This manual provides information on the diagnosis, the service procedures, the adjustments, and the specifications for the Zero motorcycles.

Detailed descriptions of standard workshop procedures, safety principles and shop operations are not included. It is important to note that this manual contains a set of specific recommended service methods and that deviation from said methods could result in personal injury to service personnel or damage to equipment. Please understand that those methods could not possibly cover all conceivable ways in which service, whether or not recommended by Zero Motorcycles Inc., might be done or of the possibly hazardous consequences of each conceivable way, nor could Zero investigate all such ways. Anyone using service procedures or tools, whether or not recommended by Zero, must satisfy him or herself thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service methods or tools selected.

The technicians who understand the material in this manual and in the appropriate Dealer Service Bulletins better, serve the motorcycle owners.

U.S. Manufacture:
Zero Motorcycles
380 El Pueblo Road
Scotts Valley, CA 95066

All information, illustrations and specifications contained in this Service Manual are based on the latest product information available. Zero reserves the right to make changes at any time, without notice, in colors, materials, equipment, specifications and models.

Zero may, subject to legal requirements, determine the Model Year designations of its vehicles. The Model Year designation on any particular model may be longer or shorter than 12 months.

Some vehicles pictured may contain non-U.S. equipment. Some models may be shown with optional equipment.

While Zero Motorcycles makes all reasonable efforts to provide accurate information in this Service Manual, there is no guarantee or warranty of accuracy. Furthermore, we do not assume any liability for the accuracy of completeness of information presented.

This Service Manual shall not be used or relied upon as a substitute for information that is available from your Zero Motorcycles dealer. Further information can be obtained from your authorized Zero dealer or Zeromotorcycles.com.

©2014 Zero Motorcycles Inc. Not to be reproduced wholly or in part without written permission of Zero Motorcycles Inc. The Zero Motorcycles name, model names and logo are registered trademarks.

Published by:
Zero Motorcycles Inc.
380 El Pueblo Road
Scotts Valley, CA 95066
www.zeromotorcycles.com

ALL RIGHTS RESERVED

No part of this manual may be reproduced, stored in any retrieval system, or transmitted in any form or by any means including, but not limited to, electronic, mechanical, photocopying, and recording without the prior written permission of Zero Motorcycles Inc. This applies to all text, illustrations, and tables.

Cautions, Notices, and Important are elements designed to prevent hazards; however, not all hazards can be foreseen. This information is placed at strategic locations within the service manual.

Caution: is used for the technician to take necessary action or not to take a prohibited action. Cautions are used to help prevent bodily injury to the technician or to the owner if the motorcycle was improperly repaired.

Notice: is used to call special attention to a necessary action or to a prohibited action. Notices are used to prevent damage to the motorcycle or prevent unnecessary repairs.

Important: is used to provide additional information or to clarify a procedure.

Loading image...

 Click here for full-size

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.

High voltage cable or wiring has an orange covering. Do not probe, tamper wtih, cut, or modify high voltage cable or wiring.

This manual covers the following motorcycles:

• Zero S: Street Fighter

- Z-Force® Li-Ion intelligent power pack ZF8.5 or ZF11.4

- 54 hp (40 kW) Motor

- Cast Wheels

• Zero SR: Max Performance

- Z-Force® Li-Ion intelligent power pack ZF11.4

- 67 hp (50 kW) Motor

- Cast Wheels

• Zero DS: Dual Sport

- Z-Force® Li-Ion intelligent power pack ZF8.5 or ZF11.4

- 54 hp (40 kW) Motor

- Spoke Wheels

Caution: Brake fluid may irritate eyes and skin. In case of contact, take the following actions:

• Eye Contact-rinse thoroughly with water

• Skin Contact-wash with soap and water

• If Ingested-contact a physician immediately

Caution: Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury.

Caution: Road test a motorcycle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize the motorcycles control. Failure to adhere to these precautions could lead to serious personal injury and motorcycle damage.

Notice: Avoid spilling brake fluid onto painted or other surfaces, electrical connections, wiring, or cables. Brake fluid will damage painted or other surfaces and cause corrosion to electrical components. If any brake fluid comes in contact with painted surfaces, immediately flush the area with water. If any brake fluid comes in contact with electrical connections, wiring, or cables, use a clean shop cloth to wipe away the fluid.

Notice: Replacement fasteners must be the correct part number for that application. Use the correct fastener in the correct location. Fasteners requiring the use of thread-locking compound are specified in the repair procedure; refer to the product manufacture for proper usage. Always use new lock nuts, lock washers and cotter pins. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener contact surfaces unless specified in the procedure. Coatings affect fastener torque and joint clamping force and may damage the fastener.

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

Failure to follow the procedures may result in serious injury or death.

• Always verify that the high voltage has been disabled before working on or around high voltage components, wires, cables, or harnesses.

• Remove all metal objects such as rings and watches.

• Always tighten the high voltage terminal fasteners to the specified torque. Insufficient or excessive torque will cause malfunctions or damage.

• After finishing work on the high voltage system and before turning the key ON.

• Verify high voltage system integrity and that all connectors and covers are installed.

• Verify that all tools or loose components have been removed.

Caution: Exposure to high voltage can cause shock, burns, and even death. The high voltage components on the motorcycle should only be serviced by technicians familiar with the circuit/system operation. Refer to System Description and Operation.

High voltage components are identified by labels. Do not remove, open, take apart, or modify these components. High voltage cable or wiring has orange covering. Do not probe, tamper with, cut, or modify high voltage cable or wiring.

Zero Motorcycles Inc. can be contacted via the contact methods listed below. Please have available the following, as it is essential to effectively and efficiently answer your questions or resolve your concerns.

• Owner’s name and address

• Owner’s telephone number

• Vehicle identification number (VIN)

• Date of purchase

• Power Pack serial number

• Motor serial number

An owner information chart is provided in the Zero Motorcycles Owner's Manual to record this information.

North American and Canada:

Zero Motorcycles 
380 El Pueblo Rd. 
Scotts Valley, California 95066
USA

Phone: (888) 786-9376
Monday-Friday
8am to 5pm Pacific Time

Europe:

Zero Motorcycles BV
Fluorietweg 12D
Alkmaar, 1812 RR
NL

E-mail: service@zeromotorcycles.com
24 hours

International Contacts:

For the most up to date information, please refer to http://www.zeromotorcycles.com/contact

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

The 12-volt fuse center is located on the left side of the frame under the seat. Remove the seat to gain access to the 12 volt fuse center.

Loading image...

 Click here for full-size

Power Pack Battery Fuses

The power pack has two fuses. The fuses are located on the back of the power pack under the seat.

Loading image...

 Click here for full-size

These fuses can be checked by removing the fuse and checking for continuity. A fuse that has no continuity is considered to be melted.

Vehicle Identification Number (VIN)

Loading image...

 Click here for full-size

Legend:

A. VIN Number

VIN Break Down

The VIN is a 17-digit number stamped on the head tube of the frame. Do not alter or remove this as it is the legal identifier for the motorcycle.

Loading image...

 Click here for full-size

Important:

• Perform a thorough inspection of the entire motorcycle at every service interval. Replace any parts found to be worn or in need of replacement.

• Use only genuine Zero or Zero-recommended parts and lubricants/cleaners or their equivalent. Parts that do not meet Zero’s design specifications may damage the motorcycle and/or void the warranty.

Caution: Refer to Road Test Caution in General Information.

Caution: Road test a motorcycle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize the control of the motorcycle. Failure to adhere to these precautions could lead to serious personal injury and motorcycle damage.

Before the road test, ensure the following:

• The exterior lighting is working correctly.

• Tire pressure is correct.

During the road test:

• Perform the test only when traffic conditions permit.

• Operate the motorcycle in a controlled, safe manner.

• Observe all traffic regulations.

• Observe any unusual vibrations.

o When braking

o When coasting

o When accelerating

o When regen braking

• Observe any unusual sounds.

o When braking

o When coasting

o When accelerating

o When regen braking

Choose different road surfaces when test driving to verify that the condition is not related to road surfaces. Observe where the problem condition is located: Front, back or under the motorcycle. If the condition is something that is heard or felt, driving a similarly equipped motorcycle may determine if the issue is an operating characteristic of the motorcycle.

Use only Zero specified tools when servicing the motorcycle. The motorcycle contains a mix of metric and standard fasteners. Use of the incorrect tool or fastener may damage the motorcycle.

All dealers should have the following:

Special Tools:

• PN 85-05665 Controller Discharge Tool

Loading image...

 Click here for full-size

Basic Tools:

• Safety glasses

• Spring loaded center punch

• 3 mm, 4 mm, 5 mm, 6 mm, 8 mm and 10 mm "T", "L", and socket hex wrenches

• Zip tie pulling/cutting gun

• Rubber dead blow hammer

• Punch

• Flat and rat tail file

•Gear Puller (motor sprocket)

•T25 Star socket

• 8 mm, 10 mm, 13 mm, 14 mm, 15 mm, 17 mm, 22 mm and 27 mm combo wrench

• Phillips and Flat head screw drivers

• 1/4" drive 1", 2”, and 3” socket extension

• 3/8" drive 1", 2", and 3" socket extension

• Needle nose pliers

• Adjustable pin spanner wrench

• 1/4" and 3/8" drive 8mm, 10mm and 13mm socket

• 1/4" and 3/8" drive socket wrench

• Bicycle type headset press and removal tool

• Motorcycle head bearing press and removal tool

• Belt Tension Tester

• External snap ring pliers

Equipment:

• Tire levers and or a tire changing machine

• Motorcycle stand/lift

CAUTION: Under-inflation is the most common cause of tire failure and may result in severe tire cracking, tread separation, “blowout,” or unexpected loss of motorcycle control causing personal injury and possible death.

The tire pressure is checked using an accurate gauge when the tires are cold. This means that the tires have not been ridden on for 3 hours. Always replace the valve stem cap when finished.

What Does This Limited Warranty Cover?

Zero Motorcycles Inc. ("Zero") warrants that all factory manufactured 2014 Zero S, Zero DS, Zero SR motorcycles are free from defects in material and workmanship during the period of this Limited Warranty.

This Limited Warranty covers parts, including the motor, motor controller, frame, swing arm, fork, rear shock, brake assemblies, wheels and electrical sub-assemblies, and approved Zero accessories installed at the time of purchase by an authorized Zero dealer.

This Limited Warranty also covers the following items, collectively referred to as "Power Packs":

• ZF2.8 Power Pack Modules on the Zero FX.

• The Z-Force® Power Tank and ZF2.8 Power Pack Modules; that are purchased within 30 days of the original motorcycle in service date. Z-Force Power Tanks or ZF2.8 Power Pack Modules purchased after this 30-day period will carry the standard Zero Accessory Limited Warranty of 1 year and unlimited miles.

• ZF8.5 and ZF11.4 Z-Force® Li-Ion Power Packs on the Zero S, Zero DS and the Zero SR.

This Limited Warranty covers all components of the Power Packs that are included as a part of the Z-Force® Power Pack, including the battery, integrated battery management system, internal wiring, and internal structures.

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. Additional information regarding transferring this Limited Warranty may be found at http://www.zeromotorcycles.com/owner-resources/ or by contacting Zero at the following:

Via phone at (888) 841-8085 or +31 (0) 72 5112014 (Europe); via e-mail at support@zeromotorcycles.com, or via letter directed to:

North America
Zero Motorcycles Inc.
380 El Pueblo Road
Scotts Valley, CA 95066
USA

Europe
Zero Motorcycles Europe
Fluorietweg 12D
Alkmaar, Noord Holland 1812RR
Netherlands

(U.S. and International Patents and Trademarks Pending)

What is the Coverage Period of This Limited Warranty?

The duration of this Limited Warranty for 2014 Zero S, Zero DS, Zero SR and Zero FX motorcycle models, not including the Power Packs, is a period of 2 years from the original "in service date." The "in service date" is the date that the authorized dealer performs a pre-delivery inspection ("PDI") and delivers the motorcycle to the customer. In the event these events occur on different dates, the later date shall be the “in service date.”

The duration of this Limited Warranty for Power Packs, not including the Power Pack’s outer case, is as follows:

• 5 years or 50,000 miles, whichever occurs first, from the "in service date" for ZF2.8 Power Pack Modules on the Zero FX.

• 5 years or 50,000 miles, whichever occurs first, from the "in service date" for the Z-Force Power Tank on the Zero S, Zero DS and the Zero SR.

• 5 years or 100,000 miles, whichever occurs first, from the "in service date" for ZF8.5 and ZF11.4 Z-Force Li-Ion Power Packs on the Zero S, Zero DS and the Zero SR.

The Power Pack’s outer case is not covered under the Power Pack Limited Warranty duration terms above. Instead, the Power Pack’s outer case is covered for a period of 2 years from its "in service date."

What is Not Covered By This Limited Warranty?

Due to the battery chemistry, there is a normal, expected reduction in range/capacity that Power Packs can yield over time and usage. Depending on use and storage conditions, Power Packs will degrade during the duration of this Limited Warranty period. Zero will only repair or replace pursuant to this limited warranty a Power Pack that exhibits a nominal storage capacity reduction of greater than 20% of the published nominal capacity, as measured by an authorized Zero dealer. To check the capacity of a Power Pack, an authorized Zero dealer can perform a battery management system log data extraction, which will confirm if a reduction is within expected norms.

Further, this Limited Warranty only covers 2014 Zero S, Zero DS, Zero SR and Zero FX motorcycles or Power Packs that are operated according to "proper use" and "under normal operating conditions." For purposes of this exclusion, the following definitions apply:

• "Normal operating conditions" require routine care and maintenance of the 2014 Zero S, Zero DS, Zero SR and Zero FX motorcycles and Power Packs as described in the Owner’s Manual.

• "Proper use" means only the use of a motorcycle in the manner intended for a rider and passenger on a Zero S, Zero SR, Zero DS and Zero FX with proper safety equipment as described in the Owner’s Manual, in accordance with local regulations.

• "Proper use" also means charging the Power Pack after each use and storing it in a fully charged state, or recharging it every 30 days, or keeping it on the charger when in storage or not in regular use.

In addition, this Limited Warranty does not cover:

• The cost of parts and labor involved in any routine care and maintenance and/or the replacement of parts due to normal wear and tear, use, or deterioration, including but not limited to: tires, brake pads and rotors, fork seals, grips, foot pegs, and the seat;

• The replacement of fluids, unless their replacement is a necessary part of warranty service on a covered component;

• 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 the Zero Motorcycle Owner’s Manual.

• Zero motorcycles and Power Packs used for racing or other competitive events;

• Zero motorcycles and Power Packs misused or improperly operated;

• Damage, malfunctions, or performance problems caused by modifications or alterations to 2014 Zero S, Zero DS, Zero SR, and Zero FX motorcycles and/or Power Packs – including modifications or alterations performed by an authorized Zero dealer – that cause the Zero motorcycle or Power Pack to fail;

• Damage, malfunctions, or performance problems caused by aftermarket accessories installed on a Zero motorcycle or Power Pack after the "in service date,” or caused by aftermarket accessories installed by someone other than an authorized Zero dealer;

• Damage, malfunctions, or performance problems caused by the improper repair of the motorcycle, installation of any parts or accessories not sold or approved by Zero, the installation and use of any parties or accessories that alter the motorcycle’s specifications from those set by Zero, or the use of new or used parts not approved by Zero;

• Damage, malfunctions, or performance problems caused by fire, collision, accident, or improper storage;

• Damage, malfunctions, or performance problems caused by continued operation of the motorcycle after a warning light, gauge reading, or other warning indicates a mechanical or operational problem;

• Motorcycles severely damaged or declared to be a total loss by an insurer, or motorcycles substantially reassembled from or repaired with parts obtained from another used motorcycle;

• Damage, malfunctions, or performance problems caused by the failure to follow recommended maintenance requirements as set forth in the Zero Owner’s Manual; and,

• Damage, malfunctions, or performance problems caused by airborne industrial pollutants (e.g., acid rain), bird droppings, tree sap, stones, flood water, windstorms, or other similar occurrences;

Further, this Limited Warranty does not apply to Zero motorcycles or parts and accessories that are not imported or distributed by Zero.

Other Expenses: This Limited Warranty does not cover any incidental or consequential damages, including loss of value of the motorcycle, lost profits or earnings, out-of-pocket expenses for substitute transportation or lodging, expenses associated with returning the covered product to a authorized service facility or dealer, towing and/or roadside assistance expenses, expenses associated with returning the covered product back to its owner, mechanic’s travel time or communication charges, loss or damage to personal property, loss or time, or inconvenience. (Some states do not allow the exclusion or limitation of incidental or consequential damages, so this limitation or exclusion may not apply to you. This warranty gives you specific legal rights and you may also have other rights, which vary from state to state.)

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. (Some states do not allow limitations on how long an implied warranty lasts, so this limitation may not apply to you.)

Zero does not assume – or authorize any person to assume – any other obligation or liability on its behalf.

What Will Zero Do Under This Limited Warranty?

During the duration of this Limited Warranty, an authorized Zero dealer will repair or replace (at Zero’s discretion), without charge, any 2014 Zero S, Zero DS, Zero SR and Zero FX models, Power Packs, or parts that are covered by this Limited Warranty and found by Zero or an authorized Zero dealer to be defective in factory materials or workmanship.

How Do You Obtain Service Under This Limited Warranty?

Warranty services may be obtained by contacting a local authorized Zero dealer. Please see the dealer locator on www.zeromotorcycles.com for the nearest location.

Warranty services may also be obtained by contacting Zero via telephone at (888) 841-8085 or +31 (0) 72 5112014 (Europe), via e-mail at support@zeromotorcycles.com, or via written letter directed to the following:

North America
Zero Motorcycles Inc.
380 El Pueblo Road
Scotts Valley, CA 95066
USA

Europe
Zero Motorcycles Europe
Fluorietweg 12D
Alkmaar, Noord Holland 1812RR
Netherlands

(U.S. and International Patents and Trademarks Pending)

In any written or telephonic communication, please state the specific nature of and any circumstances leading to the problem.

What are Your Responsibilities as a Customer?

As the owner of a product covered by this Limited Warranty, it is your responsibility to read and understand the 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.

Further, it is also your responsibility to:

• Perform all recommended and necessary routine care and maintenance and engage in proper use of your Zero motorcycle and Power Pack as detailed in the Owner’s Manual.

• Learn and obey all federal, state, and local laws governing the operations of a motorcycle, generally, and an electric motorcycle, specifically.

• At all times when operating a Zero motorcycle wear proper safety equipment and clothing, including but not limited to helmet, goggles, and appropriate boots.

What Other Limitations or Disclaimers Apply to this Limited Warranty?

The following additional limitations and disclaimers apply to this Limited Warranty:

• Zero Motorcycles reserves the right to change or improve the design of any Zero motorcycle, Power Pack, or any other Zero parts (collectively, "Zero products") at any time, without assuming any obligation to modify any Zero products previously manufactured or sold.

• The purchaser acknowledges that there is an inherent risk in the operation of motorcycles. This Limited Warranty does not cover – and Zero cannot assume responsibility for – any injury arising from the unsafe or improper operation of Zero products, or the user’s failure to comply with instructions, care and maintenance requirements, warnings, and safety precautions.

• The original registered owner or subsequent registered transferee as documented on the Zero motorcycle warranty registration form is responsible for conveying the Owner’s Manual and all safety warnings, instructions, and Limited Warranty if the unit is sold, loaned, or otherwise transferred to another person. Zero Motorcycles Inc. does not assume or authorize anyone to assume for them any other obligation.

Warranty Procedures:

Warranty services may be obtained by contacting a local authorized Zero dealer. Please see the dealer locator on www.zeromotorcycles.com for the nearest location.

Warranty services may also be obtained by contacting Zero via telephone at (888) 841-8085 or +31 (0) 72 5112014 (Europe), via e-mail at support@zeromotorcycles.com, Service may also be available from a local Zero Motorcycles dealer; please see the locator on www.zeromotorcycles.com for the nearest location.

In any written or telephonic communication, please state the specific nature of and any circumstances leading to the problem.

North America
Zero Motorcycles Inc.
380 El Pueblo Road
Scotts Valley, CA 95066
USA

Europe
Zero Motorcycles Europe
Fluorietweg 12D
Alkmaar, Noord Holland 1812RR
Netherlands

(U.S. and International Patents and Trademarks Pending)

Transfer of Ownership and Warranty?

When it comes time to sell your Zero motorcycle, please visit the Zero Motorcycles website and access the owner resources section to fill out the on-line transfer of ownership and warranty form. This must be performed to allow Zero Motorcycles the ability to contact the new owner in the unlikely event of a safety related issue. Use the URL address below or feel free to contact the Zero Motorcycles Customer Service department for assistance.

North America
Phone: (888) 841-8085
Monday-Friday
8am to 5pm Pacific Time
E-mail: support@zeromotorcycles.com

Europe
Phone: +31 (0) 72 5112014
E-mail: support@zeromotorcycles.com

For updates and additional information about your motorcycle, visit the owner resources section of Zero Motorcycles website:

http://www.zeromotorcycles.com/owner-resources/

Important: Using the following steps of the vibration diagnostic process will help you to effectively narrow-down and pin-point the search for the specific source of a vibration concern and to arrive at an accurate repair.

Vibration Diagnostic Process

1. Gather specific information on the customer's vibration concern.

2. Perform the road testing steps in sequence as identified in Road Testing Procedure in order to duplicate the customer's concern and evaluate the symptoms of the concern under changing conditions. Observe what the vibration feels like and what it sounds like. Observe when the symptoms first appear, when they change, and when they cease.

3. Determine if the customer's vibration concern is truly an abnormal condition or something that is potentially an operating characteristic of the motorcycle.

4. Systematically eliminate or 'rule-out' possible motorcycle systems.

5. Focus diagnostic efforts on the remaining motorcycle system and systematically eliminate or "rule-out" possible components of that system.

6. Make a repair on the remaining component, or components, which have not been eliminated systematically, and must therefore be the cause of the vibration.

7. Verify that the customer's concern has been eliminated or at least brought to an acceptable level.

8. Again perform the road testing steps in sequence in order to verify that the vehicle did not have more than one vibration occurring.

Preliminary Visual/Physical Inspection

• Inspect for aftermarket equipment and modifications, which could affect the operation of the motorcycles rotating component systems.

• Inspect the easily accessible or visible components of the motorcycles rotating component systems for obvious damage or conditions, which could cause the symptom.

• Inspect the tire inflation pressures for the proper pressure.

Although unpacking the 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 plastic 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 riser and remove.

• Unscrew lower crate cover retaining screws and washers.

• Lift or cut outer box away from motorcycle.

Inner Assembly

• Carefully remove plastic cover from motorcycle.

• Locate small parts box below motorcycle and put to the side. (This box contains important documentation, owner’s manual, keys, handlebar clamps and hardware, etc.)

• Cut cable ties holding handlebar to motorcycle.

• Position and center handlebar in riser and mount using handlebar clamps and bolts located in the small parts box. Torque handlebar clamp bolts to 26 N•m (19 lb ft).

• Remove the retaining pin from the power pack rail.

• Remove power pack retaining frame rail.

• Remove power pack.

• Remove cam lock tie down straps and metal tie straps from crate base.

• Carefully lift rear portion of the motorcycle over the swingarm standoff and off crate base.

• Carefully lift front wheel out of crate base.

• Deploy kickstand, lean motorcycle and inspect in accordance with delivery inspection sheet.

Recycling

The Zero Motorcycles shipping crate and packaging materials were designed to be completely recycled. Please cut down and recycle all cardboard, plastic, and metal materials in appropriate receptacles.

The tie down straps that accompanied your motorcycle can be reused as regular tie down straps for transporting your motorcycle.

*Use LOCTITE® 242® (or equivalent)

Important: Using the following steps of the vibration diagnostic process will help you to effectively narrow-down and pin-point the search for the specific source of a vibration concern and to arrive at an accurate repair.

Vibration Diagnostic Process

1. Gather specific information on the customer's vibration concern.

2. Perform the road testing steps in sequence as identified in Road Testing Procedure in order to duplicate the customer's concern and evaluate the symptoms of the concern under changing conditions. Observe what the vibration feels like and what it sounds like. Observe when the symptoms first appear, when they change, and when they cease.

3. Determine if the customer's vibration concern is truly an abnormal condition or something that is potentially an operating characteristic of the motorcycle.

4. Systematically eliminate or 'rule-out' possible motorcycle systems.

5. Focus diagnostic efforts on the remaining motorcycle system and systematically eliminate or "rule-out" possible components of that system.

6. Make a repair on the remaining component, or components, which have not been eliminated systematically, and must therefore be the cause of the vibration.

7. Verify that the customer's concern has been eliminated or at least brought to an acceptable level.

8. Again perform the road testing steps in sequence in order to verify that the vehicle did not have more than one vibration occurring.

Preliminary Visual/Physical Inspection

• Inspect for aftermarket equipment and modifications, which could affect the operation of the motorcycles rotating component systems.

• Inspect the easily accessible or visible components of the motorcycles rotating component systems for obvious damage or conditions, which could cause the symptom.

• Inspect the tire inflation pressures for the proper pressure.

Although unpacking the 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 plastic 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 riser and remove.

• Unscrew lower crate cover retaining screws and washers.

• Lift or cut outer box away from motorcycle.

Inner Assembly

• Carefully remove plastic cover from motorcycle.

• Locate small parts box below motorcycle and put to the side. (This box contains important documentation, owner’s manual, keys, handlebar clamps and hardware, etc.)

• Cut cable ties holding handlebar to motorcycle.

• Position and center handlebar in riser and mount using handlebar clamps and bolts located in the small parts box. Torque handlebar clamp bolts to 26 N•m (19 lb ft).

• Remove the retaining pin from the power pack rail.

• Remove power pack retaining frame rail.

• Remove power pack.

• Remove cam lock tie down straps and metal tie straps from crate base.

• Carefully lift rear portion of the motorcycle over the swingarm standoff and off crate base.

• Carefully lift front wheel out of crate base.

• Deploy kickstand, lean motorcycle and inspect in accordance with delivery inspection sheet.

Recycling

The Zero Motorcycles shipping crate and packaging materials were designed to be completely recycled. Please cut down and recycle all cardboard, plastic, and metal materials in appropriate receptacles.

The tie down straps that accompanied your motorcycle can be reused as regular tie down straps for transporting your motorcycle.

*Use LOCTITE® 242® (or equivalent)

Loading image...

 Click here for full-size

Legend:

1. DC/DC Converter, Fuse Center and Main Bike Board (MBB)(under seat)

2. Power Pack

3. Power Tank (Optional)

4. Integrated Power Pack Charger

5. Brushless Motor

6. Brushless Motor Controller