Service Manual
 
The information on these pages is only valid for:
2014 Zero FX Service Manual
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Fuses
 

Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one-time protection device and must be replaced each time the circuit is overloaded. Replace the fuse with one of equal current and voltage rating. If the fuse melts repeatedly, inspect the circuit for an overload or short.

Fuse Center Location

12 Volt

The 12 volt fuse center is located in front of the front power pack, on the right side of the frame. The fuse center has a protective cover that must first be removed to gain access to the fuses. To remove the cover, squeeze the tabs together and lift off the cover (A).

Fuse Number
Amp
Circuits Controlled
1
10
Voltage to Splice S25
• Headlight Switch
2
10
• Accessory Power Port
Accessory Power Connector
3
10
Voltage to Splice S27
• Horn
• Turn Signal Flasher
Brake Switches
4
5
Voltage to Splice S299
• Instrument Panel
• Tail Light
Main Bike Board
Running Light 1 and 2

Inline Fuse:

There are 3 inline 12 volt fuses, these are inside the harness covering.

DC/DC Converter Fuse

Fuse Number
Amp
Circuits Controlled
C7
4
DC/DC Converter

Note: Trim panel removed for clarity.

Below the front power pack inside the harness cover.

Main Bike Board (MBB) Fuse

Fuse Number
Amp
Circuits Controlled
C47
4
Main Bike Board (MBB)

Note: Trim panel removed for clarity.

Below the front power pack, across from the MBB, inside the harness cover. 

Charger Control Unit (CCU) Fuse

Fuse Number
Amp
Circuits Controlled
C207
10
Charger Control Unit (CCU)

Note: Trim panel removed for clarity.

Below the front power pack, across from the MBB, inside the harness cover.

Throttle Control
 
High Voltage
 
C76 Brushless Motor Controller Connector Face View
 

C76 Brushless Motor Controller Connector Face View

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Connector Part Information

  • R14-8
  • 1-Way Eyelet

Pin

Wire Color

Function

BLK (Orange Sleeve Over Cable)

Negative (-) Ground

Front of the Frame, Below the Front Power Pack

C433 Front Running Lamp 2 Harness to the Chassis Harness
 

Connector Part Information
  • OSS 43925-F
  • 1-Way F (CLR)
Connector Part Information
  • 1-Way M (CLR)
Pin Wire Color Function Pin Wire Color Function
1 BRN Running Light Control 1 BRN Running Light Control

Connector Part Information
  • OSS 43925-F
  • 1-Way F (CLR)
Connector Part Information
  • 1-Way M (CLR)
Pin Wire Color Function Pin Wire Color Function
2 BLK Running Light Ground 2 GRN Running Light Ground

Behind the Headlight Assembly

Power Pack Harness Replacement
 
Torque Table Show Torque Table

Caution: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Proper procedures must be followed.

Required Tools

• 3mm hex wrench

• 7mm socket

• Socket wrench

• 13mm wrench

• PN 85-05665 Controller Discharge Tool

Fastener Torques

• Brushless motor controller cable bolt 11 N•m (8 lb ft)

Removal Procedure

Caution: Refer to High Voltage Caution in General Information.

Note routing and location of harness and zip tie.

1. Disable the High Voltage system. Refer to High Voltage Disabling.

2. Remove the power packs.

3. Remove the lower rubber side covers (XMX CONTROLLER COVER L, XMX CONTROLLER COVER R).

4. Remove the screws securing the (1) securing the power pack connectors to the frame.

5. Remove the C138 and C148 (2) and separate C137 and C147 from the power pack connector body.

6. Remove C97 ground eyelet from the brushless motor controller.

7. Remove C296 positive eyelet from the brushless motor controller.

Note harness routing prior to removal, this will aid in reassembly of the harness to the motorcycle.

8. Release all main wiring harness zip ties and hold down brackets and remove the harness.

Installation Procedure

1. Layout the wiring harness in the same location as removed on the frame.

Notice: Refer to Fastener Notice in General Information.

2. Install C97 ground eyelet onto the brushless motor controller and tighten the bolt.
Tighten
Brushless motor controller bolt to 11 N•m (8 lb ft).

3. Install C296 positive eyelet onto the brushless motor controller and tighten the bolt.
Tighten
Brushless motor controller bolt to 11 N•m (8 lb ft)

4. Insert C137 and C147 into the power pack connector body.

5. Install the C138 and C148 (2) onto the mounting bracket.

Connector C147 is for the bottom connector and the C137 is for the top connector.

6. Install the power pack connector bolts (1) and cover.

7. Install zip ties in the same locations as removed.

8. Inspect harness routing to ensure that it is not in contact with any moving or sharp parts that could cause damage to the harness.

9. Install the lower rubber side covers.

10. Install the power packs.

Description and Operation
 

Power Pack

The battery is located within the power pack and requires no special break in period. The charging time will remain the same if the onboard charger is connected to a 120 V AC or a 240 V AC supply.

The normal recharging time of the power pack to 100% is usually less than 3 hours in mild ambient temperatures. Out of the normal temperature range charging and run-time times will vary. The power pack should not be used outside of the range of 23°F to 140°F (-5°C to 60°C); the Battery Management System (BMS) turns off the power controller outside of this range.

Note: The Battery will not charge if below 0°C or 32°F.

WARNING! Only charge the Zero power pack with the Zero charger.

Power Pack Charger

Keep the power pack connected to the charger when the motorcycle is sitting in storage or if it will be sitting unused for more than 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 to plug in the Zero Motorcycle after 30 days, even if fully charged. Leave the Zero Motorcycle plugged in whenever possible.

WARNING! Only charge the Zero power pack with the Zero charger. The chargers are located under the fairing panels in front of the front power pack.

When charging the motorcycle’s power pack, the charger can be left ON, even after the power pack is fully charged. There are two possible cases that can occur:

• When connected to the charger, the power pack will receive a full charge. Once fully charged, the charger will check the status of the power pack once every 72 hours to ensure that it maintains a full charge. When fully charged, a green light illuminates on the charger. Should the charger not read that the power pack is full, it continues to attempt to fully charge the power pack. In this event the green light may not illuminate; however, the power pack may be fully charged. To ensure that the power pack is charged, check the charge indicator on the dash display prior to riding.

• If the power pack terminates the charge before the charger reaches the state previously mentioned, then the charger continues to cycle and tops off the power pack until the power pack is removed from the charger, or the charger reaches the complete state previously noted.

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 the motorcycle outdoors, avoid charging in the rain.

The maximum power pack internal charging temperature is 131°F (55°C). If the power pack’s internal temperature is over 131°F (55°C), it will not accept a charge until it is moved to a cooler location. Also, if the power pack has just been run hard, it may internally be above 131°F (55°C) even if the ambient temperature is lower. If you experience a power pack that will not take a charge, you should ensure the internal temperature is below 131°F (55°C). If the power pack was recently run and it will not take a charge, the power pack should cool and begin taking a charge in around 30 minutes or less. The maximum charging temperature cutoff is a power pack longevity feature. Charging at higher temperatures can shorten the life of the power pack.

Note: Frequent top off charging is good for the power pack’s life span, so do not hesitate to charge frequently.

Quick Charging (Off Board Accessory Charger)

The “scalable” quick charging feature allows up to three supplemental accessory chargers (in addition to the existing integrated charger) to be connected to the motorcycle. Use of supplemental accessory chargers can reduce the charging time by up to 70%.

Note: The time for charging the motorcycle using quick charging will vary with the number of chargers used.

The accessory charging connector (1) is located above the motor. For more information on how to connect additional chargers, refer to the quick charger’s owner’s manual.

Cold and Hot Weather Considerations

Cold Weather

Cold Weather operation of the motorcycle 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. The colder the weather, the greater the effect; so that, as compared to operation in 80°F (27°C) ambient, at 30°F (-1°C) ambient the rider could experience a temporary reduction in range of up to 30%. In extreme cold weather the motorcycle may also experience a temporary reduction in power and, correspondingly, achieved top speed. It is not recommended that the motorcycle be ridden while its battery temperature is below 23°F (-5°C). If it is, its battery needs to be put on the charger at a temperature above 32°F (0°C) as soon as the ride is concluded. It is worth noting that the Battery Management System (BMS) will not allow the battery to be discharged below -22°F (-30°C), which is the absolute lowest discharge temperature prescribed by the cell manufacturer.

Storage of the motorcycle for the winter in a non-heated garage is acceptable, as long as:

1. the coldest temperature in the garage does not fall below -31°F (-35°C)

2. the battery is left on the charger continuously

3. the battery is initially topped off at a temperature above 32°F (0°C)

Storage temperatures below -31°F (-35°C) may result in accelerated permanent decay of the battery performance, and hence, it is not recommended. Above this temperature, working as a system with the BMS, the charger will ensure the battery survives winter storage with no permanent damage, even if the temperatures dip well below freezing for weeks at a time. Note that, to prevent battery damage, the BMS will prevent the charger from charging the battery at a temperature below 32°F (0°C). Again, as long as the battery was initially topped off by the charger above 32°F (0°C) and remains on the charger through the winter at temperatures above -31°F (-35°C), the system will guard the battery from damage.

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. Above a battery temperature of 131°F (55°C), the BMS will no longer allow charging.

Note: Storing the motorcycle or its battery in direct sunlight in ambient temperatures above 105°F (41°C) may result in accelerated permanent decay of battery performance, and hence, it is not recommended.

Battery Management System (BMS)

Every power pack contains a Battery Management System (BMS) which monitors the condition of the cells, and optimizes the charging process to provide the highest-performance, longest-range, and longest life for the power pack. The BMS safeguards the power pack by means of safety interlocks. These interlocks turn off or control certain operations that could damage the power pack. The BMS also monitors the power pack for a host of predefined conditions, and then takes actions according to those conditions. The BMS is sealed inside the power pack.

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. The motorcycle can’t be ridden until the problem is resolved.

• Charger Disable. The BMS prevents charging if it detects certain serious internal problems - even if the power pack is connected to a charger and plugged in to AC power. The power pack cannot be charged until the problem is resolved.

Throttle Disable Interlock

The BMS communicates with the main motorcycle control module. The BMS can send a signal to the main motorcycle controller requesting that the throttle control on the motorcycle be disabled. When the throttle control is disabled, the motor will not deliver power to the rear wheel, and the motorcycle cannot be ridden. If the throttle is disabled while riding, the motorcycle will cease to provide power, and the operator must pull over to a safe location. All conditions which would cause the BMS to disable the throttle are also signaled by a flash code pattern at self-test. If you suspect that the BMS has disabled the throttle control on your motorcycle, turn the key switch OFF and back ON again to enter self-test mode. The flash code pattern from the BMS reports any of the error conditions which would cause the BMS to disable the throttle.

• Power Pack Empty

• Too Hot

• Power Pack Unbalanced

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.Too cold

The BMS detects an internal power pack temperature below 32°F (0°C).

Description and Operation
 

Drive Belt

Proper belt tension is essential for optimum operation of the Gates Carbon Drive System. Lack of belt tension can lead to so-called “ratcheting.“ The teeth of the belt will slide over the teeth of the rear sprocket. This causes not only an unpleasant sound; the ratcheting can also cause damage to the carbon tensile cords. This would render a belt useless. If ratcheting has occurred you should replace the belt before the next time it is to be used. Too much tension can also cause damage to the bearings within the rear hub. It also increases the wear of your drive system and the system can drag.

The belt should be replaced at 40,000 km (25,000 miles).

Drive belt and sprockets do not need lubrication of any kind. For cleaning, use only water and a soft brush. Do not use any type of detergent. Proper handling of the belt is crucial to obtain maximum life expectancy. Bending or twisting of the belt may cause damage to the carbon fibers inside the belt. Avoid the following conditions when handling the belt.

Legend

1. Crimping
2. Twisting
3. Back Bending
4. Inverting
5. Zip Tying
6. Using as a wrench

MBB/BMS Interface
 

This works similar to the tera term.

1. Select the “MBB/BMS Interface” tab at the top of the window then select the “Connect” button at the bottom of the page.

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2. Once connected to the motorcycle, type commands in the area at the bottom of the window, then select “Enter”. Type the word “help” will bring up the main menu.

Main Menu Options