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.

©2016 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.

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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 with, cut, or modify high voltage cable or wiring.

This manual covers the following motorcycles:

• Zero S: Street

- Up to 197 miles city range

- 54 hp (40 kW) Motor

- 68 ft-lb torque

- 95 mph top speed

• Zero SR: Street - Max Performance

- Up to 197 miles city range

- 67 hp (50 kW) Motor

- 106 ft-lb torque

- 3.3 seconds 0-60 mph

• Zero DS: Dual Sport

- Up to 179 miles city range

- 54 hp (40 kW) Motor

- 68 ft-lb torque

- 98 mph top speed

• Zero DSR: Dual Sport - Max Performance

- Up to 179 miles city range

- 67 hp (50 kW) Motor

- 106 ft-lb torque

- 98 mph top speed

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 Discharging 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.

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.

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Legend:
1. Fuse Center
2. ABS 12 Volt Fuse

Fuses

ABS 12 Volt Fuse

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High Voltage Fuses

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To access the high voltage fuses:

1. Remove the two bolts securing the seat to the motorcycle frame.

2. Pull the seat rearward to gain access to the fuses.

3. Pull back sheathing to access fuse holders (if necessary).

4. Unscrew the fuse’s cover (1, 2, and 3).

5. Replace the fuse.

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)

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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.

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The vehicle could contain the following information for both North American and European models:

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Legend:

A. VECI (Vehicle Emission Control Information) label

B. VIN label (European Union) - certification label

C. VIN label (North America) - certification label shown

High Voltage Warning Label

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2016 S/SR/DS/DSR Service Manual
Version 1

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

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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

• T15 tamperproof 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.

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

E-mail: service@zeromotorcycles.com
24 hours

International Contacts:

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

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.

The latest version of the Pre-Delivery Inspection Checklist is available to your dealership through Zero Motorcycles Service Portal (Service.Zeromotorcycles.com) in the Dealer FAQ section.

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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.

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.

The latest version of the Pre-Delivery Inspection Checklist is available to your dealership through Zero Motorcycles Service Portal (Service.Zeromotorcycles.com) in the Dealer FAQ section.

Loading image...

 

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.

*Use LOCTITE® 242® (or equivalent)

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Legend:

1. ABS HCU/Pump

2. Power Tank (Optional)

3. Power Pack

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

5. Brushless Motor Controller

6. Brushless Motor

7. Integrated Power Pack Charger