Service Manual
 
The information on these pages is only valid for:
2020 Zero S/SR/DS/DSR 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.

Equipment, AC Power Ground
 
High Voltage
 
Equipment, AC Power Ground
 
High Voltage
 
C48 Running Light Connector Face View
 
C48 Running Light
 

Connector Part Information
  • 2-Way F (GRY)
Pin
Wire Color
Function
1
BLK
Running Lamp Ground
2
BLU/RED
Running Lamp Supply Voltage

Behind the Headlight

C368 Power Tank Battery Positive (+)
 

C368 Power Tank Battery Positive (+)

Connector Part Information

  • YBM2C-L2
  • 1-Way Eyelet

Pin

Wire Color

Function

BLK Switched Battery Positive (+)

Under the Seat, Above the Rear Tire

Splice S515
 

Left Side of the Frame, Next to the Tank Compartment/Power Tank

Joint
Point

Connector

Pin

Color

Function

graphic for table
BLK 12 Volt Ground Input from Splice S24
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C106 3 BLK 12 Volt Ground Output
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C107 1 BLK 12 Volt Ground Output
graphic for table middle
C428 1 BLK 12 Volt Ground Output
graphic for table middle
C33 2 BLK 12 Volt Ground Output
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C42 3 BLK 12 Volt Ground Output
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C428 10 BLK 12 Volt Ground Output
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C34 2 BLK 12 Volt Ground Output
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C318 1 BLK 12 Volt Ground Output
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C35 7 BLK/WHT 12 Volt Ground Output
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C282 9 BLK 12 Volt Ground Output
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C26 2 BLK 12 Volt Ground Output
C95 Brushless Motor Controller
 

C95 Brushless Motor Controller

Connector Part Information

  • S1/0-56R 
  • 1-Way Eyelet

Pin

Wire Color

Function

BLK (Orange Sleeve Over Cable) Positive (+) Voltage
BLK (Orange Sleeve Over Cable) Positive (+) Voltage

Under the Seat, Above the Rear Tire

C429 Front Wheel Speed Sensor
 

C429 Front Wheel Speed Sensor

Connector Part Information

  • 34062-0023
  • 2-Way F (BLK)

Pin

Wire Color

Function

1 BLK/RED WSP
2 BLK/WHT WSS

Behind the Headlight, On the Left Side of the Frame

 

Splice S515
 

Left Side of the Frame, Next to the Tank Compartment/Power Tank

Joint
Point

Connector

Pin

Color

Function

graphic for table
BLK 12 Volt Ground Input from Splice S24
graphic for table middle
C106 3 BLK 12 Volt Ground Output
graphic for table middle
C107 1 BLK 12 Volt Ground Output
graphic for table middle
C33 2 BLK 12 Volt Ground Output
graphic for table bottom
C42 3 BLK 12 Volt Ground Output
graphic for table middle
C34 2 BLK 12 Volt Ground Output
graphic for table middle
C318 1 BLK 12 Volt Ground Output
graphic for table middle
C35 7 BLK/WHT 12 Volt Ground Output
graphic for table middle
C282 9 BLK 12 Volt Ground Output
graphic for table middle
C142 1 BLK 12 Volt Ground Output
graphic for table middle
C142 2 BLK 12 Volt Ground Output
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C457 C BLK 12 Volt Ground Output
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C26 2 BLK 12 Volt Ground Output

Right Handlebar Control Replacement
 

Required Tools

• Philips screwdriver

• 3mm hex wrench

• 10mm hex wrench

Removal Procedure

1. Remove the instrument panel and turn signal assembly (TURN SIGNAL FR-RH RR-LH, TURN SIGNAL FR-LH RR-RH, HEADLIGHT MOUNT RIGHT, HEADLIGHT MOUNT LEFT).

2. Disconnect the right handlebar control harness connector C275. Note the location of the zip ties for reassembly.

3. Remove and discard the zip ties.

4. Remove the 2 Philips (1) from the right handlebar switch, and remove the switch.

Installation Procedure

1. Place the right handlebar control onto the handlebar aligning the switch pin with the hole in the handlebar.

2. Securely tighten the two screws (1). Do not over tighten.

3. Connect the right handlebar control harness connector C275.

4. Install new zip ties in the same location as removed.

5. Install the instrument panel and turn signal assembly. Note: Ensure that ground eyelet C239.

is attached.

Description and Operation
 

Suspension

Description and Operation

The front and rear suspension can be adjusted for sag and damping. For adjustment procedures, refer to Suspension Adjustment.

Front Suspension

The fork assembly contains the triple tree and fork legs (shocks). The triple tree holds the fork legs in place and attaches the fork assembly to the frame.

The shock has two main actions: Compression when the shock gets compressed, 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.

Rear Suspension

The rear suspension is a swingarm with a monoshock design. One end of the swingarm is connected to the frame (pivot end) and the end to the wheel. Controlling the action/movement of the swingarm is the shock.

The shock is a fully adjustable coilover design. The coilover shock contains a spring surrounding it. The spring rate is adjustable and is factory set for a 82 kg (180 lb) rider. The rate is a measure of how much force is required to compress the spring a given distance. The higher the rate, the more force it takes to compress it a given distance, and the less it compresses under a given force.

The shock has two main actions: Compression when the shock gets compressed, and rebound when the shock returns back to full length. Compression damping is the adjustment that determines how fast or slow the shock compresses. Rebound damping is the adjustment that determines how fast or slow the shock rebounds.

Diagnostic Trouble Code (DTC) List
 

The numeric error code displayed on the LCD instrument panel provides diagnostics into errors that the Main Bike Board (MBB) has set. These can be useful for troubleshooting issues and determining next steps for solving technical issues. 

Retrieving Error Codes

Adjust Button (ADJ): By momentarily pressing or holding the ADJ button (1) you can reset fields and toggle through the trip menus and display options.

Select Button (SEL): By momentarily pressing or holding the SEL button (2) you can reset or select fields in Display A and Display B, change the time, and change the display units.

DTC_1

Display A
To select Display A with the dash in its normal operating mode, momentarily press the SEL button once. Press the ADJ button to toggle through the following fields:

• Trip 1 Odometer - Displays individual trip mileage and is reset by pressing and holding the ADJ button for 2 seconds.

Note: Trip 1 is reset each time the battery is recharged to 100%.

• Range - Displays remaining battery power based on learned riding style and usage.

• Error - Displays 2-digit error codes for dealer use.

• RPM - Displays motor RPM.

DTC_2

If an error code has been recorded, it can be retrieved from the dash Display A.

DTC_3

Diagnostic Trouble Code (DTC) List-MBB

Note: If code 57 is retrieved, the motorcycle may only require recharging.

DTC
Description
0
No Error
1
High Throttle
2
Motor Temperature Warning Stage 1
3
Motor Temperature Warning Stage 2
4
Controller Temperature Warning Stage 1
5
Controller Temperature Warning Stage 2
6
BMS Throttle Enable Wire Error
7
Low Battery Voltage
8
High Battery Temperature Status
9
Low Battery Temperature Status
10
Battery Temperature Warning Stage 1
11
Battery Temperature Warning Stage 2
12
Reserve Partition Warning
13
Reserve Switch Warning
14
Safety Override Active
15
Charger Attached But Not Charging
16
CIB Contactor Compromised
17
Charger Error
18
Battery Temperature Sensor Fault
19
High Charge Current
20
BMS Low Isolation
21
Board Vpack Error
22
Board Temperature Error
23
Post Error
24
Startup Error
25
Contactor Open Warning
26
Contactor Welded Error
27
Precharge Error
28
BMS Isolation Fault
29
BMS Isolation Danger
30
BMS CAN Error
31
Sevcon CAN Error
32
Module Variance Too High
33
Sevcon Error Turn Off
34
Charge Error Turn Off
35
Loopback Error
36
Board 5V Error
37
Board 3.3V Error
38
Idle Turn Off
39
Throttle Out Of Range Disable
40
BMS Throttle Enable Wire Disable
41
Low Battery Voltage Disable
42
High Battery Temperature Status Disable
43
Low Battery Temperature Status Disable
44
Kill Switch Disable
45
Kickstand Switch Disable
46
BMS Charger Connected Disable
47
MBB Charger Connected Disable
48
Sevcon Startup Disable
49
Contactor Open Disable
50
BMS Self Test Error
51
BMS Self Test Warning
52
Reserve Partition Disable
53
BMS Internal Disable
54
BMS Internal Disable Error
55
BMS Internal Fault Error
56
Monolith Not Connected
57
Module Did Not Connect
58
BMS Sensor Warning
59
BMS System Warning
60
Bike Configuration

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