Zero S 2012 Owner's Manual

An Important Message To You From Zero .......... 1-1 Introduction ............................................................ 1-1 Index .............................................................. 1-1 Useful Information For Safe Riding.............. 1-2 Plug in Your Z-Force Power Pack™................... 1-2 Owner Information................................................. 1-3 Power Pack Serial Number .................................. 1-4 Motor Serial Number ............................................ 1-4 Key Code Number ..................................... ...

Maintenance Schedule ....................................... 5-24 Parts/Maintenance Items .................................... 5-27 Zero Motorcycle Accessories.............................. 5-27 Fuses ................................................................... 5-27 Troubleshooting ......................................................... 6-1 Power Pack And Charger ..................................... 6-1 Battery Management System........................ 6-3 Safety Interlocks .......................................... 6-10 Temperature Indicator ................................. 6 ...

2012 Zero S/DS electric motorcycle; we welcome you to the community of Zero Motorcycles riders. This manual is designed to provide you with a better understanding of the operation, inspection, and basic maintenance requirements of this motorcycle. Zero continually seeks advancements in product design and quality. Therefore, this manual contains the most current product information available at the time of printing. Because of this, your motorcycle may differ from the information supplied in this owner’s manual. No legal claims can be made on the basis of data in this manual. When it co ...

This manual contains the word CAUTION to tell about something that could hurt you or others. It also contains the word WARNING to tell about things that could damage your motorcycle. CAUTION: Please read this manual carefully and completely before operating this motorcycle. Do not attempt to operate this motorcycle until you have attained adequate knowledge of its controls and operating features, and until you have been trained in safe and proper riding techniques. Regular inspections and proper maintenance, along with good riding skills, will help you to safely enjoy the capabilities and the reliability of this m ...

VIN Telephone No. E-mail Power Pack Serial Number Name Motor Serial Number Owner Information Record important information pertaining to your motorcycle here. When contacting your dealer, you may need to provide this information. ...

(VIN) See Location Of Important Labels on page 2-3. VIN Location A. VIN Stamp Power Pack Serial Number The Power Pack serial number is located on the upper right rear of the power pack. Motor Serial Number The motor serial number is stamped on the motor housing. Key Code Number The key code is a 5 digit number used to create duplicate keys. This number is located on a tag that accompanies the original keys. ...

538 Motorcycle Type M3 = 12 MY S D3 = 12 MY DS M3 = 9.1 kW (12.2 HP) C = 2012 Production Number S M3 9 C M3 12345 538 = On Road World Manufacturer Identifier C = California Model Line Model Year Plant Location A = 11-12 MY S B = 11-12 MY DS Model Net Brake Horsepower C A VIN Break Down The VIN is a 17-digit number stamped on the head tube of the frame. Do not alter or remove this number as it is the legal identifier for your motorcycle. ...

*Environmental Protection Agency (EPA) Urban Dynamometer Driving Schedule (UDDS) **Zero chargers typically draw as much as 10 amps at 120 volts. MOTOR Type High efficiency, double-stator axial flux permanent magnet, brushless motor with integrated forced air cooling Controller High efficiency, 420 amp, 3-phase brushless controller with re-generative deceleration Estimated Top Speed (max) 142 km/h (88 mph) Estimated Top Speed (sustained) 121 km/h (75 mph) POWER SYSTEM Type Z-Force™ Patented Li-Ion Intelligent Power Pack Maximum Capacity • ZF6 6.0 kWh • ZF9 9.0 kWh Nominal Capacity • ZF6 5.3 ...

Final Drive 28T/132T Sprockets, 8 mm pitch, 200 tooth, 14 mm width, Poly Chain® GT® Carbon™ (belt) CHASSIS/SUSPENSION/BRAKES Front Suspension Travel 140 mm (5.51 in) Rear Suspension Travel 149 mm (5.85 in) Front Brakes 2 Piston Hydraulic, 310 x 4 mm Floating Rotor, Hand Actuated Rear Brakes 1 Piston Hydraulic, 220 x 4 mm Rotor, Foot Actuated Brake Rotor Minimum Thickness 3.85 mm (0.15 in) Front Tire 110/70-17 in Rear Tire 130/70-17 in Front Wheel 17 x 3.0 in Rear Wheel 17 x 3.5 in Front Suspension 38 mm inverted forks with adjustable compression and rebound damping CHASSIS/SUSPENSION/BRAKES Rear Susp ...

*Environmental Protection Agency (EPA) Urban Dynamometer Driving Schedule (UDDS) ECONOMY Typical Cost to Recharge • ZF6 $0.63 • ZF9 $0.95 Equivalent Fuel Economy (city) 487 MPGe- 0.48 Liters/100km (0.13 gallons/62 miles) Equivalent Fuel Economy (highway) 273 MPGe- 0.86 Liters/100km (0.23 gallons/62 miles) MOTOR Type High efficiency, double-stator axial flux permanent magnet, brushless motor with integrated forced air cooling Controller High efficiency, 420 amp, 3-phase brushless controller with re-generative deceleration Estimated Top Speed (max) 129 km/h (80 mph) Estimated Top Speed (sustained) 113 km/h (70 mph ...

POWER SYSTEM Input** Standard 120 V AC or 240 V AC Charger Type 1 kW integrated Estimated Power Pack Life to 80% (city) • ZF6 326,000 km (203,000 miles) • ZF9 487,000 km (302,000 miles) RANGE City EPA UDDS* Range • ZF6 121 km (75 miles) • ZF9 180 km (112 miles) Highway at 113 km/h (70 mph) • ZF6 68 km (42 miles) • ZF9 100 km (62 miles) DRIVETRAIN Transmission Clutchless One Speed Drive System (standard) 25T/132T Sprockets, 8 mm pitch, 220 tooth, 14 mm width, Poly Chain® (belt) Drive System (optional) 13T/71T Sprockets, 420 Chain CHASSIS/SUSPENSION/BRAKES Front Suspensi ...

distance the vehicle will travel on a single full charge of the power pack. Just like EPA mileage estimates on an automobile, “your mileage may vary.” Your range results are a direct reflection of your riding habits. The more conservative you ride the better range you can expect from your Zero S/DS motorcycle. Some of the factors which affect range include speed, acceleration, number of starts and stops, as well as changes in elevation. The combination of these factors, as you travel from one point to another, defines your trip profile. In addition, tire pressure and payload are ...

industry standardized formula. The range is separated into two separate specifications: “City (EPA UDDS)” Environmental Protection Agency (EPA) Universal Dynamometer Driving Schedule (UDDS) and “Highway.” The City (EPA UDDS) range is a U.S. federal test procedure to give an estimate on how many miles an electric vehicle will go on a single charge. The highway range is to provide the rider an estimate of what you can expect to achieve when using the motorcycle for highway commuting. This range takes into account the distanced traveled on city roads getting to and from the highway as well as th ...

accessories for your Zero motorcycle. Parts and accessories for your Zero motorcycle have been checked and tested for safety and suitability. Zero is unable to accept any liability whatsoever for parts and accessories which have not been approved. Emissions Information The Zero S/DS electric motorcycle is a true freeway capable zero emissions vehicle under California Air Resources Board (CARB), U.S. Federal (EPA), and European Union standards. It uses no gasoline or other liquid fuel. It has no tailpipe and therefore no tailpipe emissions. It also has no exhaust or evaporative emissions. Because th ...

pressure must be released to help prevent fork seal leaks. There is a 3 mm Allen “bleed” screw located just in front of the rebound adjuster on each fork leg. This “bleed” screw (A) is used to release the built up pressure. Loosen the screw slowly, but do not remove. Once all the air is out, tighten the bleed screw. When the fork is released, with no weight on the front tire, the screw must be opened again to allow for stabilization. Ensure that the screw is tigh ...

transporting or shipping. Remove the 80 volt fuses (A) from the fuse center. The 80 volt fuse center is located on the back upper right corner of the power pack. See page 5-29 for further information. ...

1. This is a performance motorcycle and should be treated with extreme caution. 2. Proper safety gear, including a regionally approved helmet, riding boots, gloves, and protective clothing should be worn while riding to reduce the risk of potential injury. We highly recommend the use of full height riding boots since the vast majority of motorcycle injuries are leg and foot injuries. It is not recommended to ride without protective clothing; this applies to even short journeys, and to every season of the year. 3. Read all additional warnings and product instructions in this owner’s manual, and safety ...

vehicle unsafe and may cause severe personal injury. Zero Motorcycles cannot be held liable for non-approved modifications. 12. Be very careful when loading or adding accessories to your motorcycle. Large, bulky, or heavy items may adversely affect the handling and performance of your motorcycle. 13. Failure to follow power pack storage and charging instructions, as described in this Zero Motorcycles Owner’s Manual, may void the warranty of your Zero motorcycle. These guidelines have been rigorously tested to ensure maximum power pack efficiency and service. Important Operating Information 1. Alw ...

A. Vehicle Certification Label B. Throttle and Speed Control Label The vehicle could contain the following information: • Gross Vehicle Weight Rating (GVWR) • Gross Axle Weight Rating (GAWR) Front and Rear • Vehicle Identification Number (VIN) • Rim Size • Tire Pressure • Date of Manufacture 6. The power pack does not require or tolerate deep discharging. To get the most power pack life, recharge the power pack immediately after each ride. Leaving a power pack in a discharged state will cause damage. See Charging The Power Pack on page 4-10. ...