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)