2014 OWNER’S MANUAL ™ WWW.ZEROMOTORCYCLES.
Table Of Contents 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 Plug in Your Z-Force Power Pack™ ......................... 1.
Table Of Contents 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 ............................................................
Introduction An Important Message To You From Zero Motorcycles Introduction Congratulations and thank you for purchasing the 2014 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.
Introduction Useful Information For Safe Riding Plug in Your Z-Force Power Pack™ 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! 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.
Identification Numbers Owner Information Identification Numbers Record information pertaining to your motorcycle here. When contacting your dealer, you may need to provide this information. 1.
Identification Numbers Power Pack Serial Number Vehicle Identification Number (VIN) The Power Pack serial number is located on the upper right rear of the power pack. 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. 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.
Identification Numbers 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. 1.
General Information Technical Specifications General Information Zero FX The Zero FX specifications below apply to both the ZF2.8 and ZF5.7 models (unless otherwise specified).
General Information DRIVETRAIN DIMENSIONS Transmission Clutchless Direct Drive Wheel Base 56.6 in (1,438 mm) Final Drive 132T/25T, Poly Chain® GT® Carbon™ (belt) Seat Height 34.7 in (881 mm) CHASSIS/SUSPENSION/BRAKES Front Suspension Travel 9.05 in (230 mm) Rear Suspension Travel 8.94 in (227 mm) Front Brakes Nissin 2 piston hydraulic 240 mm OD rotor, 4.5 mm thick 2 piston floating caliper Rake 26.3 degrees Trail 4.45 in (114 mm) WEIGHT Frame Curb Weight ZF2.
General Information 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 Motorcycle.
General Information Public Charging Stations Maximizing Your Range There are more public charging stations coming online every day and there may be some in your area. You can charge from a public charging station with either the optional J1772 Zero Motorcycle accessory or a CHAdeMO 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.
General Information 1.
General Information 1.
General Information 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.
General Information 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. It is recommended that the motorcycle be tied-down using ratchet straps.
Notes 1.
General Safety Precautions General Safety Precautions Safety Information General Safety Precautions This is a performance motorcycle and should be treated with extreme caution. 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.
General Safety Precautions 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.
Location of Important Labels Location of Important Labels Location of Important Labels The vehicle could contain the following (example) 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 2.
Location of Important Labels Anti-Tamper Control Label (Europe only) The Anti-Tamper control label (shown below) is located on the left-side of the frame. 2.
Location of Important Labels High Voltage Warning Labels Located near the battery Located on frame if only one battery is installed 2.
Notes 2.
Controls and Components Controls and Components THIS PAGE INTENTIONALLY LEFT BLANK 3.
Controls and Components Motorcycle Controls 3.
Controls and Components A. Mirrors This motorcycle is equipped with convex mirrors. A convex mirror has a curved surface. Convex mirrors offer a greater field of view than a similar flat mirror. However, the greater field of view makes objects seem further away than they really are. Care must be used when judging the distance of objects seen in these mirrors. B. Key Switch/Steering Lock For description and operation see page 4-4. C. Dash Overview For description and operation see page 3-6. D.
Controls and Components Side View 3.
Controls and Components A. Drive Belt For description and operation, see “Drive Belt”, on page 5-13. B. Drive Belt Tension Adjuster For the drive belt adjustment procedure, see page 5-14. C. Power Pack Rail Knob For description and operation, see page 5-8. D. Power Pack For a description, see “Power Pack”, on page 5-8. E. Power Pack Rail For a description, see “Power Pack Swapping”, on page 4-7. F. Fuse Center For a description, see “Fuses”, on page 5-24. G.
Controls and Components Dash Overview 3.
Controls and Components A. Adjust Button (ADJ) See “Dash Settings”, on page 3-10. B. Select Button (SEL) See “Dash Settings”, on page 3-10. C. Charge Indicator This indicator and readout displays the amount of energy remaining in the power pack, similar to the fuel gauge on a gasoline powered vehicle. D. Remaining Charge Time Indicator This area displays the amount of time left for the power pack to reach full charge. E. Clock The clock displays time in standard (AM/PM) or 24 hour mode.
Controls and Components Warning Indicator Lights 3.
Controls and Components A. Left Indicator Turn Signal An arrow on the lower dash flashes green in the same direction as selected by the turn signal switch. This arrow remains on until the turn signal request has been canceled. B. System Warning Indicator If a fault has been detected, count the number of times the red LED flashes. See the table on “System Warning Indicator”, on page 6-2 C. Temperature Lamp This flashes in the event that you exceed the motorcycle’s performance capabilities.
Controls and Components Dash Settings Displays A&B The displays on the dash can be customized to your personal preferences by using the ADJ (Adjust) and SEL (Select) buttons. Display A A. Adjust Button (ADJ) By momentarily pressing or holding the ADJ button you can reset fields and toggle through the trip menus and display options. B.
Controls and Components Display B Setting the Clock To select Display B with the dash in its normal operating mode, momentarily press the SEL button twice. Press the ADJ button to toggle through the following fields: Trip 2 Odometer - Displays individual trip mileage and is reset by pressing and holding the ADJ button for 2 seconds.
Controls and Components Unit Display - Speed Unit Display - Temperature To change the units that speed is shown in: To change the units that the temperature display is shown: 1. With the dash in its normal operating mode press and hold the SEL button for 5 seconds. 2. Momentarily press the ADJ button to select English (MPH) or metric (km/h). 3. Momentarily press the SEL button to return to normal operating mode. 1. With the dash in its normal operating mode press and hold the SEL button for 5 seconds.
Controls and Components Smartphone Application Bluetooth® Pairing You can download a smartphone application that lets you perform the following tasks related to your motorcycle: The following steps must be taken to properly pair a Bluetooth®-equipped smartphone with your motorcycle.
Controls and Components Handlebar Controls 3.
Controls and Components A. Flash-to-Pass When the headlight is in the low beam position, push the flash-to-pass switch and the high beam illuminates and stays illuminated until the switch is released. When released, this switch defaults back to the low beam position. The high beam indicator also illuminates. B. Headlight High/Low Beam Switch When the switch is pushed, the headlight changes from low beam to high beam. It stays in the selected position until it is switched back.
Controls and Components E. Motor Stop Switch When the top of the switch (A) is pressed, it cuts off power to the motor controller. The motor controller remains in this state until the bottom portion of the switch (B) is pressed. The switch does not turn off all electrical circuits, just the operation of the motor. F. Performance Level Mode Button The performance level button (A) toggles between ECO, SPORT, and CUSTOM modes.(refer to “Performance Level Mode Button”, on page 3-17) G.
Controls and Components Performance Level Mode Button The SPORT selection causes the motorcycle to accelerate at a significantly faster rate. This position is recommended for advanced riders. The CUSTOM selection has customizable performance settings by using the smartphone application (refer to “Smartphone Application”, on page 3-13). Those who take advantage of the ECO position are likely to see a slight increase in range and experience greater regenerative braking.
Notes 3.
Starting and Operating First Time Set-Up Starting and Operating If your motorcycle was direct-shipped you will need to perform the following: 8. Insert the key in the key switch and turn the key to the ON position. The gauge will perform a self test sweep. The charge indicator should read fully charged. 1. Remove the motorcycle from its shipping crate. See Unpacking Your Zero motorcycle on page 4-2. 2. You must charge the power pack before riding the motorcycle.
Starting and Operating Unpacking Your Zero Motorcycle Although unpacking your Zero Motorcycle can be done by a single person, it is recommended to have a second person to help lift and remove your motorcycle from the crate base. Outer Box Cover Cut and remove the two outer box retention straps. Unscrew stabilizer bar bolts, one on each side of outer box. Open box top and remove inner cardboard end reinforcement sleeves. Unscrew stabilizer bar from handlebar end and remove.
General Operation General Operation General Operation This section describes several items you should examine before operation. Pre-Ride Inspection Before operating the Zero Motorcycle, check the following to make sure the motorcycle is secure and intact: Power Pack. Make sure the dash panel charge indicator is indicating a charged power pack. We suggest you recharge before use. Always keep the charger cord with the motorcycle. Drive Belt (all models). Check the belt tension and condition.
General Operation Key Switch/Steering Lock Positions Steering Lock Using the steering lock when parked will prevent unauthorized use and help prevent theft. To operate the steering lock: 1. Turn the handlebar all the way to the left. 2. Push the key down from the OFF position and turn the key counter-clockwise while still pushing it in. This is a three-position switch that is located on the fork in front of the handlebar. The switch positions are as follows: A. Steering Lock B. OFF C.
General Operation OFF Position This position is used to turn the motorcycle OFF, disabling the electrical system. Power Pack ON Position This position is used for operating the motorcycle. In this position the following will occur: The 2014 Zero FX leverages the 2013’s new battery cell chemistry, configuration, and enhanced reliability.
General Operation It is required that you leave the motorcycle on the charger if you expect it to sit in storage or unused for over 30 days. The power pack must be charged within 24 hours if fully discharged, and charged within 90 days if stored fully charged. Zero recommends you plug in your Zero motorcycle after 90 days, even if fully charged. Please leave your Zero motorcycle plugged in whenever possible. The power pack should maintain up to 80% of its capacity for approximately: ZF2.
General Operation Power Pack Swapping The motorcycles feature a quick change power pack. This allows the rider to charge one power pack while using another. Do not operate the motorcycle without the power rail or rail fastener in place. To change the power pack, perform the following: To remove the power pack: 4. Using a firm grip, slide the power pack out of the frame. DO NOT lift the power pack by the plastic connector housing. NOTE: The power pack weighs 53lbs (24 kg). To Install the power pack: 1.
General Operation Add On Electrical Equipment WARNING! Do not add electrical components to your motorcycle unless approved by an approved Zero Motorcycles dealer. Some add-on electrical components can damage your motorcycle, prevent other components from working as they should, and/or dramatically reduce the range and/or life expectancy of the power pack.
General Operation The on-board charger indicator (A) is visible on the dash panel. The charging indicator icon flashes while charging and is continuously lit when fully charged. For examples and information on Quick Charging LEDs see page 4-13. Charging Indicator Icon 4.
General Operation Charging the Power Pack WARNING! Charge the Zero power pack with the Zero charger. It is possible for lithium ion cells to overheat and fail. Note: Charge the Zero Power pack in a location that is well-ventilated and away from combustible materials. If charging your Zero Motorcycle outdoors, avoid charging in the rain. To charge using the standard charger: 1. Ensure that the key switch is in the OFF position. 2. Plug the supplied power cord into the onboard charger connector (see inset).
General Operation Note: AVOID connecting the Zero charger and another device to a single 120 V AC 15A/20A circuit, as it may become overloaded. Zero chargers draw as much as 12 amps from the 120 V AC circuit when charging. 4. Charging a fully discharged power pack to 100% takes about: ZF2.8: 4.1 Hours ZF5.7: 7.
General Operation To charge using the Quick Charger: 1. Ensure that the key switch is in the OFF position. 2. Locate the auxiliary charging connector and remove the protective cover. 3. Connect the power pack charger to the power pack connector (A). 4. Always connect the charger to a GROUNDED outlet. When using an extension cord, avoid excessive voltage drops by using a grounded, 3-wire, 12-AWG cord no longer than 25 ft (7.6 m). The charger can be used on 4.12 120 V AC or 240 V AC current.
General Operation Quick Charger LED Indicators A. Ammeter The Ammeter LED is an amber indicator that indicates the amount of current output and should gradually ramp down from “IIIIII” to “I”. B. 80% Charge The 80% Charge LED is an amber indicator. If it is on solid, the bulk charge phase is complete, 80% charged. Charger is now in absorption phase. If the indicator is flashing, there are two issues that can cause this to occur: The charger and BMS are balancing.
General Operation Operating Your Motorcycle This section describes how to safely operate your motorcycle. Starting 1. Turn the key switch to the ON position. 2. Verify that the charge indicator reads fully charged. 3. Press the motor stop switch to the ON position. 4. With the kickstand up, twist the throttle toward you (counter-clockwise) to increase speed. When the throttle is twisted away from you (clockwise), the speed will decrease. Braking On the right handlebar is the hand operated brake lever.
General Operation a different sustained high power event, such as continued powering through a low traction surface, power will simply be reduced to ensure the continued safe operation of your powertrain. The red temperature indicator light (A) on your Zero motorcycle’s lower dash has two informational stages. Stage 1, is presented by flashing this indicator and advises you that the bike is about to enter its thermal strategy.
General Operation Front Suspension Adjustment A shock has two main actions: compression when the shock gets loaded, and rebound when the shock returns back to full length. Compression damping is the adjustment that determines how fast or slow the fork compresses. Rebound damping is the adjustment that determines how fast or slow the fork rebounds. Bleed Screw The 3 mm Allen M5 screw (A) at the top of the fork leg is the “bleed” screw. The bleed screw serves two purposes: 1. Transporting your motorcycle.
General Operation Compression Damping The compression damping is adjusted by turning a screw on the bottom of each fork leg. There is a rubber dust cover protecting the jam nut (A) securing the screw (B). will pack-up (feel harsh over consecutive bumps) while compression that is set too fast will cause the fork to bottom out harshly. If the fork is bottoming out, turn the adjuster one click at a time until the bottom-out stops. Adjust each fork leg evenly.
General Operation Rear Shock Adjustment Spring Adjustment Obtaining the correct rear spring preload is critical for proper handling. The spring preload must be set to match the weight of the rider. The spring is preloaded for an 180 lb (82 kg) rider. This puts the rear tire 1/3 of the way through its vertical travel. Heavier riders require stiffer spring rates. A good approximation of your rear spring requirements can be found by measuring the rear suspension’s sag.
General Operation 9. Record this measurement, this will be measurement M2. Example: MEASUREMENT OPERATOR M1 VALUE 23.62 in (600 mm) M2 - 21.65 in (550 mm) Sag = 1.97 in (50 mm) The total sag (in example above) is 1.97 in (50 mm). The recommended total sag is 2.3 in to 2.9 in (69-76 mm). If the sag is not correct, the spring pre-load should be adjusted. See “Spring Pre-load Adjustment”, on page 4-20. 10.Subtract the second measurement (M2) from the first measurement (M1). 4.
General Operation Spring Pre-load Adjustment 1. Clean any dirt or debris from the threads of the shock near the lock ring (A). 2. Using a lock ring wrench loosen the lock nut (A). 3. For measurements less than the specified value, decrease the pre-load on the spring by turning the spring nut (B) counter-clockwise on the shock. If more than the specified value, increase the pre-load on the spring by turning the spring nut (B) clockwise on the shock. 4.
General Operation Rebound Adjustment The rebound adjuster knob (A) is at the bottom of the shock. There are 12 clicks of rebound adjustment. The adjustment knob is located at the base of the shock. Printed on the knob is S-F, meaning Slow and Fast. The rebound adjuster knob controls how slow or fast the shock returns to its extended position after being compressed. Turning the knob clockwise, or S direction, is good for big impacts.
General Operation Compression Adjustment The compression adjustment knob is at the top of the shock. There are 16 clicks of compression adjustment. The knob has “+” (slower compression) and “-” (faster compression). Turn the adjuster clockwise for slower compression. To speed up compression, turn the adjuster counterclockwise. Start with the stock clicker settings and fine tune the compression from there. Proper compression will allow the tire to track the ground over consecutive bumps.
General Operation Factory Supplied Rear Suspension Settings The following information will allow you to adjust the rear suspension back to the factory settings the motorcycle was originally supplied with. FX Model ADJUSTMENT SETTING Rear Shock Compression 16 clicks out from fully closed Rear Shock Rebound 12 clicks out from fully closed Rear Shock Spring Preload 6 mm 4.
Notes 4.
Maintaining Your Motorcycle Owner’s Responsibilities Parts/Maintenance Items Listed below are the responsibilities afforded to the owner: The proper replacement parts, fluids, and lubricants to use are listed in the table below. Maintaining Your Motorcycle Maintenance This owner’s manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold.
Maintaining Your Motorcycle Maintenance Schedule The scheduled maintenance must be performed in accordance with this chart to keep your Zero motorcycle in top running condition. The initial maintenance is vitally important and must not be neglected. Where time and mileage are listed, follow the interval that occurs first. # 1 2 ITEM Brake Fluid (front and rear) Front Brake ROUTINE Check brake fluid level. Add brake fluid as necessary.
Maintaining Your Motorcycle # 7 ITEM Drive Chain ROUTINE 9 Drive Belt - Check belt slack and condition. - Replace a worn/damaged belt. - Check for cracking and/or replace the belt every 25K mi (40K km) Steering Bearings - Check all chassis fittings and fasteners. - Correct if necessary. 10 Chassis Fasteners - Check all chassis 11 Front Brake Lever Pivot Shaft - Apply silicon grease lightly. - Check operation and for oil leakage. - Service/rebuild if necessary.
Maintaining Your Motorcycle # ITEM ROUTINE 14 Throttle Grip - Check operation and free play. 15 Kickstand Pivots - Check operation. - Apply silicon grease lightly. 16 Kickstand Switch Check operation and replace if necessary.
Maintaining Your Motorcycle Component Fasteners Periodically check and tighten the following fasteners on your motorcycle. Torque Table LOCATION ITEM TORQUE NOTES A Front axle end bolts 19 lb ft (26 Nm) Use LOCTITE® 242® (or equivalent) B Handlebar clamp mount bolts 18 lb ft (24 Nm) - C Main pivot bolt/nut (swingarm) 75 lb ft (102 Nm) Use LOCTITE® 242® (or equivalent) D Shock mount bolts (upper/lower) 52 lb ft (70.5 Nm) / 38 lb ft (51.
Maintaining Your Motorcycle Left Side Of Motorcycle Refer to Torque table on page 5-5. 5.
Maintaining Your Motorcycle Right Side Of Motorcycle Refer to Torque table on page 5-5. 5.
Power Pack Power Pack Power Pack WARNING! You must leave your motorcycle connected to the charger if you expect it to be in storage or unused for over 90 days. The power pack must be charged within 24 hours if fully discharged, and charged within 90 days if stored fully charged. Please leave your Zero Motorcycle plugged in whenever possible. 1. The power pack is a lithium ion power system. While it does require charging, it does not require maintenance. 2.
General Maintenance Brakes General Maintenance This section describes how to inspect the brake fluid level for both the front and rear brakes. Your motorcycle uses specific brake pads for stopping power. Both front and rear pad examples are shown in the following sections. Rear Brake Pads An example of the rear brake pads is shown below. Front Brake Pads An example of the front brake pads is shown below.
General Maintenance Front Brake Rear Brake Inspect the level of the front brake fluid through the sight glass (C). If the fluid level is visibly below the low level indicator (B), brake fluid must be added. Clean any dirt or debris from the cover (A) before opening the reservoir. Note: The motorcycle should be in an upright position prior to checking fluid level. 1. Remove the two Phillips screws securing the cover onto the reservoir. 2. Add new DOT 4 brake fluid. 3.
General Maintenance Brake Pad Inspection The brake pads must be inspected when specified in the maintenance schedule. See Maintenance Schedule information on page 5-2. Visually inspect the brakes by looking at the remaining brake pad material through the sides of the brake caliper. Replace the brake pads if either pad’s thickness is 0.05 in (1.35 mm) or less. If the brake pads (A) are worn, replace both brake pads immediately. The brake rotor should also be checked for thickness. The minimum thickness is 0.
General Maintenance Wheels and Tires Tire Inflation Inspect both wheels for the following: CAUTION: Under-inflation is a common cause of tire failure and may result in severe tire cracking, tread separation, “blowout,” or unexpected loss of motorcycle control causing serious injury or death.
General Maintenance Drive Belt The drive belt provides low maintenance and quiet operation with minimal stretch. Keep dirt, grease, oil, and debris off the belt and sprockets. The drive belt tension should be checked and adjusted at the intervals specified in the Maintenance Schedule. For maintenance, see Maintenance Schedule on page 5-2. Clean the belt with mild soap and water when washing your motorcycle. Towel dry and inspect for the following: Cuts or unusual wear patterns.
General Maintenance Drive Belt Adjustment Procedure Note: Adjust both sides equally. 1. 2. 3. 4. Remove key from the key switch. Loosen the rear axle nut (A). Loosen the (left and right) 13 mm jam nuts (C). Turn the (left and right) 13 mm adjustment bolts (B) 1/4 turn at a time until the belt adjustment is within specification. Note: Belt tension will increase slightly when motor mount bolts are fully torqued. 1. Remove the key from the key switch. 2.
General Maintenance Drive Chain (Optional) Cleaning The Drive Chain CAUTION: Always wear safety glasses when cleaning the chain to prevent eye injuries. CAUTION: Never place your hand or any other body part between the chain and sprockets. Work with the chain only in the middle between the two sprockets; failure to do so could result in serious injury. CAUTION: Do not allow any of the drive chain cleaner to get on the brake rotors or brake pads.
General Maintenance Lubricating The Drive Chain CAUTION: Wear safety glasses when lubricating the chain to prevent eye injuries. CAUTION: Never have the motor spinning the wheel. Turn the wheel only by hand. Failure to do so could result in serious personal injury. CAUTION: Never place your hand between the chain and sprockets. Work with the chain only in the middle between the two sprockets. Failure to do so could result in serious personal injury.
General Maintenance Adjusting The Drive Chain Note: Adjust both sides equally. 1. 2. 3. 4. Remove key from the key switch. Loosen the rear axle nut (A). Loosen the (left and right) 13 mm jam nuts (C). Turn the (left and right) 13 mm adjustment bolts (B) 1/4 turn at a time until the chain adjustment is within specification. Note: Chain tension will increase slightly when motor mount bolts are fully torqued. 5. 6. 7. 8. Tighten left and right jam nuts (C) to secure the chain. Tighten the axle nut (A).
General Maintenance Headlight Alignment The headlight should be checked for correct alignment periodically. It must be aligned any time the suspension sag is adjusted because this will affect the headlight alignment. Before the headlight can be aligned, the suspension sag and tire pressure must be correctly adjusted. The headlight can be adjusted vertically. If the vertical adjustment is off, it will cause the beam to point too close to or too far ahead of the motorcycle.
General Maintenance To replace the bulb: 1. Remove the two bolts (A) securing the trim cover above headlight assembly to the motorcycle. 2. Release and remove the trim cover. 3. Remove the four bolts (B) securing the headlight assembly to the headlight assembly retaining brackets. 5. Disconnect the headlight bulb connector (C). 6. Release the headlight bulb sealing boot (D). 4. Release the headlight assembly. 5.
General Maintenance 7. Unhook the headlight bulb spring clip (E) by pushing down and to the side. Turn Signal Light Bulb Replacement To replace the signal light bulb: 1. Remove the turn signal lens screw (A) and remove the lens. 8. Lift up on the spring clip and remove the headlight bulb. WARNING! Do not touch the glass portion of the headlight bulb. Keep the headlight bulb free of contaminants. Oil from your fingers or contaminants will shorten the life of the bulb.
General Maintenance Brake/Tail Light Bulb Replacement Running Light Bulb Replacement To replace the brake/trail light bulb: 1. Remove the two bolts (A) securing the trim cover above headlight assembly to the motorcycle. 2. Release and remove the trim cover. 3. Remove the four bolts (B) securing the headlight assembly to the headlight assembly retaining brackets. 1. Remove the brake/tail light lens screws (A) and remove the lens. 2.
General Maintenance 5. Release the running light bulb retainer from headlight (C). 6. Remove the running light bulb from retainer. 7. Install the replacement running light bulb into retainer. 8. Installation is the reverse of the removal procedure. 5.
General Maintenance Cleaning WARNING! Improper cleaning can damage electrical components, cowling's, panels, and other plastic parts. Do not use high pressure water or steam cleaners; they can cause water intrusion of bearing, seals, and electrical components. Avoid spraying water of great force around the dash unit, quick charge connector, power pack, or controller. To prolong the life of your motorcycle it should be washed periodically.
General Maintenance Parking and Long Term Storage It is recommended to always leave the power pack plugged in. The Zero charger is designed to maintain a balanced and complete charge at all times without wasting any electricity. Over extended periods of time the power pack is checked every 72 hours to ensure that the cells are balanced and that the power pack is full. To prolong the life of your power pack you should store your motorcycle in a cool area.
General Maintenance 12 Volt Fuse Center The 12 volt fuse center is located behind the front forks under the left trim panel. To access the 12 volt fuse center: 1. Remove the left trim panel by removing 3 hex bolts, 1 standard bolt, and (push-in) plastic rivet. 2. Turn the forks to full lock position. 3. Remove the cover from inside the cavity. 4. Replace the fuse(s). 5. Reinstall the cover. 6. Reinstall the trim panel.
General Maintenance High Voltage Fuse Center The high voltage fuse center is located on the left side of the motorcycle (in a cluster of five fuses). The high voltage fuse values are listed below: FUSE RATING CIRCUITS CONTROLLED 1 ABC10A Charger 2 ATM30A Quick Charger 3 ABC4A DC/DC Converter 4 ABC4A Main Bike Board/Controller 5 ABC4A Low_Pwr_B- 5.26 To replace a high voltage fuse: Unscrew the fuse cover. Replace the fuse. Reinstall the cover.
Service Record Follow the maintenance schedules on page 5-2. After a scheduled service or routine is performed, record the information on the chart below. Service Record DATE ITEM SERVICE/ROUTINE DESCRIPTION 5.
Notes 5.
Troubleshooting Electric Motorcycle Safety Precautions Troubleshooting Your Zero Motorcycle has high voltage components. The high voltage used by these components is dangerous and can cause personal injury, severe burns, electric shock and even fatal injury unless appropriate precautions are taken. Always observe and obey the instructions on labels attached to components on the motorcycle - they are there for your safety.
Troubleshooting System Warning Indicator If a fault has been detected, count the number of times the red indicator light (A) flashes. Refer to the table on the following pages for a possible cause and solution to the issue. 6.
Troubleshooting NUMBER OF RED FLASHES CAUSE SOLUTION 1 Motor Stop Switch Disabled or Kickstand Switch Disabled Motor stop switch is in the OFF position. Press the motor stop switch ON button. Kickstand is down. Raise kickstand. 2 Indicator Always ON Contact Zero or your dealer. 3 Self-Test Failed Unplug charger. 4 Charger Connected Throttle is ON or throttle/connection is bad. Verify throttle action and/or check connection. 5 High Throttle Disable Could not pre-charge motor controller.
Troubleshooting NUMBER OF RED FLASHES CAUSE SOLUTION 11 Motor Temperature Sensor Out of Range Bad motor temperature sensor or connections. Replace temperature sensor and/or check connections. 12 MBB Voltage Error Contact Zero or your dealer. 13 Board Temperature Warning Board may have overheated. Let the motorcycle cool down. 14 Current Sensor Error 15 Welded Contactor Contact Zero or your dealer. 16 High Current Disable Turn the ignition OFF and ON.
Troubleshooting General Troubleshooting SYMPTOM POTENTIAL CAUSE POTENTIAL SOLUTION Motorcycle does not turn on Power Pack not charged. Key not properly engaged. Motor stop switch turned OFF. Fault code set. Charge Power Pack. Recheck key in ignition, turn OFF/ON again. Press the motor stop Switch ON button. See Understanding BMS Flash Code Patterns (Charge Mode) on page 6-8. Charger not working A/C power missing Fault code set Check A/C outlet for power, A/C source check fuse/voltage.
Troubleshooting Battery Management System The Battery Management System (BMS) is located inside the power pack and is fitted with a window (A) to provide visual notification about the status of the power pack. There are four LED lamps that will flash: one red and three green lamps. The window is located on the front side of the power pack. Refer to the following pages to understand the meaning of the BMS flash code patterns. Note: The other circular cover is for diagnostics only. 6.
Troubleshooting Understanding BMS Flash Code Patterns (Idle Mode) In this mode the key is OFF and the power pack is not being charged (the BMS is only monitoring the battery).
Troubleshooting Understanding BMS Flash Code Patterns (Charge Mode) This mode is with the charging cord plugged into the AC power, and the key in the OFF position. During the Charging process, first all lights will flash. Next, lights 1 through 4 will flash depending on the power pack’s state of charge.
Troubleshooting Understanding BMS Flash Code Patterns (Run Mode) In this mode, the key is in the ON position. 1 RED 2 GREEN 3 GREEN 4 GREEN ON OFF MEANING SOLUTION 5 sec 1 sec 25% of Power Remaining Charge Soon 5 sec 1 sec 50% of Power Remaining Charge Soon 5 sec 1 sec 75% of Power Remaining Charge Soon 5 sec 1 sec 100% of Power Remaining OK sec = seconds ms = milliseconds 6.
Troubleshooting Power Pack Empty If the power pack is completely empty, an error-beep sounds and the BMS disables the throttle. You cannot ride the motorcycle until you recharge the power pack. If the Power Pack Empty error-beep still sounds after two hours of charging time, contact your dealer. Your power pack may need to be repaired or replaced.
Troubleshooting Other Error-Flash Patterns If the BMS in your power pack produces an error code which is not described in Understanding BMS Flash Code Patterns, then the power pack has encountered a serious internal hardware problem and must be repaired or replaced by a dealer. 6.
Troubleshooting Cold and Hot Weather Considerations Cold Weather Operation Operation of the motorcycle in cold temperatures has no permanent impact on its battery pack/cells; however, the rider may see a reduction in range due to the effect cold temperature has on the amount of energy the pack/cells can release.
Troubleshooting Hot Weather Operation Operation of the motorcycle in hot temperatures should not result in any noticeable performance changes. However, the BMS will not allow motorcycle operation and its associated battery discharge above 140°F (60°C), as measured at the battery. In hot temperatures greater than 110°F (43°C), the charger reduces its charge current to the battery, increasing charge time accordingly; the hotter the ambient temperature, the greater the effect.
Troubleshooting Safety Interlocks If the BMS detects a serious internal fault, it can take either or both of two actions to prevent damage to the power pack: Throttle Disable. The BMS disables the throttle if the power pack is empty, or if the BMS detects certain serious internal problems. You cannot ride the motorcycle until the problem is resolved. Charger Disable.
Troubleshooting Charger-Disable Interlock When the charger is attached and plugged in to AC power, the BMS communicates with the charger. The BMS can send a signal to the charger requesting that charging terminates immediately. When the charger is disabled, the indicator lights on the charger displays that charging has stopped. There are two conditions that cause the BMS to disable charging: 1. Too hot The BMS detects an internal power pack temperature above 131°F (55°C). 2.
Notes 6.
Limited Warranty Information What Does This Limited Warranty Cover? WarrantyWarranty Limited and Customer Information Information Zero Motorcycles Inc. ("Zero") warrants that all factory manufactured 2014 Zero FX motorcycles are free from defects in material and workmanship during the period of this Limited Warranty.
Limited Warranty Information Instead, the Power Pack’s outer case is covered for a period of 2 years from its “in service date.” Who Does This Limited Warranty Cover? This Limited Warranty applies to all original owners who submit the warranty registration card within the required time period as printed on the registration card. This Limited Warranty may only be transferred to new owners with payment of a $50 processing fee and submission of a new registration card by the new owner.
Limited Warranty Information Wheels on off-road bikes once they have been ridden Any cosmetic concerns that arise as a result of environmental conditions, owner abuse, misuse, lack of routine care and maintenance, and/or improper use; Parts or components damaged by use or operation under abnormal circumstances or contrary to the requirements described in this Owner's Manual.
Limited Warranty Information What Other Limitations Or Disclaimers Apply To This Limited Warranty The following additional limitations and disclaimers apply to this Limited Warranty: This Limited Warranty is the only express warranty made in connection with the sale of this Zero Motorcycle model. Any implied warranty, including any warranty of merchantability or warranty of fitness for a particular purpose is limited in duration to the stated period of this written warranty.
Limited Warranty Information What Are Your Responsibilities As A Customer? What Will Zero Do Under This Limited Warranty? As the owner of a product covered by this Limited Warranty, it is your responsibility to read and understand this Owner's Manual, this Limited Warranty, and all product warnings before operating your Zero motorcycle. Serious injury or death can result from improper operation or failure to observe warnings and safety instructions on any motorcycle.
Limited Warranty Information How Do You Obtain Service Under This Limited Warranty? Warranty services may be obtained by contacting your local Zero Motorcycle dealer. Please refer to the dealer locator on our website (www.zeromotorcycles.com/locator) for your nearest location. In the event that a dealer is not in your state, province, or country, you can contact Zero Motorcycles Inc. directly at +1 (888) 841-8088 (Monday-Friday, 8am to 5pm Pacific Time) or via e-mail at support@zeromotorcycles.com.
Customer Information Customer Assistance Reporting Safety Defects Please have the following available when contacting Zero Motorcycles Inc. as they are essential to effectively and efficiently answer your questions or resolve your concerns. If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Zero Motorcycles Inc.
Notes 7.
Index A Accessories .................................................................5.24 B Drive Chain ..................................................................5.15 Adjustment Procedure.............................................5.17 Cleaning ..................................................................5.15 Lubricating...............................................................5.16 Bolt Torque Specifications............................................. 5.
Index Pre-Ride.................................................................... 4.3 Instrument Panel ....................................................3.6, 3.8 K Keys Replacement Code Number ..................................... 1.4 L Plug in Your Z-Force Power Pack............................. 1.2 Serial Number ........................................................... 1.4 Pre-Ride Inspection ....................................................... 4.3 Public Charging Stations .....................
Index Suspension settings Front (Factory) ........................................................4.17 Rear (Factory) .........................................................4.23 Understanding Your VIN Number .............................1.5 Vehicle Range ...............................................................1.8 VIN.................................................................................1.4 T W Technical Specifications Zero FX Technical Specifications.............................. 1.
Notes INDEX.
First Responder Information - High Voltage Components Locations
2014 OWNER’S MANUAL ™ WWW.ZEROMOTORCYCLES.
