZF9 183 km (114 miles)
Highway at 113
km/h (70 mph) • ZF6 69 km (43 miles) • ZF9 101 km (63 miles)

1-7
DRIVETRAIN
Transmission Clutchless one speed
Final Drive 28T/132T Sprockets, 8 mm
pitch, 200 tooth, 14 mm width,
Poly Chain® GT® Carbon™
(belt)
CHASSIS/SUSPENSION/BRAKES
Front Suspension
Travel 140 mm (5.51 in)
Rear Suspension
Travel 149 mm (5.85 in)
Front Brakes 2 Piston Hydraulic, 310 x 4 mm
Floating Rotor, Hand Actuated
Rear Brakes 1 Piston Hydraulic, 220 x 4 mm
Rotor, Foot Actuated
Brake Rotor Minimum
Thickness 3.85 mm (0.15 in)
Front Tire 110/70-17 in
Rear Tire 130/70-17 in
Front Wheel 17 x 3.0 in
Rear Wheel 17 x 3.5 in
Front Suspension 38 mm inverted forks with adjustable compression and
rebound damping
CHASSIS/SUSPENSION/BRAKES
Rear Suspension Direct-link shock with adjustable spring preload, compression and
rebound damping
DIMENSIONS
Wheel Base 144 cm (56.6 in)
Seat Height
(standard) • ZF6 83 cm (32.5 in) • ZF9 84 cm (33 in)
Low Seat Height
(option) • ZF6 80 cm (31.5 in)
• ZF9 81 cm (32 in)
Rake 23.1 degrees
Trail 76 mm (3.0 in)
WEIGHT
Frame 10 kg (22 pounds)
Curb Weight • ZF6 135 kg (297 pounds)
• ZF9 155 kg (341 pounds)
GVWR • ZF6 289 kg (637 pounds)
• ZF9 309 kg (681 pounds)
Carrying Capacity 154 kg (340 pounds)

1-8
Zero DS Technical Specifications
*Environmental Protection Agency (EPA) Urban Dynamometer Driving
Schedule (UDDS)
ECONOMY
Typical Cost to
Recharge • ZF6 $0.63
• ZF9 $0.95
Equivalent Fuel
Economy (city) 487 MPGe- 0.48 Liters/100km (0.13 gallons/62 miles)
Equivalent Fuel
Economy (highway) 273 MPGe- 0.86 Liters/100km (0.23 gallons/62 miles)
MOTOR
Type High efficiency, double-stator axial flux permanent magnet, brushless motor
with integrated forced air cooling
Controller High efficiency, 420 amp, 3-phase brushless controller with re-generative
deceleration
Estimated Top
Speed (max) 129 km/h (80 mph)
Estimated Top
Speed
(sustained) 113 km/h (70 mph)
POWER SYSTEM
Type High efficiency, double-stator axial flux permanent magnet, brushless motor
with integrated forced air cooling
Maximum
Capacity • ZF6 6.0 kWh • ZF9 9.0 kWh
Nominal
Capacity • ZF6 5.3 kWh • ZF9 7.9 kWh
Charge Time
(standard)
• ZF6 6.0 hours (100% charged)/5.3
hours (95% charged)
• ZF9 9.0 hours (100% charged)/8.0
(95% charged)
Quick 2X
Charger Time
(accessory)
• ZF6 3.0 hours (100% charged)/2.7
hours (95% charged)
• ZF9 4.9 hours (100% charged)/4.0
hours (95% charged)
Quick 3X
Charger Time
(accessory)
• ZF6 2.2 hours (100% charged)/1.8
hours (95% charged)
• ZF9 3.1 hours (100% charged)/2.7
hours (95% charged)
Quick 4X
Charger Time
(accessory)
• ZF6 1.6 hours (100% charged)/1.3
hours (95% charged)
• ZF9 2.4 (100% charged)/2.0 hours
(95% charged)

1-9
**Zero chargers typically draw as much as 10 amps at 120 volts.
POWER SYSTEM
Input** Standard 120 V AC or 240 V AC
Charger Type 1 kW integrated
Estimated Power
Pack Life to 80%
(city)
• ZF6 326,000 km (203,000
miles)
• ZF9 487,000 km (302,000
miles)
RANGE
CityEPA
UDDS* Range • ZF6 121 km (75 miles) • ZF9 180 km (112 miles)
Highway at 113
km/h (70 mph) • ZF6 68 km (42 miles) • ZF9 100 km (62 miles)
DRIVETRAIN
Transmission Clutchless One Speed
Drive System
(standard) 25T/132T Sprockets, 8 mm pitch,
220 tooth, 14 mm width, Poly
Chain® (belt)
Drive System
(optional) 13T/71T Sprockets, 420 Chain
CHASSIS/SUSPENSION/BRAKES
Front Suspension
Travel 240 mm (9.4 in)
Rear Suspension
Travel 195 mm (7.69 in)
CHASSIS/SUSPENSION/BRAKES
Front Brakes 2 Piston Hydraulic, 310 x 4 mm
Floating Rotor, Hand Actuated
Rear Brakes 1 Piston Hydraulic, 240 x 4 mm
Rotor, Foot Actuated
Front Tire 100/80-17 in
Rear Tire 110/90-16 in
Front Wheel 17 x 2.5 in
Rear Wheel 16 x 3.0 in
Front Suspension 38 mm inverted fork with adjustable compression and
rebound damping
Rear Suspension Direct link shock with adjustable spring preload, compression and
rebound damping
DIMENSIONS
Wheel Base 145.5 cm (57.3 in)
Seat Height
(standard) • ZF6 89.7 cm (35.3 in)
• ZF9 88.3 cm (34.8 in)
Low Seat Height
(optional) • ZF6 87.1 cm (34.3 in)
• ZF9 85.8 cm (33.8 in)
Rake 25.3 degrees
Trail 89 mm 3.5 in

1-10
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 S/DS motorcycle.
Some of the factors which affect range include speed,
acceleration, number of starts and stops, 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.
WEIGHT
Frame 10 kg (22 pounds)
Curb Weight • ZF6 135 kg (297 pounds)
• ZF9 155 kg (341 pounds)
GVWR • ZF6 289 kg (637 pounds)
• ZF9 309 kg (688 pounds)
Carrying Capacity 154 kg (340 pounds)
ECONOMY
Typical Cost to
Recharge • ZF6 $0.63
• ZF9 $0.95
Equivalent Fuel
Economy (city) 480 MPGe- 0.49 liters/100km
(0.13 gallons/62 miles)
Equivalent Fuel
Economy (highway) 267 MPGe- 0.88 liters/100km
(0.23 gallons/62 miles)

1-11
Average motorcycle range is calculated using an
industry standardized formula. The range is separated
into two separate specifications: “City (EPA UDDS)”
Environmental Protection Agency (EPA) Universal
Dynamometer Driving Schedule (UDDS) and
“Highway.” The City (EPA UDDS) range is a U.S.
federal test procedure to give an estimate on how
many miles an electric vehicle will go on a single
charge. The highway range is to provide the rider an
estimate of what you can expect to achieve when
using the motorcycle for highway commuting. This
range takes into account the distanced traveled on
city roads getting to and from the highway as well as
the distance spent in highway congestion. The
average highway commute is made up of 50% steady
highway speed riding and 50% city- like riding. See
technical specification charts on page 1-6 through
1-10 for these ranges.
Optimizing Your Range By Adapting
Your Riding Style
•Apply the throttle slowly and try to match the
motorcycle’s acceleration with your throttle
position.
•Hard acceleration will decrease your range.
•The Zero S/DS has the ability to start, from a
standstill, up a steep 13% grade when fully
loaded. It is not recommended that you stop on
a grade of more than 13% with a fully loaded
motorcycle.
•Example: If 108 km/h (67 mph) can be reached at
100% throttle, 75% throttle will give you about 89-
95 km/h (55-59 mph) (a 25% energy savings for
an approximate 12% speed loss).
•Coasting whenever possible makes a significant
difference. The regenerative braking system on
deceleration takes some of the energy from the
motor and turns it back into electrical energy. This
energy is then stored back into the power pack.
•Plan ahead for decelerations and coast whenever
possible. For example, do not rush to traffic
signals.

1-12
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.
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.
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 public charging station with
the optional J1772 S/DS 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.”

1-13
S
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A A
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.
When the fork is released, with no weight on the front
tire, the screw must be opened again to allow for
stabilization. Ensure that the screw is tightened before
riding.
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.
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.

1-14
1 2 34
30A
80V
30A
80V
AMP
VOLTS
CIRCUIT
QUICK CHRGR CHRGR DC/DC CONV MBB
7.5A
80V
7.5A
80V
A
The electrical system must be disconnected when
transporting or shipping.
Remove the 80 volt fuses (A) from the fuse center.
The 80 volt fuse center is located on the back upper
right corner of the power pack. See page 5-29 for
further information.

2-1
Safety Information
General Safety Precautions
1. This is a performance motorcycle and should
be treated with extreme caution.
2. 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
protective clothing; this applies to even short
journeys, and to every season of the year.
3. Read all additional warnings and product
instructions in this owner’s manual, and safety
labels, before operating the electric motorcycle.
4. Never carry a passenger unless your motorcycle
is upfitted with the passenger optional accessory,
which can be found on the Zero Motorcycles
website.
5. Never permit a guest to ride your electric
motorcycle without proper instruction.
These are performance motorcycles and should
be treated with extreme caution.
6. Do not ride on frozen, oily, or pitted surfaces.
Avoid potholes, surface cracks, and other
obstacles.
7. Never use alcohol or mind-altering drugs before
operating an electric motorcycle.
8. 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.
9. Prior to each use, the rider must check everything
in the “every ride” column of the maintenance
schedules on pages 5-24 through 5-26, and the
charge level of the power pack as indicated on
the instrument panel charge indicator.
10. 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.

2-2
11. Modifications of the motorcycle may render the
vehicle unsafe and may cause severe personal
injury. Zero Motorcycles cannot be held liable for
non-approved modifications.
12. 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.
13. 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.
Important Operating Information
1. Always turn the key switch and the 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.
2. Turn the motor stop switch OFF when backing up
or pushing the motorcycle while dismounted. It is
possible to unintentionally twist the throttle,
resulting in unexpected acceleration.
3. 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.
4. The Zero S/DS power pack should be plugged in
when storing the motorcycle for extended periods
of time.
5. Keep your Zero S/DS connected to the charger
when your motorcycle is sitting in storage or if it
will be sitting unused for more than 7 days.
WARNING: Charge the Zero power pack with the
Zero charger.
The power pack must be charged within 24 hours
if fully discharged, and charged within 60 days if
stored fully charged. Zero recommends that you
plug in your Zero motorcycle after 7 days even if
charged. Please leave your Zero motorcycle
plugged in whenever possible.

2-3
A
B
Location Of Important Labels
A. Vehicle Certification Label
B. Throttle and Speed Control Label
The vehicle could contain the following information:
•Gross Vehicle Weight Rating (GVWR)
•Gross Axle Weight Rating (GAWR) Front and Rear
•Vehicle Identification Number (VIN)
•Rim Size
•Tire Pressure
•Date of Manufacture
6. The power pack does not require or tolerate deep
discharging. To get the most power pack life,
recharge the power pack immediately after each
ride. Leaving a power pack in a discharged state
will cause damage. See Charging The Power
Pack on page 4-10.