Zero 2022-2023 SR S Service User manual

Type
User manual
SR/S SERVICE MANUAL
Release 1.1
© 2022 Zero Motorcycles, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of
printing and is subject to the copyright and other intellectual property rights of Zero Motorcycles Inc. No part of this
document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic,
mechanical, photocopying, recording, or otherwise. These materials must not be modified or reposted to other sites,
without the prior expressed written permission of the copyright holder.
Table of Contents
1
i
1 General Information
How To Use This Manual...................................................................................... 1-1
Important Repair Information................................................................................ 1-2
10 Maintenance and Safety
Lockout Procedure
Lockout Procedure...........................................................................................................10-1
Adjust Drive Belt
Adjust Drive Belt ...............................................................................................................10-2
Brake Maintenance Procedures
Brake Bleeding Procedure (Front) ..................................................................................10-5
Brake Bleeding Procedure (Rear) ...................................................................................10-6
Brake Bedding ..................................................................................................................10-7
Key Programming
Key Programming .............................................................................................................10-8
Motor Commissioning
Motor Commissioning ................................................................................................... 10-10
Motor Controller Firmware Update
Motor Controller Firmware Update............................................................................... 10-14
20 Power Pack
Power Pack
Power Pack .......................................................................................................................20-1
BMS (Battery Management System) [Before 2022MY] .................................................20-6
Battery Management Unit (BMU) [22MY Onwards].................................................... 20-14
Power Pack Battery Signal Harness [Before 2022MY] ............................................... 20-15
Power Pack Accessory Power Bus [Before 2022MY]................................................. 20-20
Power Pack Heat Sink Skins [Before 2022MY]........................................................... 20-28
Service Cover [22MY Onwards].................................................................................... 20-31
Front Cover [22MY Onwards] ....................................................................................... 20-31
Rear Cover [22MY Onwards] ........................................................................................ 20-32
Mid Pack Protection Unit [22MY Onwards]................................................................. 20-32
Top Cover [22MY Onwards] ......................................................................................... 20-33
Cooling Fan [22MY Onwards]....................................................................................... 20-34
Assembly Cell Management Unit (CMU) [22MY Onwards]........................................ 20-35
Power Leads - Positive & Negative [22MY Onwards].................................................. 20-37
Contactor [22MY Onwards] .......................................................................................... 20-38
Controller BUS Set [22MY Onwards] ........................................................................... 20-39
12 Volt Harness [22MY Onwards] ................................................................................ 20-41
BCB Main BUS Set [22MY Onwards]........................................................................... 20-42
2
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i
25 Charging System
Chargers
3KW Rapid Charger (Front) [Before 2022MY] ...............................................................25-1
3KW Rapid Charger (Front and Rear) [Before 2022MY]............................................... 25-7
6KW Charger [22MY Onwards] .....................................................................................25-14
Charge Inlet Harness......................................................................................................25-17
DC/DC Converter
DC/DC Converter ...........................................................................................................25-20
30 Motor and Drive System
Motor
Motor .................................................................................................................................30-1
Motor Stop Switch
Motor Stop Switch..........................................................................................................30-14
Throttle
Throttle (Without Heated Grips) ....................................................................................30-18
Throttle (With Heated Grips)..........................................................................................30-22
Controller
Motor Controller [Before 2022MY]................................................................................30-27
Motor Controller Carrier [Before 2022MY] ...................................................................30-39
Motor Controller with Heatsink [22MY Onwards] ........................................................30-42
Rear Sprocket
Rear Sprocket.................................................................................................................30-43
40 Suspension
Wheel Speed Sensor (WSS)
Wheel Speed Sensor (Front) ...........................................................................................40-1
Wheel Speed Sensor (Rear) ............................................................................................40-6
Front Suspension
Steering Stem .................................................................................................................40-11
Rear Suspension
Rear Shock .....................................................................................................................40-16
Swingarm ........................................................................................................................40-19
Doubler Plate Seals ........................................................................................................40-29
Replace Drive Belt..........................................................................................................40-35
Adjust Drive Belt .............................................................................................................40-39
Table of Contents
3
i
45 Brakes
Brakes
Brake Master Cylinder (Front)..........................................................................................45-1
Brake Pads (Front)............................................................................................................45-3
Brake Pads (Rear).............................................................................................................45-5
Brake Caliper (Front) ........................................................................................................45-6
Brake Caliper (Rear) .........................................................................................................45-8
Brake Rotor (Front)........................................................................................................ 45-11
Brake Rotor (Rear)......................................................................................................... 45-15
Hydraulic Control Unit (HCU)........................................................................................ 45-19
50 Wheels
Front Wheel
Front Wheel .......................................................................................................................50-1
Rear Wheel
Rear Wheel........................................................................................................................50-4
60 Body
Trim
Rider’s Seat.......................................................................................................................60-1
Body
Headlight Upper Fairing ...................................................................................................60-2
Headlight Inner Fairing .....................................................................................................60-3
Hela Bracket......................................................................................................................60-6
Tank Removal ................................................................................................................ 60-10
Side Fairings (Outer)...................................................................................................... 60-14
Side Fairings (Inner)....................................................................................................... 60-19
Tank (Disassembly and Reassembly) .......................................................................... 60-22
Grab Handles (Right and Left)...................................................................................... 60-32
Tank Storage Liner ........................................................................................................ 60-34
Tail
Tail Assembly ................................................................................................................. 60-36
70 Electrical
High Voltage Fuses
High Voltage Fuses...........................................................................................................70-1
12 Volt Battery
12 Volt Battery (Disconnect) ............................................................................................70-3
12 Volt Battery (Removal).................................................................................................70-5
4
Table of Contents
i
Lighting
Headlight...........................................................................................................................70-8
Tail Light..........................................................................................................................70-10
Turn Signal (Left Front) ..................................................................................................70-11
Turn Signal (Right Front)................................................................................................70-12
Turn Signal (Rear) ..........................................................................................................70-16
Instruments
Dash.................................................................................................................................70-19
Key Switch
Key Switch.......................................................................................................................70-21
Mode Switch
Mode Switch (Without Heated Grips) ...........................................................................70-23
Mode Switch (With Heated Grips).................................................................................70-26
Heated Grip
Heated Grips (Left) .........................................................................................................70-29
Kickstand Switch
Kickstand Switch ............................................................................................................70-33
Cellular Connectivity Module (CCM)
Cellular Connectivity Module (CCM).............................................................................70-36
Main Bike Board (MBB)
Main Bike Board (MBB) .................................................................................................70-39
General Information
2-1
General Informa tion
How To Use This Manual
General
To assist in the use of this Manual, it is divided into
numbered sections (shown on the previous page).
Each section starts with a contents page listing the
service procedures covered within that section.
Each section is numbered from page 1, and the
page number is shown at the bottom of each page.
References will be made from within a service
procedure to other procedures that should be
carried out as part of the main procedure.
The individual actions of the service procedures
must be followed in the sequence in which they
appear. Annotation numbers on the illustrations
refer to the relevant numbered action after the
illustration.
For reference purposes, an illustration number is
shown in the bottom left hand corner of each
illustration.
Important Information Types
The following words are used within this manual to
call your attention to specific types of information.
WARNING! An action or information which must
be followed precisely to avoid the possibility of
injury.
CAUTION: Calls attention action or information
which must be followed to avoid damage to
components.
NOTICE: Information that must be performed
before starting the repair procedure.
Note: Gives helpful information.
Dimensions
The dimensions quoted are to design engineering
specification. Service limits are included where
applicable.
Terminology
Left side of motorcycle.
Right side of motorcycle.
2-2
General Information
Abbreviations and Symbols Important Repair Information
Replacement Fasteners
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
manufacturer for proper usage.
One-time Use
Always use new lock nuts, lock washers, crush
washers, cotter pins, and cable ties.
Coatings
Do not use paints, lubricants, or corrosion inhibitors
on fasteners or fastener contact surfaces unless
otherwise specified in the installation procedure
notes. Coatings affect fastener torque and
clamping force, as well as damage the fastener.
Coatings can also affect the operation of electrical
components.
Lifting and Supporting the Motorcycle
CAUTION: DO NOT LIFT THE MOTORCYCLE BY
JACKING UP THE CONTROLLER! DO NOT
SUPPORT THE WEIGHT OF THE MOTORCYCLE
BY SUPPORTING THE CONTROLLER! Doing so,
will damage the controller and other
components.
AC Alternating current
Amp (A) Ampere
AUX Auxiliary
CCelsius
CCM Cellular Connectivity Module
CEL Check Engine Light
cm Centimeter
DC Direct Current
dia. Diameter
DOT Department of Transportation
EPA Environmental Protection
Agency
EV Electric Vehicle
FFahrenheit
FRT Flat Rate Time
HCU Hydraulic Control Unit
HV High Voltage
HW Hardware
lb-ft pounds-feet
in-lb inch-pound
MBB Main Bike Board
mm millimeter
Nm Newton-metre
OAL Overall Length
OBC On-Board Charger
SoC State of Charge
RH Right-Hand
VVolt
WWatt
General Information
2-3
Repair of Electric Vehicles
Zero Motorcycles are electrically powered
vehicles (“e-vehicles”) under which Regulation
No. 100 of UNECE [2015/505] applies. In order
to safely repair Zero Motorcycles, it is essential
that any electrical hazards are eliminated, and
damaged motorcycles or electrically hazardous
components should be handled and stored
safely. All work on Zero Motorcycles and their
components must be carried out in compliance
with safety instructions supplied by Zero
Motorcycles and all applicable local standards
and e-vehicle requirements.
Testing After a Repair
Operations covered in this Manual do not include
reference to testing the motorcycle after repair. It is
essential that work is inspected and tested after
completion and if necessary a road test of the
motorcycle is carried out. This is of particular
importance where safety related items are
concerned.
2-4
General Information
Maintenance and Safety
Lockout Procedure 10-1
10
Maintenance and Safety
Lockout Procedure
Lockout Procedure
WARNING! For your safety and for the safety of
others, perform the following steps prior to
performing work on the Zero Motorcycle!
Lockout Procedure Steps
1. Set up safety barricades around your work
area.
2. Confirm your work area is equipped with a
high voltage safety hook.
3. Inspect your high voltage safety gloves are not
damaged and are properly certified.
10-2 Adjust Drive Belt
Maintenance and Safety
10
Adjust Dr ive Belt
Adjust Drive Belt
Tools Required (includes tools required for
parent jobs):
T45
27mm socket and ratchet
Smartphone with Gates® Carbon Drive
Application
Motorcycle stand
Removal
1. Remove the key from the key switch.
2. Safely raise rear tire off the ground using a
motorcycle stand.
3. Loosen rear axle nut. Tool: 27mm socket
4. The alignment marks stamped on the
swingarm are for initial alignment, but are not
equal on both sides of the swingarm and
should not be used as final adjustment marks.
5. Turn the left (and right) belt tension
adjustment bolts a 1/4 turn at a time until the
belt adjustment is within specification. Tool:
T45
6. Rotate the tire in the forward direction until
the belt has made two full revolutions.
Maintenance and Safety
Adjust Drive Belt 10-3
10
NOTICE: Rotating the tire in the reverse
direction will give a false adjustment. Failing to
follow this instruction could cause damage to
the drive belt.
NOTICE: Rotating the tire two full revolutions
isn’t enough to normalize the belt on the two
sprockets, so be sure to rotate the belt two full
revolutions by counting the number of times
the printing on the belt passes by the rear
outer fender arm. Failing to follow this
instruction could cause damage to the drive
belt.
7. After rotating the drive belt two revolutions
and the adjustment bolts are adjusted
properly, the belt should have a 1-2mm gap
between the belt-side face of the rear sprocket
and the drive belt.
8. Tighten the rear axle nut. Torque 75 lb·ft
(102 Nm). Tool: 27mm socket
9. After the axle is torqued properly, rotate the
belt two full turns and confirm that the belt still
has a 1-2mm gap between the belt-side face of
the rear sprocket and the drive belt.
10. Using the Gates® Carbon Drive™ application
on a Smartphone, confirm the microphone is
ON and hold the phone so that the
microphone is as close to the drive belt as
possible (without touching the belt). Test the
belt as close to the center between the front
and rear sprocket for best readings. Pluck the
belt with your thumb or with a wrench so that
the belt vibrates like a guitar string. Check the
belt tension range and readjust the belt, if
necessary. Recommended belt tension range:
62 Hz to 82 Hz
11. Test ride motorcycle.
10-4 Adjust Drive Belt
Maintenance and Safety
10
12. Recheck the belt adjustment after the test ride
and readjust, if necessary.
Maintenance and Safety
Brake Maintenance Procedures 10-5
10
Brake Maintenance Procedures
Brake Bleeding Procedure (Front)
WARNING! Only use new brake fluid from and
airtight container. Fluid from open containers or
fluid previously used in the system will have
absorbed moisture, which will adversely affect
performance and must not be used.
WARNING! Brake fluid is highly toxic; keep
containers sealed and out of the reach of
children. If accidental consumption of brake fluid
is suspected, seek medical attention
immediately. If the brake fluid comes into
contact with the skin or eyes, rinse immediately
with plenty of water.
CAUTION: Brake fluid can damage plastic, as
well as painted and coated surfaces. Handle with
care and wipe up spills and wash the surfaces
immediately.
Tools Required:
8mm hex wrench
9mm hex wrench
Vacuum bleeder
Fluid Required:
DOT4 Brake Fluid
Bleeding
1. Fill the front master cylinder brake fluid
reservoir with DOT4 brake fluid. Keep the
reservoir full during this procedure.
CAUTION: Do not allow air to enter the
system during the bleeding procedure, or
the procedure will need to be repeated.
2. Open the front bleed screw. Tool: (9mm).
3. Slowly pull the brake lever toward the grip and
hold it until brake fluid flows out of the bleeder
and most of the air is gone. Tighten the
bleeder screw while holding the lever toward
the grip.
4. Repeat this sequence for the left and right
calipers until all the air is out of the system and
the lever is firm. Tool: (8mm).
10-6 Brake Maintenance Procedures
Maintenance and Safety
10
Brake Bleeding Procedure (Rear)
WARNING! Only use new brake fluid from and
airtight container. Fluid from open containers or
fluid previously used in the system will have
absorbed moisture, which will adversely affect
performance and must not be used.
WARNING! Brake fluid is highly toxic; keep
containers sealed and out of the reach of
children. If accidental consumption of brake fluid
is suspected, seek medical attention
immediately. If the brake fluid comes into
contact with the skin or eyes, rinse immediately
with plenty of water.
CAUTION: Brake fluid can damage plastic, as
well as painted and coated surfaces. Handle with
care and wipe up spills and wash the surfaces
immediately.
Tools Required:
9mm hex wrench
Vacuum bleeder
Fluid Required:
DOT4 Brake Fluid
Bleeding
1. Fill the rear master cylinder brake fluid
reservoir with DOT4 brake fluid. Keep the
reservoir full during this procedure.
CAUTION: Do not allow air to enter the
system during the bleeding procedure, or
the procedure will need to be repeated.
2. Open the rear caliper bleed screw (9mm).
3. Slowly press the brake lever down and hold it
until brake fluid flows out of the bleeder and
most of the air is gone. Tighten the bleeder
screw while holding the brake lever down.
4. Repeat this sequence until all the air is out of
the system and the lever is firm.
Maintenance and Safety
Brake Maintenance Procedures 10-7
10
Brake Bedding
Note: Bedding in new brake systems or new
pads is recommended to ensure proper brake
performance and maximize brake life. Proper
bedding improves brake pedal/lever feel and
reduces or eliminates brake squeal. Bedding
in the brakes is a process of depositing an
even layer of pad material on the surface of the
brake rotor.
CAUTION: With new brake systems or just new
pads, the first few braking applications will result
in very little braking power. Gently use the brakes
a few times at low speeds (<25 mph) to develop
proper braking friction.
Process
1. From 50 mph, apply the brakes firmly, but do
not lock up the tires or engage ABS. Slow
down to 10 mph. Do not come to a complete
stop as this can cause the pad material to
become imprinted on the rotor causing
vibration.
2. Gradually accelerate back up to 50 mph. This
will prevent the brake system from
overheating.
3. Repeat previous steps 15-20 times.
10-8 Key Programming
Maintenance and Safety
10
Key Programming
Key Programming
Items Required:
Yellow key: quantity 1
Black keys: quantity 1 or 2
Program
Programming Note: Pause for one second between
each key turn.
Note: Only two black keys can be programmed to
one motorcycle.
Note: If the yellow key is lost, it is not possible to get
a replacement yellow key using the key number.
Note: Each key switch has its own exclusive yellow
key. If the yellow key is lost, the entire key switch
must be replaced to get a replacement yellow key.
1. Insert the yellow key into the key switch.
2. Turn the yellow key to the ON position and the
to the OFF position. This takes motorcycle out
of programming mode.
3. Remove the yellow key.
4. Insert one black key.
5. Turn the black key to the ON position and then
to the OFF position.
6. Remove the first black key.
7. Insert the second black key.
Maintenance and Safety
Key Programming 10-9
10
8. Turn the second black key to the ON position.
9. Turn the second black key to the OFF position.
10. Remove the second black key.
11. Re-insert the yellow key.
12. Turn the yellow key to the ON position.
13. Turn the yellow key to the OFF position. This
removes the motorcycle from programming
mode.
10-10 Motor Commissioning
Maintenance and Safety
10
Motor Commiss ioning
Motor Commissioning
Items Required:
Laptop (with ZDU software)
CAN cable
Black key
Important Commissioning Tasks:
WARNING! The motorcycle must be on a
motorcycle stand with the rear tire raised off
the ground and you must stand clear of the
rear tire, rear wheel, and drive belt, because
the rear will automatically start to rotate at a
high rate of speed during the motor
commissioning process!
Raise rear tire off the ground by using a
motorcycle stand.
Perform commissioning within 30 seconds of
key turned to the ON position.
“Run Mode” is kickstand up and kill switch in
run position.
Green Check Engine Light on the dash must
be illuminated during the process.
Procedure
1. Use a motorcycle stand to raise the rear tire off
the ground.
WARNING! The motorcycle must be on a
motorcycle stand with the rear tire raised off
the ground and you must stand clear of the
rear tire, rear wheel, and drive belt, because
the rear will automatically start to rotate at a
high rate of speed during the motor
commissioning process!
2. Connect a laptop (with ZDU software loaded)
to the motorcycle’s OBDII diagnostic
connector with CAN cable.
3. Begin with the key to the OFF position.
4. Open the ZDU program.
5. Click on the “Motor Controller Interface” tab.
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Zero 2022-2023 SR S Service User manual

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