Zero X Dirt 2011 User manual

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
Key Code Number ...............................................1-4
Motor Serial Number............................................1-4
Motor Identification................................................1-4
Identification Numbers .........................................1-5
VIN/PIN Breakdown ......................................1-6
General Information .............................................1-7
Zero X Dirt/X Street Legal
Technical Specifications ...............................1-7
Zero MX Dirt/MX Street Legal
Technical Specifications ...............................1-8
Zero XU Technical Specifications ..............1-10
Vehicle Range ....................................................1-12
Optimizing Your Range By Adapting
Your Riding Style ................................................1-12
Public Charging Stations ...................................1-12
Emissions Information.......................................1-13
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 (X/MX Dirt) ...........................3-1
Motorcycle Controls (X/MX/XU Street Legal) .......3-2
Right Side View (X/MX Dirt) .................................3-3
Right Side View (X/MX/XU Street Legal).............3-4
Instrument Panel (X/MX Dirt) ...............................3-5
Charge Indicator ...........................................3-5
Main Power Indicator....................................3-5
Table Of Contents

TOC-2
Maintaining Your Motorcycle ....................................5-1
Owner’s Responsibilities ....................................5-1
Bolt Torque Table .................................................5-2
Power Pack...........................................................5-5
General Maintenance ...........................................5-6
Motor ..............................................................5-6
Brakes ...........................................................5-6
Suspension ...................................................5-8
Wheels And Tires .........................................5-8
Tire Inflation ..................................................5-9
Drive Chain ...................................................5-9
Headlight Alignment....................................5-12
Headlight Bulb Replacement.....................5-13
Turn Signal Light Bulb Replacement .......5-15
Brake/Tail Light Bulb Replacement...........5-16
Running Light Bulb Replacement.............5-17
Cleaning ......................................................5-18
Parking And Long Term Storage.......................5-19
Maintenance Schedule.......................................5-20
Parts/Maintenance Items ...................................5-26
Accessories ........................................................5-26
Fuses ..................................................................5-26
Temperature Indicator...................................3-6
System Warning Indicator ............................3-6
Performance Level Switch (X/MX Dirt) ................3-6
Instrument Panel (X/MX/XU Street Legal) ...........3-7
Indicators .......................................................3-8
Performance Level Switch ....................................3-9
XU Street Legal.............................................3-9
X/MX Street Legal........................................3-10
Handlebar Controls (X/MX Dirt) .........................3-11
Left Handlebar Control...............................3-12
Right Handlebar Control ............................3-12
Handlebar Controls (X/MX/XU Street Legal).....3-13
Starting And Operating .............................................4-1
First Time Set-Up.................................................4-1
Unpacking Your Zero Motorcycle .................4-2
General Operation ................................................4-4
Pre-Ride Inspection......................................4-4
Key Switch/Fork Lock Positions ..................4-5
Power Pack ...................................................4-6
Operating Your Motorcycle..............................4-21
Suspension Adjustment .............................4-22

TOC-3
Troubleshooting ..........................................................6-1
Power Pack And Charger ....................................6-1
Understanding Beep Sequences ................6-3
Safety Interlocks............................................6-6
Motor Temperature Indicator ......................6-11
General Troubleshooting ...........................6-14
Warranty/Customer Assistance ............................... 7-1
Customer Assistance...........................................7-1
Warranty Information ............................................7-2
Zero Motorcycles Limited Warranties.....................7-3
Standard Warranty.........................................7-3
Extended Warranty ........................................7-4
Disclaimers Applicable to Standard
Warranty and Extended Warranty.................7-5
Proper Use....................................................7-6
Purchaser’s Responsibilities.......................7-6
Warranty Procedures ....................................7-6
Transfer Of Ownership And Warranty ..........7-7

TOC-4
NOTES

1-1
Introduction
Introduction
This manual covers the following motorcycles:
•X Dirt
•MX Dirt
•X Street Legal (stand-alone charger)
•MX Street Legal (stand-alone charger)
•XU Street Legal (integrated charger)
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.
Congratulations and thank you for purchasing the
2011 Zero electric motorcycle; we welcome you to the
community of Zero motorcycle 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
motorcycle, 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].
An Important Message To You
From Zero

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 careful maintenance, along with good
riding skills, will help you to safely enjoy the
capabilities and the reliability of this motorcycle.
Disregarding the above may render the warranty
invalid.
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.

1-3
Owner Information
Record important information pertaining to your motorcycle here. When contacting your Certified Service Center
(CSC), you may need to provide this information.
CSC Information Motorcycle Information
Power Pack Serial Number
Address PIN (X/MX)
Key Code
Date of Purchase
VIN (X/MX/XU)
Telephone No.
E-mail
Name
Model

1-4
AB
Power Pack Serial Number
The power pack serial number is located on the
inside edge of the connector 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.
Motor Serial Number
The motor serial number is stamped on the silver
metal cooling cover that wraps around the Agni motor
or on the casting band for the Mars motor.
Motor Identification
A. Mars
•X - Dirt
•X/XU - Street Legal
B. Agni
•MX - Dirt
•MX - Street Legal

1-5
A
Identification Numbers
See Location Of Important Labels on page 2-3.
The Vehicle Identification Number (VIN) is found on
the XU/X/MX Street Legal. The Production Identification
Number (PIN) is found on the X/MX Dirt. This is a
17-digit number (A) stamped on the head tube of the
frame. Do not alter or remove this as it is the legal
identifier for your motorcycle.

1-6
Z2 = X/MX Platform
538
Motorcycle Type
B = 2011
C = 2012
D = 2013
Production Number
XM2 X BA1 12345
538 = On Road
A4Z = Off Road
X1 = 11 MY X
E1 = 11 MY MX
U1 = 11 MY XU
U2 = 11 MY XU LSM
X0 = 11 MY X
M0 = 11 MY MX
C = 11 MY X
D = 11 MY MX
E = 11 MY XU
F = 11 MY XU LSM
1 = 11 MY X
2 = 11 MY MX
M1 = Electric Motor Type
M/ 16.2 - 19.8 HP
A1 = Electric Motor Type
A/ 26.1 - 31.9 HP
World Manufacturer Identifier
C = California
Model Line
Model Year
Plant Location
Model
Net Brake Horsepower
CC
VIN/PIN Breakdown

1-7
General Information
Zero X Dirt/X Street Legal
Technical Specifications
*Environmental ProtectionAgency (EPA) Urban Dynamometer Driving Schedule (UDDS)
**Zero chargers typically draw as much as 10 amps.
MOTOR
Type High Efficiency, Air Cooled, DC,
Radial Flux, Permanent Magnet
Estimated
Top Speed • X Dirt-75 km/h (47 mph)
• X Street Legal-86 km/h (53 mph)
POWER SYSTEM
Type Z-Force™ Patented Li-Ion Intelligent
Power Pack
Maximum
Capacity 2 kWh
Nominal
Capacity 1.7 kWh
Range
• X Dirt-30-60 minutes
• X Street Legal-(maximum) 42 km
(26 miles)
35 km (22 miles)*
Recharge Time
(standard) 2 hours
Quick Recharge
Time (optional) 1.2 hours (100% charged) 1.0 hours (90+% charged)
POWER SYSTEM
Input** Standard 120 V AC or 240 V AC
Charger Type Stand-alone
Estimated Pack
Life (to 80%) • X Dirt-1,215 hours
• X Street Legal-47,000 Km
(29,000 miles)
DRIVETRAIN
Transmission Clutchless one speed
Drive System • X Dirt-13T/71T Sprockets, 420
Chain
• X Street Legal-13T/61T
Sprockets, 420 Chain
CHASSIS/SUSPENSION/BRAKES
Front Suspension
Travel 210 mm (8.3 in)
Rear Suspension
Travel 221 mm (8.7 in)
Front Brakes 2 Piston Hydraulic, Stainless Rotor,
Hand Actuated
Rear Brakes 1 Piston Hydraulic, Stainless Rotor,
Foot Actuated
Brake Rotor Minimum Thickness 3.85 mm (0.15 in)

1-8
Zero MX Dirt/MX Street Legal
Technical Specifications
CHASSIS/SUSPENSION/BRAKES
Front Tire • X Dirt-100/70-19 in
• X Street Legal-90/80-19 in
Rear Tire • X Dirt-100/90-16 in
• X Street Legal-90/90-16 in
Front Wheel 19 x 1.85 in
Rear Wheel 16 x 2.15 in
DIMENSIONS
Wheel Base 141 cm (55.5 in)
Seat Height
(standard) 84.5 cm (33.3 in)
Low Seat Height
(option) 79.4 cm (31.3 in)
Rake 24.9 degrees
Trail 80 mm (3.2 in)
WEIGHT
Frame 6.7 kg (14.8 pounds)
GVWR • X Dirt-197 kg (435 pounds) • X Street Legal-205 kg
(451 pounds)
WEIGHT
Curb Weight • X Dirt-84 kg (185 pounds)
• X Street Legal-91 kg (201 pounds)
Carrying Capacity 113 kg (250 pounds)
ECONOMY
Typical Cost to
Recharge $0.21
MOTOR
Type High Efficiency, Air Cooled, DC, Axial
Flux, Permanent Magnet
Estimated
Top Speed • MX Dirt-64 km/h (40 mph)
• MX Street Legal-92 km/h(57 mph)
POWER SYSTEM
Type Z-Force™ Patented Li-Ion Intelligent
Power Pack
Maximum
Capacity 2 kWh
Nominal
Capacity 1.7 kWh

1-9
*Environmental ProtectionAgency (EPA) Urban Dynamometer Driving Schedule (UDDS)
**Zero chargers typically draw as much as 10 amps.
CHASSIS/SUSPENSION/BRAKES
Front Suspension
Travel 210 mm (8.3 in)
Rear Suspension
Travel 221 mm (8.7 in)
Front Brakes 2 Piston Hydraulic, Stainless Rotor,
Foot Actuated
Rear Brakes 1 Piston Hydraulic, Stainless Rotor,
Foot Actuated
Brake Rotor Minimum Thickness 3.85 mm (0.15 in)
Front Tire • MX Dirt-100/70-19 in
• MX Street Legal-90/80-19 in
Rear Tire • MX Dirt-100/90-16 in
• MX Street Legal-90/90-16 in
Front Wheel 19 x 1.85 in
Rear Wheel 16 x 2.15 in
DIMENSIONS
Wheel Base 141 cm (55.5 in)
Seat Height
(standard) 84.5 cm (33.3 in)
Low Seat Height
(option) 79.4 cm (31.3 in)
POWER SYSTEM
Range • MX Dirt-30-60 minutes
• MX Street Legal-(maximum)
42 km (26 miles)
35 km (22 miles)*
Recharge Time
(standard) 2 hours
Quick Recharge
Time (optional) 1.2 hours (100% charged) 1.0 hours (90+% charged)
Input** Standard 120 V AC or 240 V AC
Charger Type Stand-alone
Estimated Pack
Life (to 80%) • MX Dirt-1,215 hours
• MX Street Legal-47,000 Km
(29,000 miles)
DRIVETRAIN
Transmission Clutchless one speed
Drive System • MX Dirt-13T/71T Sprockets, 420
Chain
• MX Street Legal-13T/61T
Sprockets, 420 Chain

1-10
Zero XU Technical Specifications
*Environmental ProtectionAgency (EPA) Urban Dynamometer Driving Schedule (UDDS)
**Zero chargers typically draw as much as 10 amps.
DIMENSIONS
Rake 24.9 degrees
Trail 80 mm (3.2 in)
WEIGHT
Frame 6.7 kg (14.8 pounds)
GVWR • MX Dirt-197 kg (435 pounds)
• MX Street Legal-205 kg
(451 pounds)
Curb Weight • MX Dirt-84 kg (185 pounds)
• MX Street Legal-91 kg
(201 pounds)
Carrying Capacity 113 kg (250 pounds)
ECONOMY
Typical Cost to
Recharge $0.21
MOTOR
Type High Efficiency, Air Cooled, DC, Axial
Flux, Permanent Magnet
Estimated
Top Speed 82 km/h (51 mph)
POWER SYSTEM
Type Z-Force™ patented Li-Ion intelligent
power pack
Maximum
Capacity 2 kWh
Nominal
Capacity 1.7 kWh
Maximum
Range Up to 48 km (30 miles)
EPA UDDS*
Range 40 km (25 miles)
Recharge Time
(standard) 2 hours
Quick Recharge
Time (optional) 1.2 hours (100% charged) 1 hours (90+% charged)
Input** Standard 120 V AC or 240 V AC

1-11
CHASSIS/SUSPENSION/BRAKES
Front Wheel 19 x 1.85 in
Rear Wheel 16 x 2.15 in
DIMENSIONS
Wheel Base 138 cm (54.3 in)
Seat Height
(standard) 80.6 cm (31.8 in)
Low Seat Height
(option) 75.6 cm (29.8 in)
Rake 24.2 degrees
Trail 83 mm (3.3 in)
WEIGHT
Frame 6.7 kg (14.8 pounds)
Curb Weight 99 kg (218 pounds)
GVWR 212 kg (468 pounds)
Carrying Capacity 113 kg (250 pounds)
ECONOMY
Typical Cost to
Recharge $0.21
POWER SYSTEM
Charger Type Integrated
Estimated Pack
Life (to 80%) 52,000 Km (32,000 miles)
DRIVETRAIN
Transmission Clutchless one speed
Drive System 13T/61T Sprockets, 420 Chain
CHASSIS/SUSPENSION/BRAKES
Front Suspension
Travel 135 mm (5.3 in)
Rear Suspension
Travel 140 mm (5.5 in)
Front Brakes 2 Piston Hydraulic, Stainless Rotor,
Hand Actuated
Rear Brakes 1 Piston Hydraulic, Stainless Rotor,
Foot Actuated
Brake Rotor Minimum Thickness 3.85mm (0.15 in)
Front Tire 90/90-19 in
Rear Tire 90/110-16 in

1-12
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 and conditions. 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, terrain, 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. Once you become familiar with the range
versus performance of your motorcycle, then you can
adjust your riding characteristics if you so desire.
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 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.”
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.
•Coasting whenever possible makes a significant
difference; the motorcycle will coast for a long
distance (take advantage of this).

1-13
A
SF
SF
A
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.
Emissions Information
The Zero electric motorcycle is a zero emissions
vehicle under California (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 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 (ZEVs) 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
products 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.
Transporting

1-14
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.

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 the
correct 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, as well as
safety labels, before operating your electric
motorcycle.
4. Never carry a passenger. This motorcycle is
designed for a SINGLE RIDER ONLY.
5. Never permit a guest to ride your electric
motorcycle without proper instruction.
6. Never use alcohol or mind-altering drugs before
operating your electric motorcycle.
7. 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.
8. Prior to each use the rider must check everything
in the “every ride” column of the maintenance
schedules on pages 5-20 through 5-25, and the
power pack function level as indicated on the
instrument panel charge indicator.
9. 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
10. 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.
11. 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.
Important Operating Information
1. 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.
2. Switch the power OFF when backing up or
pushing the motorcycle while dismounted.
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 power pack should be plugged in when
storing the motorcycle for extended periods of
time.
5. Keep your Zero connected to the charger when
your motorcycle is sitting in storage or if it will be
sitting unused for more than 7 days.
The power pack must be charged within 24 hours
if fully discharged, and must be charged within 60
days if stored fully charged. Zero recommends
you plug in your power pack after 7 days even if it
is fully charged. Please leave your power pack
plugged in whenever possible.
WARNING: Charge the Zero power pack with the
Zero charger.
6. Always firmly apply the rear brake while turning
the key switch ON or OFF. In the event of a
malfunction, the firm application of the rear brake
will help keep the motorcycle from running away.
7. The power pack does not require, or tolerate,
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. See Charging The
Power Pack on page 4-14.