Common Modifications

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Procedures on this page are low-risk, OEM-supported, and widely desirable for everyday use.

Spare Onboard Charger Power Cables

The charging cord should have no higher gauge than 14AWG with a NEMA 5-15P (US) to IEC320 C13 output plug rated for 15A; the onboard charger draws 11-12A at 120V AC (and half the amps at ~220V). A shorter cable can be more efficient by offering less resistance. Any cable rated below this specification will heat up and deteriorate so would be unsafe.

For reasonably-priced replacements, Monoprice has options in a few lengths: Power Cords w/ 3 Conductor PC Power Connector.

Longer (25+ft) cables should be bought in a lower gauge (thicker wire) like 12AWG. Or, if 25+ft needs to be made from two cables, make sure that most of the run is a 12AWG cable and only use 14AWG for a short section at the end (3-6ft).

15 vs. 25 feet at 12 amps (max pull in the Zero manual) is a 0.76% vs.1.27% voltage drop over distance respectively. A single use socket (no other attached devices - as recommended in the Zero manual) should work. Even assuming max pull at 15 amps (120v breaker/socket) it is 0.95% vs. 1.58%; either way it is over 110v over the distance, which is normal for the residential circuit of that type.

Do not use a retractable extension cord reel! Unless it is completely extended, the cord will not dissipate heat properly.

12V Electrical System

Accessory Power

Zero S/DS/SR/DSR models have an accessory power circuit, ending in plugs under the tank plastics in front of the area reserved for the tank bin or power/charge tank, behind the front wheel. They can be accessed by hand without removing plastics but are easier with plastics removed. Both plugs are fed power from the same 10-amp circuit.

All 2013+ models have a Sumitomo power connector which is weather sealed. 2014+ models also include a standard SAE connector in the same area on the same circuit and fuse.

Connectorsabovebattery.jpg

The 12v system on a Zero is very fault tolerant. It operates at a very consistent 14 volts, which provides up to 140W of power available on the accessory circuit, and 300W total. Some owners have used increased size fuses such as 12.5 or 15 amp for even more accessory power.

The wattage pulled by the accessory power has a negligible, almost immeasurable affect on range. Even at the maximum 140 watt output over 2 hours of straight riding, the 12v accessories would use 0.28 kWh of the total capacity of the battery, which for a ride under 2 hours is about 2-2.5% of the total power available. For reference, a heated jacket at full power will typically draw 90W, greater than the stock headlamp at 60W. The impact on the battery is greater if making a very long, slow use of the battery (say, under 35mph for at least 4 hours).

Zero's 12v accessories will plug directly into the Sumitomo connector.

Eastern Beaver makes motorcycle 12V circuitry parts including Sumimoto connectors:

The SAE connector is more common for third party accessories and can be easily adapted to other plugs (such as coaxial for heated gear) very easily.

Patrick Truchon wrote up his 12V port enhancement:

  • dual USB adapter
  • He shows how he built a splitter and USB outlet into the plastic tank bin.
Accessing Ports on the S/DS/SR/DSR
Tools
  • Torx T45 wrench (MY2015+) or 5mm allen key (MY2013-2014) to remove the seat.
  • 3mm allen key wrench to remove plastics.
Steps
  1. Remove the seat.
  2. Remove the tank plastics.
    For the Power Tank, it is unclear how to access the relays forward.
  3. Tucked under the frame near the helmet lock, you will see a Sumimoto connector with a cap installed and a SAE 2-pin connector with some dielectric grease on the end.
Installing the Accessory Kit
  1. Loosen collet from accessory kit and set aside
    SDS12VACCESSORYSOCKETKIT14MY10-0750401 pnandremovekitcollet.jpg
  2. Remove rubber blank from bike dash.
    SDS12VACCESSORYSOCKETKIT14MY10-0750401 removerubberplugblank.jpg
    This is now an extra part you will not be needing while the accessory power kit is installed.
  3. Feed the wire assembly through the hole in dash and align the 12v socket key into the keyway of the hole in the dash.
    SDS12VACCESSORYSOCKETKIT14MY10-0750401 feedassyinhole.jpgSDS12VACCESSORYSOCKETKIT14MY10-0750401 alignassyinhole.jpg
    You may want to undo the right-hand turn signal light 2x 3mm mushroom socket head bolts, to get better access and visibility.
  4. Return collet over wire assembly and rotate to fasten the 12v socket into place.
    SDS12VACCESSORYSOCKETKIT14MY10-0750401 threadcollettoassy.jpg
    Take care not to pinch the turn signal wires.
  5. Route wires to left-hand side and into compartment.
    SDS12VACCESSORYSOCKETKIT14MY10-0750401 routeassywires.jpg
  6. Remove rubber protective boot from Sumitomo socket and connect to 12v accessory socket wiring Sumitomo plug.
    SDS12VACCESSORYSOCKETKIT14MY10-0750401 locatesumitomo.jpgSDS12VACCESSORYSOCKETKIT14MY10-0750401 connectsumitomo.jpg
  7. Button up everything. You are done!
Reference Video
AIKI Rob's Zero DSR usb accessory and helmet mods
FX/FXS

Installing a USB adapter for the SAE port on an FX Installing a USB adapter (post about the FX on a more general thread)

Heated Accessories

Heated handgrips and heated seats were offered from 2013-2014 but have since been discontinued. The handle bar changes in 2015 made the handgrips non-transferrable.

Aerostitch noted some interesting details while installing these heated grips:

New Circuits

How to tie into +12v and bypass the fuses

Instructions
  1. Remove the seat
    The fuse box will be under the left side of the Y-arm under the seat that connects the frame's tail to the crossmember around the battery.
  2. Remove the bolt on the left that holds the fuse box in place.
    This will allow the box to swing towards you and out from under the frame.
    On top of the fuse box are a bunch of blue connectors.
    They're the female side of spade connectors, covered by a rubber boot.
    The male side comes out of the top of the fuse box.
  3. Pick a connector and pull the blue boot straight up and off.
    Underneath, you'll see the male connector, with a small hole in the end.
  4. Connect your circuit's wire.
    If you're daring, you can try to thread your connector wire through this hole.
    You might instead strip off an inch or so of the wire from the horn, make a loop, and drape it around the male connector.
  5. Twist, wrap, tape or solder your loop once it's around the connector so it's reasonably tight.
  6. Replace the female connector in the blue boot back onto the male connector.
    Push hard so it goes all the way down and presses the wire loop down against the top of the fuse box.
  7. Test your new circuit/load.
  8. Apply electrical tape as you see fit.
  9. Replace the left bolt in the fuse box.
  10. Replace the seat.
  11. Test your new circuit/load again.

Horn

Install reports
One installation with pictures, for a Screaming Banshee: Air horn on the DSR 2016
One simpler install of Hella Supertones: Horn mod
Stebel Nautilus Horn Connection Question
Other discussions
Has anyone replaced their horn with something people will actually hear?

Frame

Plastics/Bodywork

Swap Colors

Zero S/DS/SR/DSR plastics are all interchangeable, aside from DS/DSR plastics being a different shape around the thighs (to allow for an easy transition to/from a standing position).

Zero doesn't make this clear on their website, but you can order any plastics that they offer through the dealer network - so, any color that has been offered for a model-year is probably in stock and can be shipped. The default tank plastics are the cheapest ($100 for a tank), the Power Tank plastics are slightly more expensive, and Charge Tank plastics are closer to a few hundred dollars. Tank plastics exchange is very quick, along with the front fender. The tail plastics can be bought with the tank plastics but the tail plastics swap process is more involved.

The front fender plastics only apply to S/SR/FXS models - DS/DSR/FX models have a 19-inch front wheel which does not accommodate it.

Splitting Up Tank Plastics

The centerpiece of the tank plastics is plastic welded with retaining lock washers through/around holes in the side pieces. They can be detached either with very focused heat application (a soldering iron works; a hot air gun will be less precise) or just taking a pair of pliers and carefully twisting each weld back and forth until it deteriorates and can be broken off. The centerpiece you remove will no longer be joinable the same way, but you can take a fresh one and make plastic welds to join it to the side pieces.

Applying Vinyl

Get a professional to do it if you're not very patient, unless you have experience working vinyl. The compound curves of the tank plastics are not too easy to wrap with.

Plastidip

Painting

Luggage Rack Installation

OEM Top Rack

Zero OEM Top Box Rack Kit 10-06921 $150 USD on Zero website or $200 USD in 2016 dealer parts catalog.

Installation
Adapted from this forum thread: Zero top rack and GIVI case install.
Manifest
TOPRACKKIT10-0692107 label.jpgTOPRACKKIT10-0692107 contents.jpg
This process takes about 15 minutes and is very easy.
  1. Remove the seat.
  2. Install the rubber cap on the tab under the plate.
    TOPRACKKIT10-0692107 installbumpercap.jpg
  3. Pull the seat off and fit the rack over the bike frame.
    Set the tab on the end of the tail plastics.
    TOPRACKKIT10-0692107 alignholes.jpg
  4. Install two 4mm socket head bolts through the frame holes.
    Use Blue Loctite thread-locker to keep them firmly in place.
    Torque the bolts to 6 ft-lb.
    TOPRACKKIT10-0692107 clampoptional.jpgTOPRACKKIT10-0692107 securefourmm.jpg
  5. Replace the seat and tighten the T-45 Torx bolts (MY2015+) or 5mm socket head bolts (MY2013/MY2014; extras are provided) back in through the rear rack frame.
    Torque the bolts to 16 ft-lb.
    TOPRACKKIT10-0692107 complete.jpg
Loading
Once the top rack is installed, the bolts holding the seat on are load-bearing.
If the tab under the tail rack does not directly contact the tail plastics while unloaded, going over bumps at speed can wear on the mounting bolts over time and might break them. Fixing a cushioned (rubbery) spacer underneath it will dampen this dynamic load.
If you need to remove the seat, take off the top case or remove any heavy contents to avoid stressing the rack over time.
Side racks (both OEM and Happy Trails) are both installed in a way that somewhat stabilize the dynamic load on the top rack, but it's still fundamentally vulnerable to a lever effect on the bolts holding it down.
Plate Adapter Compatibility
The Givi M5 adapter does not fit the Zero factory rack without having made some hardware modifications to the plate.
Non-Givi adapters will likely require similar customizations unless they are made for the same fastener geometry.
The plate is made of steel so make sure to coat any exposed surfaces from drilling with paint etc to minimize corrosion.

Givi Monokey adapter plate E251

  1. To install any Givi box get the universal Monokey (part E251) top case adapter and mount it using four 5mm socket head bolts and 10mm locknuts with clamps that will fit almost any rack.
    GIVIE251 boxed.jpgGIVIE251 unboxed.jpgGIVIE251 contents.jpg
  2. The clamps are not needed for the Zero OEM top rack, just the square washers.
    GIVIE251 orientation.jpgGIVIE251 inset.jpgGIVIE251 fastened.jpg
    There's some leeway in how far forward or back to place the adapter on the plate.
    It helps to use some Blue Loctite threadlocker and corrosion inhibitor on the screws and bolts used for the adapter, since these get heavily weathered from the wheel below and then the moisture sticks around.
    It helps to use the clamps so that they alternate direction and hold the adapter firmly in the lateral and forward-to-back directions.
  3. The cover plate includes four PH1 screws and also two much smaller PH1 screws. The smaller screws seem to be free spinning and the threads do not engage when installed, so a work-around is to stuff some plastic bag material or other filler into the plastic column underneath in the mounting plate where each fastener should attach to. This seems like an oversight by Givi and it is not mentioned anywhere in the instruction sheet.
    GIVIE251 coverplate.jpg

OEM Side Racks

This process is a little more complicated. The rack kit comes with reasonably good instructions so for now this only addresses the complications to be aware of:

  • The lower mounts are a pair of brackets that bolt to the inside of the frame where the passenger pegs are installed.
    There is very little clearance in this area, because it faces the motor.
    A telescoping ratcheting wrench or a small open ended socket wrench will be necessary to tighten the bolts.
    Removing the lower side plastics yields some clearance from the front for working with these bolts using a flat wrench.
    Do not fully tighten these bracket mounts until the entire assembly is in place, and then tighten them evenly.
  • The assembly that holds the turn signals will be projected rearwards to clear the cases.
    This requires some work with the wiring to re-run them through the new bracket and is slightly awkward but can be finished with a little patience.
  • The rubber bumpers needed to dampen side case vibration might fall out if you ride without the cases.
    Maybe apply a little rubber glue or such to hold them in place if this is a concern.

OEM Crash Bars

The police models (SP/DSP) include some broad crash bars. The width is about 7 inches on the top half, but they taper to the bottom so lean angle is not affected (see photos).

Zero does not list all drop bar options on their website, but dealers can request them by part number.

MY2016DSR dropbarsnonpolice partscontents.jpg MY2016DSR dropbarsnonpolice pnXX.jpgMY2016DSR dropbarsnonpolice pn03.jpg

Options
Part Number Name Price
Police Drop Bars
Includes mounts for siren and lights
$450
10-08062XX Dual Sport Drop Bars $250
10-0806203 Frame Protection Bar Accessories Kit, Non-Police, 13-16 MY
Includes 20-07053-01 skid plate 1PCS PO10224
10-08028 Zero FX Drop Bars $175
Install Variations
MY 15+, the frame is predrilled to mount them, but the lower mount varies slightly per model year and may require modification to the belly pan.
MY 14, the belly pan required drilling, and use of Rivnuts. Zero was not cooperative in acquiring, but parts from a downconverted SP were found.
Installation
Ensure you have all the parts:
  1. Two side bars, one per side.
  2. One crossmember piece.
  3. Two shoulder brackets, one per side.
  4. Two heavy bolts for joining the crossmember to the bars through the shoulder brackets.
  5. Shoulder mount bolts: 4 M5 bolts of 20mm overall length with a 5mm long shoulder that is 6mm diameter.
  6. Lower mount bolts: 4 M6 bolts of perhaps 15mm length.
Crash-bars.jpg
Tools
  • Allen wrenches for M5 and M6 bolts (depends on what is chosen).
  • Wrench for hex head M10x70mm stay bolts.
Steps
  1. (Pre-2015) Create frame holes for the upper and lower pair of bolts on each side of the frame.
    Installing rivet nuts as Zero started doing for 2015+ frames is a good practice.
    Zero chose M5 rivet nuts with a 5mm deep, 6mm diameter shoulder space above it. M6 might be a more robust choice.
    One pair goes into the rear/top of the angled bar before it comes to the frame shoulder, 30mm between hole centers.
    One pair goes into the side of the belly pan / bash plate. The DS' metal bash plate is more suitable for this.
  2. (2015+) Remove the plastic threaded cover inserts in the pair of holes on each side of the bash plate.
    You may need to remove the plate to rotate them out from the inside. Remount after.
  3. Install the small shoulder brackets on each side of the frame shoulder area, using the pair of holes to anchor the brackets.
    Do not tighten the bolts until all pieces are in place.
  4. Detach the horn and the bracket holding it and set it aside.
    You may relocate it closer into the front of the frame or move it to the side (no recommendation here).
    For the DS/DSR, the front fender will interfere with this and the next step. Detach it and set it aside.
  5. Take the cross member and place it between shoulder brackets.
    It has a flat edge which should rest against the front of the diagonal frame bars.
    The shoulder brackets might be under tension once the bar is in between the brackets. This is normal.
    Crash-bar-crossmember.jpg
    Crash-bar-shoulder-mount.jpg
  6. Hold the cross member in place by running the M10x70mm bolts through the main holes.
  7. Attach each crash guard bar to the M10 bolt and fasten the lower end to the side of the bash plate using a pair of bolts.
    Tighten the bolts in concert.
  8. Once both crash guard bars are fastened tightly, check and tighten the bolts holding the small shoulder brackets.
    For the DS/DSR, replace the front fender if you removed it before.


Notes for 2016 DSR: The skidplate included in the 10-08062XX kit is redundant it is the exact same one already on a factory new DSR, with plastic plugs in the threaded inserts that need removed.

Helmet Lock Removal

Steps (MY2016 DSR)

  1. Remove the front fender
  2. Remove the cowl
  3. Loosen the bolt holding the ABS module in place from underneath, located above where the front fender was. The ABS module appears to be mounted on two or three of these bolts with rubber vibration isolation around the bolts. When this bottom bolt is free the ABS module can be rotated from within the under-cowl area for better access to the innards.
    MY2016DSR helmetlock absrotated.jpg
  4. Drop the flasher relay and accessory power plugs out of the way and, using a mirror, locate the bolt holding the helmet lock in place.
    MY2016DSR helmetlock mirrorview.jpg
  5. Loosen the bolts holding the helmet lock in place. The left one is more easily accessible. Clearances for the right bolt are very tight and it may not be possible to rotate any tool to loosen the right bolt. After removing the left bolt, it can be possible to loosen the right bolt by holding the right bolt in place and rotating the helmet lock itself.
    CAUTION: the left side bolt will have a ground strap ring and bite washer attached, take extra care DO NOT lose these.
    MY2016DSR helmetlock groundstrapbolt.jpgMY2016DSR helmetlock mirrortool.jpg
  6. (Optional) Chargetank Bracket Installation
  7. Reinstall the bottom bolt for the ABS unit bottom bolt, cowl, and front fender.
  8. (Advanced) Relocate the helmet lock

Chargetank Inlet Bracket

Bracket p/n 12-08047XX (formerly p/n 12-0804713) special order $106 USD

MY2016DSR chargetankhwinletbracketkit inventorylabel1216.jpgMY2016DSR chargetankhwinletbracketkit inventorylabelold.jpg
MY2016DSR chargetankhwinletbracketkit open1.jpgMY2016DSR chargetankhwinletbracketkit open2.jpgMY2016DSR chargetankhwinletbracketkit open3.jpg
MY2016DSR chargetankhwinletbracketkit contentsbags.jpg
MY2016DSR chargetankhwinletbracketkit contentslayout1.jpgMY2016DSR chargetankhwinletbracketkit contentslayout2.jpg

Steps (Used MY2016 DSR)

  1. Remove helmet lock
  2. Thread ground strap onto studded bracket and reinstall through frame. Suggest to use a short section of painters masking tape stuck around the thread of the studs to itself like a "flag" to keep the ground strap secure in its position until the studded bracket can be fully seated to where the helmet lock used to be secured; the "flag" can be pulled up through the bolt holes in the frame and removed when ready.
    FIXME: There is an alternative way to secure the ground strap which is easier and recommended by the OEM.
    MY2016DSR chargetankbracket groundstrapbracket.jpg
  3.  ?? Take a guess. There's a bag of parts. FIXME: Describe what all the parts are and how they should be installed.
    MY2016DSR chargetankbracket scv2badinletdetail.jpgMY2016DSR chargetankbracket scv2badinletview.jpg
  4. With the inlet bracket installed, two of the top mounting holes on the bracket are meant to be fastened through the chargetank cowl and into the inlet bracket. You only need to mount the J1772 inlet itself to the bracket using the rear top two locations. The front top two locations will be further secured when the chargetank cowl is mounted.

Handlebars and Controls

Third-Party Mirrors

Any aftermarket "stalk" mirrors or mirror extenders with the Yamaha/Ducati-style left-hand-threaded left mirror will fit.

The bolt/thread specification appears to be M10 with x 1.25 pitch, left-hand-threaded on the left side.

Bar-End Mirrors

2013-2014
7/8" bar-end mirrors are generally compatible, including offset and fold-away models, but the rubber grips must be cut to give access for installation.
2015-2016
7/8" bar-end mirrors are likewise compatible. The bar ends are sealed with a round nub at the end. Pull the nubs off with pliers to remove. Installation is straightforward and doesn't deviate from the manufacturer's instructions.
2016 handlebar end plug


Owners have reported that bar-end mirrors by Constructors Racing Group (CRG), Ferrara and Astra Depot work.

Astra Depot bar end mirrors


With Cycra Hand Guards
Mirrors of this type (Cheap Amazon Mirrors) work very well by putting them outboard of the hand guards and securing with a longer screw (M8-1.25 x 70mm, SS philips head from Home Depot will do).
Bar End Mirror with Hand Guard


Bar Risers

Zero S/DS/SR/DSR models have 1⅛" diameter (28mm), 2" length clamps which are common dimensions so can be supported by most vendors.

Clip-On Handlebars

Nothing confirmed yet; one hack is to rotate the handlebars (or rotate a compatible replacement set) to get the desired height/angle.

Disable ABS

Options for disabling ABS, particularly for offroading with downhill runs:

  • Per the official manual, you can disable ABS once per active session.
    1. Place the kickstand down.
    2. Turn off the Motor Stop switch.
    3. Key the bike on.
    4. On the dash, press and hold both the ADJ and MODE buttons simultaneously.
      Wait about 4 seconds until the ABS light starts flashing slowly, then release both.
    5. Restore by getting the contactor to open, by keying the bike off without being plugged in.
  • Remove power to the ABS pump (works basically permanently).
    • Remove the ABS pump fuse under the seat.
    • Disconnect the power connector to the pump itself.
      Cover the connector to prevent electrical problems, and tape it to prevent wear from shaking while riding.

Brake Lever

A 2014 Zero FX brake lever replacement was found on Ebay. It seems that the Suzuki DR350 has a compatible shape or even the same system as the front 13-14 brakes:

Brake Lever Regens before Pad Contact

This is a recipe to allow better regen and coasting control on a Zero.

Goal
While using Custom Mode, touch the brake lever gently to get the Custom max regen brake regen level without using the brake pads.
This exercises more control over when to coast and when to slow down, particularly when using the economizing hack of 0% Custom max regen and 100% Custom max regen brake.
Mechanism
The brake light switch on the side of the right hand switch assembly also activates the Custom max regen brake regen level.
  • The brake lever at rest normally presses it down (i.e., when you're not squeezing the lever to stop).
  • Squeezing the lever increases the distance between it and the switch and the switch gets released to activate the brake light.
The brake lever depresses the hydraulic cylinder from the front via a push pin, which has an adjustment knob to change the brake lever distance.
  • See the Front Brake Lever Adjuster section of the Official Owners Manual for a basic diagram and description.
Adjust the front brake lever to release the brake light switch before the push pin contacts the hydraulic actuating cylinder.
Risk/Warning
  • The pressure from the master cylinder is what supports the lever to keep the brake light switch pressed down.
  • So, when shortening the push pin, the lever becomes more wobbly and more likely to accidentally trigger the brake light switch due to vibrations or wind.
    See Lurching/jerking issue, as if pumping brake.
  • Also, the brake lever needs to be squeezed closer to the throttle.
    Don't shorten the push pin so much that the lever contacts the throttle too easily, limiting full braking power.
    With good brakes that should not happen, but if you have air in the system your front brake might be squishier than normal and you might not be able to pressurize it fully, thus you may not stop as fast as it would be possible otherwise.
If your disk brake doesn't engage immediately upon contact with the hydraulic actuating cylinder, you can set the regenerative brake activation immediately after the lever contacts the cylinder.
Other preventative measures:
  • Using a longer or stronger spring.
  • Placing something in the spring slot to (slightly) shorten it.
  • Increase the friction between the brake lever and its seat by coating the contact areas with paint, etc.
Tools
(Optional) 7/64 wrench for the brake lever adjustment knob.
Small flat-blade screwdriver for the brake light switch set screw.
(Optional) Light thread-lock compound (Blue Loctite, say).
Procedure
  1. Adjust the brake lever adjustment knob to engage the brake as loose as seems comfortable.
  2. Then, adjust the set screw to activate the brake light switch earlier in the engagement pull.
  3. Test ride to calibrate this.
    • Ensure it is safe to engage and release.
    • Ensure it is not difficult to fully engage the brake pads themselves.
  4. (Optional) use thread-lock compound to ensure the set screws stay where desired.

See Re: Solved: Full regen instead of 50% for the thought process framing this documentation.

See also the third-party brake light modifications that help alert drivers when using regen.

Handguards

OEM Handguards

Products
OEM Cycra handguards for 2013-2014
OEM Cycra handguards for 2015+
Details
Zero provides versions of Cycra handguards customized to fit around the Zero brake lever geometry.
The brake lever customization is why the part numbers vary from 2013-2014 models and 2015+ models - the front brake system and reservoir differ.
Fitment for DS/DSR/FX/FXR are identical. S/SR fitment is likely.
Cycra equivalent parts:
Inventory
Box1 invlabel 10-0806001 SDS HAND GUARDS BLACK.jpgBox1 open 10-0806001 SDS HAND GUARDS BLACK.jpgBox1 reverse 10-0806001 SDS HAND GUARDS BLACK.jpg
Cap Screw Corrosion
Both Cycra and Zero's customized handguard kits come with socket cap bolts that corrode too easily.
Replace them with equivalent stainless socket cap screws for better weather resistance.
Example replacements: M5X25 Socket Head Cap Screw FT Stainless Steel A2 DIN 912
Installation
MY2016 DSR used for photos.
See also Zero FX Handguard Installation
Tools
PH2 bit, 6mm hex bit, 13mm socket, 4mm hex bit, channel locks pliers (optional).
Contents
(Ref kit 10-0806001 SDS HAND GUARDS BLACK)
Smaller left/right plastics, Self-tapping PH2 fasteners approx 12mm length (4 qty), thick metal washer, thin metal washer, handlebar mounting inserts (2 qty), alternative inserts for larger I.D handlebar tube (2 qty).
SDSHANDGUARDSBLACK10-0806001 partsbag1contents.jpg
Larger left/right plastics, mounting brackets, metal washers (6 qty), self-tapping PH2 fasteners approx 12mm length (6 qty).
SDSHANDGUARDSBLACK10-0806001 partsbag2contents.jpg
Handlebar left/right mounting clamps
SDSHANDGUARDSBLACK10-0806001 partsbag3contents.jpg
Steps
  1. For left and right assemblies each, align the plastic end cover with matching bracket.
  2. Affix with self-tapping PH2 (approx 12mm length) fasteners
    Use moderate pressure and be sure to drive the screw straight into the bracket.
    This can be tricky because the plastics do not conform exactly to the metal bracket.
    SDSHANDGUARDSBLACK10-0806001 partsbag1assembly.jpg
    Note: It seems easier to start with the inside corner fastener first and then working outside to the end of the bracket.
  3. For each of the six PH2 self-tapping screws, insert one screw through washer then plastic hand guard and into hole on aluminum bracket.
    SDSHANDGUARDSBLACK10-0806001 partsbag2assembly.jpg
    Note: Again it seems easier to start with the fastener on the inside corner first, and then follow with the two fasteners on the straight run towards the end of the bracket.
  4. Remove 6mm hex bit bolts from handlebar mounting insert hardware as shipped.
    Insert bolt into end of assembled guard bracket, then a washer (thick for throttle / right side and thin for non-throttle / left side), an appropriate expansion insert for the diameter of your handlebar tube, and a cone nut.
    • Do not tighten too much, but be sure this is snug fitting so that friction allows the 6mm bolt to be tightened without supporting the pieces that will be free-standing in the tube.
    • If this is too lose, you would insert the assembly into the tube and not be able to tighten.
    • If it is too tight, the cone nut will expand the mounting insert and it won't fit into the tube.
    SDSHANDGUARDSBLACK10-0806001 preparehandlebarinserts.jpg
    Note: The washers look to have a bit of a cone shape. Best guess is to point the narrower end towards the head of the bolt.
  5. Using a channel locks pliers or maybe just pull with your hands, remove plastic plugs from handlebar ends.
    SDSHANDGUARDSBLACK10-0806001 removehandlebarplugs.jpg
  6. Insert the appropriate handlebar guard assembly that has been prepared.
    SDSHANDGUARDSBLACK10-0806001 inserthandlebarguardassembly.jpg
  7. While holding the handlebar guard assembly true and flush with the end of the handlebar, tighten the 6mm hex bit bolt until the assembly is secure.
    This took a bit of wrenching and not sure about torque specifications so be careful there;
    tighten until the assembly doesn't wiggle around too much and is positioned where you want the outside end of it to be for the install.
    SDSHANDGUARDSBLACK10-0806001 tightenhandlebarguardassembly.jpg
  8. Lay out the handlebar clamp assembly: 4mm hex bit bolts (4 qty) in tapered cap end bracket, tapered bracket clamp, bushing, 13mm hex socket bolt. R is right side and L is left side.
    The manufacturer imprint should read upside-down (this is obvious when you notice the taper of the clamp and how the Zero handlebars are a wider diameter at the fork clamps and tapering down to a smaller diameter outward towards the handlebar grips).
    Set aside the bushing and 13mm hex socket bolt for the final step.
    SDSHANDGUARDSBLACK10-0806001 layouthandlebarclampassembly.jpg
  9. Install the handlebar clamp bracket to the handlebar tube and tighten the 4mm hex bit bolts.
    Use a 16mm socket for reference of the gap between the fork handlebar clamps and the handlebar guard clamps.
    Don't worry about trying to make the open threaded end line up with the slot in the handlebar assembly, the assembly will be bent into place to meet the clamp later.
    Try to install the clamp so it is at a reasonable angle (for this install it kind of points towards the middle of the height of the dashboard display).
    SDSHANDGUARDSBLACK10-0806001 clampinstallreferencewidth.jpgSDSHANDGUARDSBLACK10-0806001 clampinstallangle.jpgSDSHANDGUARDSBLACK10-0806001 clampinstalltubedone.jpg
  10. Grab that bushing and 13mm hex socket bolt from earlier.
    Install the bolt through slot in the handlebar guard assembly, then the bushing, and bend the whole contraption into place so you can get threaded into the clamp bracket.
    Note: To avoid cross-threading the clamp bracket, take your time and use your hands to get it started.
    Note: For this install, it was attempted with the bushing to the inside and to the outside of the two metal brackets versus the head of the bolt; Bushing sandwiched between the two metal brackets seems to be the best but you may want to throw a washer on the head of the bolt and perhaps some Loctite on the threads. (Needs to be verified against the original instructions if anyone has these?)
    SDSHANDGUARDSBLACK10-0806001 clampboltbushingdetail.jpgSDSHANDGUARDSBLACK10-0806001 clampinstalldone.jpg
  11. Done! Tighten everything again to your liking.
Left-over parts
Plastic handlebar caps, alternative handlebar inserts.

Barkbuster

Barkbuster Storm Handguards
These use bar-end mounts only, avoiding handlebar modifications.
Revzilla has them at a good price. BikeWorld review
Confirmed fit on a 2017 Zero SR with stock handlebars.
Barkbuster Blizzard Universal Handguards
Provides additional coverage for cold/wet weather.
The Blizzard handguards fasten directly over top the Storms for less defection at speed while keeping your hands warmer.

16 - 1 (4).jpg

Handgrips

Zero handlebars are 7/8" near the controls and grips, so any handgrips for that size should work.

Forum thread on grip size and options

Crampbusters are a very good and cheap solution ($10 USD) for grip ergonomics if the existing grips are acceptable but your hands get tired in traffic or on the highway.

Handlebars

Zero handlebars are 1 1/8" through the risers, so many handlebars will be suitable to adapt (e.g. ProTaper).

Confirmed fit
ProTaper EVO Adventure Bars
Installation
Remove the handlebar clamps.
Remove the controls from the stock bars.
Take measurements from the stock handlebars for what hole pattern the controls mount to.
You will have to drill one hole to mount the throttle and potentially three holes for the switch gear.
Install the controls over the new set of bars.
Mount the handlebars with the clamps. Make sure to use thread-locker fluid to hold them in place once the positioning is verified.

Throttle Lock

Benefits
Generally, a throttle lock is a cheap way to get a basic cruise control mechanism.
Electric motorcycles never stall and have a broad torque curve, so throttle locks are very effective despite their simplicity.
A Zero with a cruise control will speed up and slow down to maintain an overall constant power/torque output, which makes range and power consumption much more predictable.
5% range gain can be had just from removing wrist adjustments from the throttle.
Holding a throttle steady is a source of fatigue, so a lock helps minimize that.
Hazards
Any traction loss with an electric motor while using a throttle lock is dangerous.
The rear wheel could spin up rapidly, faster than one's reaction time.
This wastes precious seconds when the bike could lose stability and go down, when the throttle should be immediately eased off and balance recentered.
For this reason, using a throttle lock should be limited to highway stretches with good visibility and no traction risks.
Make sure, otherwise, that you can release the throttle lock very quickly and easily to avoid an emergency.
Tested Options
  • Brian Rice found and installed an Atlas throttle lock which seems to suit the Zero well, particularly because it avoids taking up valuable handgrip space and has a generic fitment. The Magura throttle's space for the Atlas to fit into is extremely narrow, though.
    Atlas nicely posted a comparison chart illustrating how different throttle lock mechanism approaches have tradeoffs.
  • Go Cruise throttle lock is generic and easy to use, but does take up space on the inside of the throttle grip, which can make the throttle and mode switches harder to use.
  • Kaoko throttle locks operate as bar ends with a dial and are good if the bike fit is confirmed, which Zero does not have.

Cruise Control

Not available yet; see Crampbusters or Throttle Locks above.

Windscreen

OEM options
Zero OEM Touring Screen 10-08058 MY2016 S, SR, DS, DSR $250.00

OEM Touring Screen

Installation

Notes
Used a MY2016 DSR
OEM Screens are from MRA; most MRA screens for naked bikes have the same hardware type, so these instructions apply to the commuter screen as well, aside from the spoiler.
Tools (common to many MRA mounts' hardware)
  • 6mm Allen key wrench for the handlebar clamp bolts and replacements.
  • 3mm Allen key wrench for the screen mounts.
  • (Optional) flat blade screwdriver to set spoiler adjustment tension/firmness.
Contents of kit (TOURING SCREEN 10-08058 $250 usd)
TOURINGSCREEN10-08058 parts1contents.jpg
  • Windscreen assembly, plastic edge piping trim and two metal clips.
TOURINGSCREEN10-08058 parts2package.jpgTOURINGSCREEN10-08058 parts2contents.jpg
  • A lot of these things are shrink wrapped to a card.
Steps
  1. Assemble ball socket windscreen things to be tensioned by nuts and socket head bolts
    TOURINGSCREEN10-08058 ballmountnuts.jpgTOURINGSCREEN10-08058 ballmountbolts.jpg
  2. Orient ball mount assemblies and slide on handlebar mounting brackets
    TOURINGSCREEN10-08058 orienthandlebarbrackets.jpg
  3. Prepare windscreen through-mount pieces and affix to windscreen
    TOURINGSCREEN10-08058 windscreenthroughmountnut.jpgTOURINGSCREEN10-08058 windscreenthroughmountbolt.jpg
  4. Mount to handlebars using provided bolts to replace the top stock handlebar clamp bolts. Torque per the owner's manual.
    TOURINGSCREEN10-08058 handlebarbolts.jpg
  5. Add piping
    Begin with one end
    TOURINGSCREEN10-08058 pipingstart.jpg
    Add a clamp
    TOURINGSCREEN10-08058 pipingfinaltop.jpg
    Trim to length and add the other clamp. If enough is left over you could attach some to the bottom.
    TOURINGSCREEN10-08058 pipingfinalbottom.jpg
Left-over parts
  • Handlebar clamp bolts
  • Piping scrap.

Lighting

Headlamps

The entire headlamp may be replaced with some work.

Front view of Zero SR 2014 with new LED headlamp

The picture shows the TruckLite 7" LED Headlight.

It is necessary to replace or remove the existing Zero headlamp housing. This also means adding another possibility to mount the new headlamp.

Side view of Zero SR 2014 showing the headlamp bracket

In this case, as shown in the picture, I chose the Highsider headlamp bracket set Z-STYLE.

Headlamp Housing
You will also need a cover/encasing for the 7" headlamp.
This is what I did: I bought a cheap 7" British Style Cafe Racer Flat Black Headlight and replaced the old lamp with the LED.
Details of the remaining bracket holding the dashboard in place

I only removed some parts of the original bracket, because it also holds the dashboard in place.

With changes to the mounting bracket or some DIY, it should be easily possible to mount the LED headlamp higher to provide better coverage of the innards.

Pro tip: don't enter "innards" to google's image search.

For the final adjustments, add a windscreen for round headlights.

Headlamp Products

Headlamp
TruckLite 7" LED Headlight (SKU 27270C)
TruckLite 7" LED Headlight (SKU 27270C) on Amazon
Headlamp Housing
7" British Style Cafe Racer Flat Black Headlight
7" Headlight (DE)
"motorcycle headlight housing" Google search
Brackets
Highsider headlamp bracket set Z-STYLE

FX/FXS Specific

Chain Kit

Motivation
Chain vs belt comparison
Solution
OEM chain kit for FX
Install
OEM install instructions posted

FX Dual to Single Battery

If you want to use your dual brick FX/FXS with a single battery, you need to place a special dummy plug in place of the missing battery to ride.

Apparently the FX/FXS are delivered with this plug zip-tied under the front of the seat.

Ref. http://electricmotorcycleforum.com/boards/index.php?topic=6090.0

FXS battery dummy plug 1489298032899-1485253032.jpg