Service Manual
 
The information on these pages is only valid for:
2015 Zero S/SR/DS Service Manual
Welcome! Use the navigation to the left to view documents.
Unpacking Procedure
 

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.

Wood Shipping Crate

Outer Box Cover

• Cut and remove the two metal outer box retention straps.

• Remove the screws along the crate base.

• Remove screws along the side of the crate that has the metal clamps on it.

• Remove the metal clamps, and remove the side panel.

• Remove the remaining outer box cover.

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.)

• 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.

Card Board Shipping Crate

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.)

• Remove the tie down straps from the 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.

Accessory Power
 
ABS Indicator and OFF Signals
 
C47 Main Bike Board Inline Fuse
 

C47 Main Bike Board Inline Fuse

Connector Part Information

  • 8000000005
  • ABC 4A
  • 2-Way (BLK)

Pin

Wire Color

Function

1 ORN Voltage from Power Pack
2 ORN/BLU Voltage to  Main Bike Board

Under the Fuse Center, Inside the Harness

 

C366 Power Tank Signal Connector Face View
 

C366 Power Tank Signal Connector Face View

Connector Part Information

  • 3-6018P1
  • 16-Way F (BLK)

Pin

Wire Color

Function

P1 Not Used
P2 RED CAN 5 Volts
P3 Not Used
P4 YEL/GRY 12 Volt Output
P5 WHT CAN High
P6 Not Used
P7 GRY/BRN Node ID 1
P8 GRY/BRN Ground
S1 BRN System ON Reference
S2 BLK CAN Ground
S3 BRN/WHT System ON
S4 BLU CAN Low
S5 PNK HVIL Output
S6 GRN/YEL Chassis Ground
S7 PNK HVIL Return
S8 BLK/WHT Throttle Enable

Under the Tank Assembly, On Top of the Power Tank

Splice 488
 

Photo Not Available

Joint
Point

Connector

Pin

Color

Function

graphic for table
C306 - BLK Ground
graphic for table middle
C50 2 BLK Ground
graphic for table bottom
C97 1 BLK Ground

DC/DC Converter
 
Indicators
 
Torque Specifications
 

Application
Specification
Metric
English
Banjo Bolt
31 N•m
23 lb ft
Caliper Bleeder Valve
7 N•m
62 lb in
Front Brake Caliper Bolts
26 N•m
19 lb ft
Front Brake Rotor Bolt
26 N•m
19 lb ft
Rear Axle Shaft Nut
102 N•m
75 lb ft
Rear Brake Caliper Slide Pin*
46 N•m
34 lb ft
Rear Brake Rotor Bolts
13 N•m
9.5 lb ft
Front Axle Pinch Bolts
22 N•m
16 lb ft
Seat Bolts
22 N•m
16 lb ft
Rear Tank Bolts
5 N•m
44 lb in
Front Fairing Screws
2 N•m
18 lb in
Front Tank Bolts
4 N•m
35 lb in
ABS HCU Bolts
11 N•m
8 lb ft
Front Fender Bolts DS
3 N•m
24 lb in
Front Fender Bolts S/SR
11 N•m
8 lb ft
Front Axle Shaft
54 N•m
40 lb ft
Brake Caliper Slide Pin*
46 N•m
34 lb ft

*Use LOCTITE® 242® (or equivalent)

MBB/BMS Interface
 
Editing Source Code

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.

22238

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