Zero Aftermarket

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General Information

Twisted Throttle has some Zero-specific and Zero-fit-suitable product listings.

They resell R&G products for the North American market:

Otherwise, they list waterproof DrySpec soft bags and tires that fit.

Battery Upgrades

OEM Power Tank

The Power Tank by Zero is the only available battery upgrade that is officially supported or has a straightforward path to install (dealer-only). It's equivalent to a single Power Pack battery for a Zero FX/FXS, and has its own internal BMS.

The current version adds 2.8kWh to the main pack, recently available as 3.3kWh to match the latest Power Pack capacity. Only one Power Tank may be installed per vehicle, and it is not set up for disconnect without dealership involvement.

Part number 24-08153 TANK BODYWORK ASSEMBLY CHARGETANK $300 MSRP.

Part number 24-08175-1XX DSR TANK ASSEMBLY BLACK $? MSRP.

Part number 24-08177-1XX DSR POWER TANK ASSEMBLY BLACK $125 MSRP.

It fits in the tank area for 2014+ Zero models of S/DS/SR/DSR. The 2013 models do not have an interconnect harness capable of accommodating it, much like their accessory charging circuit is lower capacity.

Dimensions
9.5 x 7.5 x 9.75in (HxWxL)
Weight
45lbs.
Troubleshooting
Early installations (2014) of the Power Tank had issues where the Power Tank's capacity would not count towards the bike's capacity, or the bike might shut down.
General consensus appears to be that charging a bike with the Power Tank (prior to some BMS firmware revision) could cause a self-protective disconnection due to imbalances between the Power Tank and the main Power Pack.
While this shouldn't happen with 2015+ Power Tanks, they can still have issues during or after installation if the Power Tank's charge state is not matched / balanced with the main Power Pack.
Installation

The Power Tank is placed in the cradle on 2014+ S-platform frames under the tank plastics.

There are 2 J-bolts attached to a retaining corner bracket that hold the Power Tank diagonally in place, anchored by two pre-drilled holes in the frame in the forward area of the cradle along the sides.

These holes typically are covered by cable runs, and can be found by moving them aside.

A cable harness attaches to the Power Tank's output port and hooks into the bike's main systems to communicate with the MBB, and also runs to the B+ and B- terminals on the controller to deliver power to the motor.

Only connect or disconnect this cable while the main contactor is open and the motorcycle is fully de-energized.

Wait a full 10 minutes to be absolutely sure that components have discharged fully, but 2 minutes is typically safe.
Confirm this with a DC voltmeter.
Operation

The Power Tank has its own BMS and contactor and coordinates with other bike systems via the MBB.

The contactor limits are presumably the same as for the main Power Pack contactor limits, except that the current/power input limit would be ¼ of the Power Pack.

The Ah rating of the Power Tank should be displayed on it just to understand what the current basis for 1C is.

Power tank-left.JPG Power tank-right.JPG Power tank-center.JPG

Chargers

Level 1 AC

The following chargers can handle 110V or 220V AC at common frequencies, but have individual power ratings that fit the common NEMA 5-15 North American outlet plug (typically 15A at 110V but it's safest to draw 1.3kW or less).

OEM Quick Charger

Zero sells a custom version of the Delta-Q QuiQ Charger for the Zero battery pack.

Attributes
Only 1kW per unit.
Handles 110V or 220V and varying AC frequencies.
Lightweight; easily fits Zero's Givi E21 side cases.
Can be combined with other Quick Chargers for up to 4kW additional charging.
Ruggedized (IP66 rating).
Plugs into the Zero accessory charging port.
Maintains the bike in charging mode even when keyed off.
Can be combined for up to 4 Quick Chargers / 4kW.

Delta-Q QuiQ Charger

This is the generic version of Zero's Quick Charger, and is not usable as sold.

It would require programming to work with the Zero, including the enable signal.
The output voltage is fixed when bought, and cannot be adjusted; the highest is 96V, not directly usable for the Zero battery pack.

GreenWattPower

This is Zero's onboard charger for model years 2014 onwards. It delivers 1.3kW on 110V AC and delivers the same output if connected to 220V AC.

It's a CC-CV mode charger that has a CAN bus connection for vehicle integration.

See their 1200 Watt EVC Product Page.

Level 2 AC

All of the Level 2 AC options so far seem to be single-phase oriented. There's discussion of Mennekes adapters but it's unclear which chargers (likely only the Dignow SuperCharger) could draw additional power from those stations.

Adapter Cord

The onboard charger will accept 208-240V AC but still charge at a 1.3kW. Using a splitter between the onboard charger and other Quick Chargers or the Elcon is a common configuration.

OEM
SAE J1772 Charging Adaptor is just the J1772 to C14 cable adapter cord, at $300.
SAE J1772 Charging Socket Kit for 2013 Zero models mounts the connector in front of the left frame stanchion next to the onboard charger inlet, at $500.
After 2013, the frame shape there is slightly different and would require a different fitment.
TusconEV
TucsonEV makes plugs, inlets, wires, and cords for J1772.
They offer a specific J1772 To Zero Adapter product to connect to the onboard charger and a (preconfigured) number of Delta-Q QuiQ chargers officially supported by Zero (basically splits into 1-3 C14 plugs).
It's cheaper than Zero's cord, and offers a splitter option to power one or two Delta-Q QuiQ chargers in parallel with the onboard charger, up to 30A theoretically.

OEM Charge Tank

The most convenient charging option is the OEM-supported Charge Tank for 2015 models onward.

It's more convenient than an Elcon 2500, but for subtle reasons seems to be slightly less compatible with a range of charging stations (see the User Guide).

Power Level
Provides 2.8kW (2.5kW claimed) while also engaging the onboard charger for a total of 4.1kW (3.8kW claimed) while leaving the charging accessory port free.
Location
It only fits in the Power Tank area (so they can't both be installed) and requires a dealer-only installation (very involved).
Operation
The bike must be keyed on before initiating a charge cycle with the Charge Tank.
Once charging, the bike can be keyed off; the Charge Tank and onboard charger will keep the bike in charge mode.
Reference
Zero Charge Tank User Guide
install video by a dealer showing what it looks like under the tank
Charge Tank Bracket Installation

DigiNow Super Charger

This refers to the V2 of the product as released in 2017.

Product link DigiNow Super Charger V2.

Limited orders made for the Super Charger V1 through 2016 have been upgraded to a two module version of the V2, and ordering is now generally available at a scaling price by having a modular assembly.

Features
Made of 3.3kW modules in configurable numbers, up to 11.2kW for current Zero models' charging limits.
Tank Bag cowl area fitment for one module air-cooled.
Power Tank cowl area fitment for two modules air-cooled, and three modules with a yet-to-be-designed thermal management system.
Ordering
DigiNow has two primary dealer partners who are experienced with the hardware and can answer questions and provide support:
Hollywood Electrics' Diginow Supercharger V2
Grand Canyon Cycles' DigiNow Supercharger
Technology
V2 is based on a new Elcon charging product arranged in multiples.
Cooling is provided by air-blowing fans; a liquid cooling system is also available by special request.
The Elcon product page indicates that it can communicate over CAN bus, which requires a custom control module to tell it what to do for integration with Zero's systems to be safe and reliable.
Also, Elcon supplies are electrically isolated, eliminating some design and handling issues with the V1 platform.
There is no controlling user interface currently provided, but DigiNow has stated they intend to add Bluetooth / BLE support (including for units already shipped), implying some kind of mobile application to communicate over a protocol.
Guides
DigiNow's Supercharger V2 unboxing video for a quick overview of the hardware.
Eric Shattow's Supercharger V2 unboxing video for a closer showing of the hardware.
Eric Shattow's Video showing the Supercharger V2's hardware connections
Connections
  • J1772 primary inlet.
  • Anderson connector (SBS75XBRN) primary outlet with a "keepalive" signal transmitter.
  • (Unlisted, must ask) a controller connection with a separate Anderson "keepalive" signal transmitter.
Optional Inlet Adapters
Hardware
Modular Connector Q&A with photos

DigiNow Super Charger Installation

This charger can be ordered in a few different configurations, making it the most flexible charging option currently available.

This attempts to describe most available options and concerns.
Your charging arrangement may vary per your requested options.
Reference
Supercharger Tank installation with photos
The following photos feature a MY2016 DSR, charge tank bracket and cowl, and single module SCV2.
Parts
  • (1) J1772 inlet wired for 2 charging units, or 1 charging unit and a split to feed the onboard charger.
    For 3 charging units, two J1772 inlets will be provided, one wired for 2 units and one for 1 unit with an onboard charger split.
  • (1 to 3) Elcon HK-J charging units with 12V fans wired and mounted to a simple aluminum heat sink on one side.
  • (1) Y-split cable with two (2) Brown Anderson SBS-75X connectors and one (1) downstream Red Anderson SBS-75X connector.
  • (1) Potted aluminum box containing the control board. The wiring should connect to each charging unit.
Instructions
  1. Discharge your power pack to 75% or lower.
  2. Power down your motorcycle and unplug the charger, ensuring the contactor clicks open.
  3. Wait 10 minutes for all components to completely discharge.
  4. Connect the J1772 inlet to the chargers, and the control board to the chargers.
  5. Perform an unloaded test:
    1. Connect the J1772 inlet to a source of 220V power rated for 6.6kW (30A) (via adapter if necessary).
    2. Verify that the fans turn on and if a light is visible on the control box, that it is lit.
    3. Station power (if confirmable) should read a few tens of watts, like 40W.
    4. Disconnect the J1772 inlet.
  6. Wait a couple of minutes for the charging units to discharge fully before connecting them to the motorcycle.
  7. Connect the charging system to the vehicle: connect the output Anderson connector to the accessory charging port.
  8. Turn on the bike and make sure the contactor closes.
  9. Make sure the bike operates (twist throttle or roll the bike to make sure the controller is engaged).
  10. Open the Zero mobile app if possible to check charging activity on the battery.
  11. Repeat the test above with the battery connected and verify charging by the amount of amps reaching the battery in the Zero app Battery Screen.
  12. Verify that the charge-mode enable signal works by keying the bike off.
    • Observe that the bike stays in charge mode and the app continues to report incoming current.
    • If this fails, disconnect the inlet from the upstream source and recheck connections once discharged.
  13. Verify that tapering works at high states of charge by completing a charge beyond 80% SoC. The tapering should happen in concert with battery voltage reading 116V.
Install Chargetank Inlet Bracket (Optional)
  1. Prep the aux power wires to be fed through the bike frame.
    (Optional) apply wire routing conduit and electricians vinyl tape also zip tie the signal wire at the one end as a strain relief.
    DIGINOW3KWSCV2 chargetankscv2 auxwireprep.jpg
  2. Going fishing!
    Stuff something insulated down one side of the frame behind the DC-DC converter.
    The 2016 model year has an advantage to use the right side, while other model years may depend on the right or left side.
    Once you're routed through, you can tightly tape the aux power and control wire ends to your insulated fishing wire and feed back up through the frame.
    DIGINOW3KWSCV2 chargetankscv2 auxroutetank.jpg
    DIGINOW3KWSCV2 chargetankscv2 auxroutemotor.jpgDIGINOW3KWSCV2 chargetankscv2 auxroutesbxport.jpg
  3. Prep the J1772 inlet assembly provided with your Super Charger V2 system
    For use with the Chargetank cowl, you will need to remove the captive dust cap and latch.
    DIGINOW3KWSCV2 chargetankscv2 inletprep.jpg
    Also for the Chargetank inlet bracket you will need to elongate the existing fastening holes on the J1772 inlet piece towards the center, so that they will allow for using the Chargetank inlet bracket mounting.
    If you elongate the J1772 inlet fastener mounting holes up to the center most edge of where the countersunk section visibly begins on each hole it will fit very nicely.
    Additionally, there is a circular lip on the bottom of the J1772 inlet that needs to be sanded a few light passes with a rotary tool so that it will seat correctly in the circular cutout in the top of the Chargetank inlet bracket.
  4. Layout the components of the Super Charger V2 system in place.
    DIGINOW3KWSCV2 chargetankscv2 inletfitment.jpg
    Note the J-hooks which secure the charging module
    DIGINOW3KWSCV2 chargetankscv2 hookdetail.jpg
  5. Take care to insulate or provide strain relief to any cables that might move around or encounter any forces in their lifecycle.
    DIGINOW3KWSCV2 chargetankscv2 powerconnectordetail.jpg
    This J1772 inlet assembly was a very early construction and failed when installed with the Chargetank inlet bracket
    DIGINOW3KWSCV2 chargetankscv2 inletdetail.jpg
    The broken J1772 inlet assembly has been RMA'd and replaced with an assembly that has more forgiving wiring flexibility to work with the Chargetank inlet bracket.
    DIGINOW3KWSCV2 chargetankscv2 juiceboxandupgrades.jpg
    There was also delivered an EMW JuiceBox 40A charging station (previously available to order with the Super Charger V1), and a new revision of the Super Charger V2 control module that fixes some harmless warning indications induced by the oldest revision.
    The newer revision appears potted in a metal case with a clear epoxy, while the older revision seems potted in a plastic case with some RTV silicone.

EVTricity Fast Charging Kit

EVtricity offers two options for fast charging - a 3.3-4.4kW AC charger and 6.6-8.8kW AC charger. This charging kits are fully assembled in Australia and are constructed using Emerson R48-2000e3 rectifiers, custom PCBs & wiring, and a rugged anodised aluminium case. The units are programmed to charge Zero motorcycle models from 2013-2017.

The units are configured for Zero motorcycles maximum voltage (116V) and the AC input current limit can be specified at ordering to suit the power sources used by the Zero owner e.g. 15A/16A or 20A. EVtricity also offers a matching Mennekes or J1772 adaptor to allow two 3.3kW chargers and an onboard to be plugged in simultaneously or one 6.6kW charger and an onboard charger. The 6.6kW unit is effectively two single chargers placed in one case with independent AC input and DC outputs providing modularity in case only lower current (15A) power supplies are available.

The unit is not weatherproof so needs to be carried on the bike in weatherproof luggage and kept away from rain/dust when charging or in storage.

The charging kits do include DC output cables to plug into the Zero fast charge port but do not include the AC input power cables required for each location e.g. NEMA to C19 cables, Schuko to IEC C19 cables etc. The units have IEC C20 sockets - an international standard socket - and power cables with a matching IEC C19 plug are readily available in most countries.

The charging kits are one of the lightest, most compact and power dense chargers available for Zero motorcycles as at May 2017.

3.3+kW: - Dimensions = 29cm x 18cm x 5cm (excl. cable glands and cables) - Weight = 3kg

6.6+kW - Dimensions = 29cm x 18cm x 10cm (excl. cable glands and cables) - Weight = 6kg

Ref. Products Page

Variants
Double Fast Charging Kit supports 6.6kW AC (up to 8.8kW AC with custom configuration)
Single Fast Charging Kit supports 3.3kW AC (up to 4.4kW AC with custom configuration)
Default input limits vary by Level 2 AC standards per region (EU = 16A, US = 15A, AU = 15A) and custom AC input levels up to 20A per input (two inputs on the 6.6+kW charger) are available on order.
J1772 to C19/C13 adapter
Mennekes to C19 adaptor

DigiNow Super Charger V1 (discontinued)

Product link DigiNow Super Charger V1 (courtesy of Internet Archive's wayback machine).

This charging product went through an intense development and testing phase in late 2015. Due to manufacturing and contractual issues this is now discontinued and has been replaced by the Zero Aftermarket#DigiNow Super Charger V2.

Features
Monolithic 12kW charging capability
Power Tank area fitment air-cooled.
Ordering
Product is discontinued.
Technology
V1 was assembled as a homologated single 12kW high powered switching power supply derived from an existing generic unit to fit in the Zero tank area.
eMotorWerks product page for generic/programmable version
Patrick Truchon described some more general information about it
The control board sets up a WiFi access point with a mobile-web application server for adjusting how it operates once it's supplying power.
The control board is powered from the external charging source.
DigiNow has indicated that the V1 situation was difficult for some reason involving the supplier, but specifics are not commented on publicly yet.
V1 is working for customers in the field, and provided a reasonable development platform for understanding the parameters of operation and compatibility issues with various charging station technologies, that fed into the V2 platform.

Hollywood Electrics Elcon PFC 2500

Harlan at Hollywood Electrics sells a customized, programmed Elcon PFC 2500 charger to work well with the Zero battery pack.

Product Page
Elcon Quick Charger
The Elcon Quick Charger product page is no longer available (this link is form archive.org's wayback machine); presumably it can be ordered specially or serviced but it seems like the Supercharger v2 (also Elcon-based) in the 3.3kW configuration is considered a better value and the way to go forward.
Customizations
It is programmed for the Zero voltage range and performs smooth charging cutbacks as a full voltage is approached.
The output leading to the accessory charging port uses the signal pins to ensure that the motorcycle stays in charging mode once charging has started, even without the onboard charger or leaving the motorcycle keyed on.
The input plug is an IEC 60320 C20 coupler instead of Elcon's stock NEMA 5-15P plug (for US 110V outlets).
Cabling
See Custom J1772 Adapter
This includes a splitter for the onboard charger, for conveniently reaching 3.8kW for a single Elcon or 6.6kW for dual Elcon inputs.
A single Elcon or a pair may be accommodated.
NEMA 14-50 (typical RV park 50A plug) support is also available.
Other customizations can be accommodated on request.

DIY assembly of power cables and adapters is possible and can be cheaper than purchasing, but should be learned and performed carefully to avoid high power electrical faults that could cause damage or injury. Crimping should be performed by a professional with the best possible tool for the connectors and cable gauge to avoid dangerous bad connections.

Product Information
Elcon PFC 2500
It is very flexible and robust, but requires programming to adapt it to a specific vehicle.
It performs at 2.5kW at 220V AC input or at 1.2kW at 110V AC input (effectively current-limited).
It is primarily designed for use in electric forklifts and light industrial trucks.
As delivered, it takes power in through a NEMA 5-15P plug and outputs through a grey Anderson connector.
The Elcon PFC product range offers a variety of power outputs; the 2500 happens to be the most powerful that can be effectively carried on a Zero in a Givi case.

Elcon 3.3KW UHF CAN bus charger

The HK-J charger is a newer model that outputs 3.3kW at 220V AC or 1.6kW at 110V AC. It's smaller and lighter than Elcon's PFC 2500. It would require significant programming and customization to be used with a Zero.

Product link: Elcon's HK-J series 3.3kW charger

The Diginow Supercharger v2 is based on these chargers plus a sensor and controller unit.

TSM2500 Charger and Controller

Thunderstruck EV sells a non-homologated assembly of what appears to be the same charger as used in the OEM Charge Tank with a separate generic controller. Naturally, this requires using quite a bit of programming and configuration to set up successfully. It's a 2.5kW charger with ample air cooling.

Combining Chargers

One can combine chargers to feed the Accessory Charging Port using the right cable.

Zero's Y-Cable below is designed to do this. It's intended for their Quick Charger but can be used on an Elcon 2500 or other isolated charger able to work with the enable pins.

Notes
  • There are 2 enable pins on the Accessory Charging Port.
    You have to use two chargers to each pin.
    One pin can't drive more than 2 chargers.
    If one pin drives two chargers, the other pin must drive 2 chargers or none at all.
    So, 1, 2, or 4 chargers can be supported, but not 3...
    UNLESS you add a jumper and pin to the Anderson connector to bring both pins on the same sensor wire.
  • 2013 and earlier models accessory charging port have a 30A current limit, so can't handle 4 Quick Chargers.
Steps
  1. Join a pair of chargers with a Y-cable.
  2. For a second pair, join them with a second Y-cable.
    To combine the pairs, you need a third Y-cable that output can be connected with your bike.

Ref. If I add the third QuiQ charger, it cancels out one of the other two leaving one QuiQ charger working, along with the onboard charger (about 2000 watts)

Y-Cable

Zero sells a splitter input cable for combining their Quick Chargers into the Accessory Charging Port.

It can be used on any charger rated for the Anderson connector (SBS75XBRN).

Alternative
DIY Charger Y-Cable procedure.

DC

DC charge stations are conceptually just offboard AC chargers programmed for higher voltages.

DC charging works differently than AC to DC charging. The power output is based on voltage rise. A CHAdeMO can only charge 6.2 kW at 50v if it follows the spec, which most do not.

Most DC chargers (ChaDeMo and CCS, in practice) do not go below 200V, meaning the Zero has to fake the system out. In doing so, you get an immediate voltage rise causing the DC charger to think you have completed your charge nearly immediately.

A CHAdeMO station is no different from an offboard high power charger which would also result in the same thing.

  • If you plugged the output of one charger into the input of another charger, the first charger, which is powering the second charger would turn on and off again immediately.
  • The nature of DC charging uses the battery itself as a load causing voltage drop.
  • This is the premise of how DigiNow controls the Supercharger power and voltage output, and how it knows when to slow down and by how much.
Cost
Inlet hardware which can handle reasonable power run around 800 for the incomplete plug alone excluding control board's, wiring harnesses etc.
For this reason, DC charging hardware still costs more than AC charging hardware.

Ref. DC-DC charger

CHAdeMO

OEM

Zero offered a CHAdeMO solution for the 2013 models that placed an inlet on the left side of the frame behind the battery and installed a custom charging path to the battery. Unfortunately, they had enough troubles with charging station implementation for Zero battery voltage that they abandoned support for this solution.

Comments from Aaron at Zero

There is controversy about this action from Zero. The core feature of the problem is that some earlier implementations of CHAdeMO charger stations did not provide DC voltage in the range that the Zero battery operates in. The lowest voltage that is supposed to be supported in a CHAdeMO implementation is 50VDC, however, most other CHAdeMO consumers operate at above 200VDC, so some implementations were made only to support that voltage range. Unfortunately, Zero's range is around 96VDC-118VDC depending on the state of charge. If properly implemented, a CHAdeMO charging station and a Zero Motorcycle are compatible. To compound this, most of the charging stations that were installed that were only 200VDC+ compatible were installed within the stomping grounds of Zero's HQ, so they received an inordinate level of reinforcement of their incompatibility worries. Later implementations of charging stations, done in other areas of the country, were much more consistently compatible. [1]

Charged EVs magazine story about Zero and CHAdeMO has the most detail of any explanation so far.

station compatibility summary on the forum

Third-Party

TusconEV CHAdeMO inlet at $650 is the cheapest option for a DIY CHAdeMO solution. QuickChargePower CHAdeMO products are promising, between an available CHAdeMO inlet at $800 and the JdeMO setup for the RAV4 EV. There are reports that the owner plans to develop a solution for the Zero.

SAE/Combo

CCS

CCS builds on the J1772 plug to add a DC plug.

CCS is actually more complex than ChaDeMo by far, but that complexity also makes it much more secure. It uses encrypted TCP sockets over the power lines themselves with security certificate transfers, etc. Whereas CHAdeMO works via simple CAN bus messages.

DIY Chargers

A thread on DIY charging on a budget: Charging solution for $2k or less?

QuickChargePower offers a number of components at reasonable prices (relative to the market and electronics sophistication).

Building a series of two high-density 48 V DC power supplies is a way to get a custom charge assist, although computer power supplies are not ruggedized or weatherproof. The power supply will need adjustment to produce a higher voltage of 54-55 V DC so that in series the pack produces 108-110 V DC, sufficient to run through most of a battery charge cycle.

Meanwell
Burton's RSP-2000 build
A howto on building a Level 2 charger from the RSP-1000's
Eltek
Eltek Flatpack S 48V

Windscreens

OEM Windscreens

Touring
Recent addition with a spoiler and more design for aerodynamic comfort.
Commuter
Provides efficiency gains of 10-15% particularly when crouched.
Dual Sport
Relatively modest with more angular styling.

Other Manufacturers

MRA
Makes the mounts and windscreens that Zero brands for its bikes. They have other options that provide some choices.
Puig
Makes windscreens and mounts for sportbikes, naked bikes, and cruisers.
California Scientific
Sells a variety of motorcycle accessories, focusing on adventure and sport touring styles.
They have a particular design philosophy around windscreens that works rather well for good airflow and low drag.
A 2016 DSR owner in the Sacramento area has reported they've developed a Zero fitment for him that could be replicated on request ([ call to inquire]).
Parabellum
Makes windscreens designed for maximum efficiency, claims +15mpg difference at highway speeds for a number of motorcycle models.
Offers some windshields for naked bikes that can be adapted to a Zero:
Discussion thread proving and itemizing a BMW fitting by user:BrianTRice. Efficiency gains are 15-20% except in severe headwinds.
Slipstreamer
Slipstreamer S-05 Turbo Zero SR install confirmation, with a successful aerodynamic and comfort improvement. (forum reference).
Slipstreamer Spitfire install confirmation.
Slipstreamer SS-10 Viper install confirmation.
Chinese LARGE Windscreen from eBay
This is apparently a family of windscreens (sport-touring and cruiser style) with handlebar mounts. They are cheap ($55) but not of great quality.
First found EBay listing
EBay Search: Large 19"x17" Clear Windshield For Motorcycle Yamaha Cruiser 7/8 & 1"Handlebars

Crash Bars

Zero has a parts catalogue for dealers for the police (SP/DSP/FXP) models - the crash guards and crossbar, and the upper left and right brackets, but they don't sell the hardware (screws and bolts). The manual entry for the Frame attachment points is sufficient now to source the hardware easily. Drop bars for FX now come with hardware, but might not be complete. (It appears they might assume you have the frame mounting screws.)

There is apparently now a "retail civilian version" (ask your dealer) of the Drop Bar Kit that is complete, and includes a new skid plate because the S/SR skid plate is not designed with the drop bars in mind (lighter weight, probably plastic, with no pre-drilled holes for mounting). The civilian version does not include brackets for mounting extra hardware, however, but it is apparently cheaper.

Fairings

Zero seems reluctant to commit to an OEM fairing design, for probably mostly business, branding, and budget reasons. However, a well designed conventional front fairing should increase range at highway speeds by 30%. A front fairing with a carefully crafted rear tail could do more, up to 50% (oversimplifying how this works here).

Primarily for styling reasons and a racing crouch, Zero's Indonesian distributor commissioned this customization with carbon fiber texture:

Cosmetic Bodywork

OEM

  • Fly Screen for 2013 S and DS models.
    Later years have a plastic enclosure for the headlamp that interfere with this.

Hollywood Electrics devised some carbon fiber body pieces:

Tank Grips

Tank grip pads are very useful for maintaining a crouched position comfortably and getting better control over the balance of the motorcycle.

OEM

As of 2017, Zero offers soft TechSpec tank pads for 2013+ models on the S platform for $60:

Third-Party

TechSpec makes many different shapes in a soft material. Some generic shapes are suitable for customizing (1200GS pads fit the DS tank with a little adjustment) with the right cutting tools.

Mudguard

Product: OEM Rain Guard

Parts and tools needed: Rain guard kit, optional washers, license plate bolts long enough to add the rain guard, Phillips head screw driver (not a bit driver), wrenches or screw driver for the license plate hardware.

  1. Remove the license plate.
  2. Peel off the red reflector above the license plate.
  3. Back out, clean, and save the three screws under the reflector to remove the reflector bracket.
  4. Put the rain guard in place with the wide tabs lined up with the top holes of the license plate frame.
  5. Locate two recessed Phillips head screws under the tail that are in line with the narrow-spaced holes at the front of the rain guard and remove.
  6. Make sure the wires feeding the turn signals are in the forward notch on the rain guard.
  7. Put the white spacers in the kit into the recessed tail holes and secure the front of the rain guard using the supplied long screws. Optionally add washers to the underside of the rain guard before inserting the screws.
  8. Attach the new reflector bracket and apply the new reflectors.
  9. Attach the two wide tabs to the back of the license plate support using the license plate bolts while reinstalling the plate.

This installation takes under an hour.

Photos of installation on Facebook

Forum post

Fender Brace

The DS/DSR models have a fender which does flex a bit at speed.

Some research indicates that the bolt pattern mounting the fender matches the Honda XR650L, allowing third-party fenders to replace it.

Confirmed fit:

JSN Engineering's fender braces.
JSN Engineering also offers an auxilliary LED mount that uses the same attachment point.
Installation
The pattern is 4 holes in a rectangular shape 58mm (2.3in) wide and 50mm (1.95in) front to back (center to center).
The bolts are M5x15mm button head socket screw for a 3mm Allen key.
  1. Remove the fender with a 3mm Allen key.
  2. Install the fender brace above the fender and replace the fender.
  3. Flex the fender to match the fender brace while keeping the mounting bolts in the fender to hold the brace the way it will be installed.
  4. Mark the fender where the holes for bracing align with the fender plastic.
  5. Remove the fender and drill holes matching the marks.
    Double check how the alignment should happen since flexing will cause it to differ.
  6. Replace the fender with the brace above it, and then fasten the fender to the brace.
Trivia
the S fork bracket has the same hole pattern as the DS, allowing it to mount hardware there.

Streamlining

Craig Vetter has been working on eco travel options for motorcycles for decades. He recently got enthusiastic about electric motorcycle focus and helped Terry Hershner perform his streamlined cross-country trips, and has had a more conventional variant in the works for a couple of years. However, a recent riding accident seems to have slowed or halted this progress.

As Vetter has explained, there are three major goals for a streamline fairing which have tradeoffs against each other:

  1. Range
  2. Comfort
  3. Speed

Although they require a significant amount of work to mount, the Vetter streamliner is available for sale for $2000 plus taxes and shipping.

Luggage

Tank Bags

There's nothing explicitly fit for Zero for a number of reasons:

  • The tank isn't made of metal.
    Magnetic tank bags might find a Power Tank or Charge Tank underneath it quite attractive, but it's unclear whether they could damage them over time.
  • The tank is relatively small.
    Most mid-sized tank bags will seem very large on it.
  • There's no gas cap to clip onto.
    Maybe a J1772 inlet would work but don't compromise its waterproofing.
  • Running straps around the tank plastics requires a bit of finesse.
    There's room above the battery to run straps but you might want to remove the tank plastics a bit to get the straps in there.

That said, people have fit backpacks, rucksacks, and tank bags onto their Zeros, but it's all been ad hoc so far.

Examples:

Soft Luggage/Cases

In short, most soft bags can be adapted to a Zero if they are roughly fit for its size.

ongoing forum thread of recommendations

Hard Cases

Top Rack

The OEM top rack comes with a Monolock or Monokey mounting plate if you buy it with a case from Zero.

The only alternative top rack that works with a Zero is the Givi Wingrack universal-fit series, which won't support OEM or other side racks that fit the Zero.

Mounting plates
the Givi E251 Monokey universal mounting plate adapts most large Givi cases to the OEM top rack.
Monolock universal mounting plate adapts smaller, more scooter-oriented Givi cases to the OEM top rack.
All Givi top plate options, most not confirmed to fit.
early forum thread about some options
Installation
Installation is trivial (15 minute job).
  1. Two small button-head M5 bolts mount vertically to anchor the rack bracket to the top of the frame under the seat.
  2. A protective cap goes over a tab that the plate itself uses to rest on the end of the tail plastics.
  3. Ensure the front and back of the rack rest in contact simultaneously.
    The goal is to minimize the dynamic load on the small mounting bolts while riding.
    Hitting bumps at highway speed (if the tail can move freely) can add up over time and break the mounting bolts.
    • Place a washer under the front part of the bracket, or
    • Put some adhesive firm padding on the tail to support the tab.
Design Issues
  • The rack is only fastened via the two M5 bolts into the top of the frame under the seat.
    Downside: The strain on those bolts can accumulate if the rack has any freedom of motion.
    Upside: This connection makes the top rack a cheap sacrificial point if the bike goes down in a certain way, particularly with the police models' use of a rear rack bar.
  • The top rack plate is smaller than a Givi Monokey or other larger vendor's case surface.
    Crafting an aluminum plate to fix to the existing plate is workable with a drill and the right machined piece of (say) aluminum.

Side Rack

OEM Side Rack
Fits the Givi PL/PLR side case holder spec.
Monokey side cases all fit EXCEPT for the V35 series which require a PLX rack (which is attractive and tries to conform around the tail).
Boxy/sturdy Trekker side cases all fit.
Noticeably, there is a design revision between 2013-2014 racks and 2015+ racks.
  • The tail mount is more robust, no longer using a pipe clamp to hang from the tail.
  • The turn signal mounts are sturdier and well-integrated.
Happy Trails Side Rack
Fits their "SU" holder spec, also offers some adapters for Givi PL/PLR mounting.
Designed around the 2015 DS, judging from the photos and time of release.
The rack hardware is robust:
  • Primarily 1/2" diameter square and circular tubing.
  • All the bolts are M8 bolts with 13mm hex heads which match the footpeg bracket bolt heads.
  • The rack mounts to the seat bolts instead of the smaller holes through the top rack which do not directly anchor to the frame.
  • The rack includes a bracket anchored directly to the frame where the tail piece attaches, avoiding turn signal wiring extensions.
Confirmed to fit a 2014 SR, although the clearance against the rear brake master cylinder is very tight and might be of concern.
All Happy Trail products vouched for the Zero fit, lists saddlebags, tank bags, pannier bags, etc., very good adventure options listed.
SW-Motech's QUICK-LOCK EVO Side Carrier
Has quick-release fasteners (that can be locked with an add-on) that allow the side rack to be mostly removed from the bike.
Other products have been confirmed fit for the DSR: SW-Motech by model: DSR
Installation
Both racks rely on lower brackets that attach to the inside of the rear footpeg mounting brackets.
These mounts re-use the OEM bolts (13mm hex head M10 bolts) which are difficult to work on (clearance around the motor, suspension, cabling, and hydraulics is extremely tight).
The straightforward way to work on this aspect is twofold:
  • For the upper bolts, use a long extension (12" or so) that can swivel a bit to reach across the underside of the frame. Use a socket wrench to operate from there.
  • For the lower bolts, remove the lower side plastics and then use a low-overhead angled socket wrench from the front side of the frame vertical to reach the bolt and operate on it.

12V Circuit

Eastern Beaver is a good resource for motorcycle 12V electrics:

Horn

Most horn upgrades will challenge the DC converter's power load, particularly while the ABS brake pump is running.

See the common modifications section on horns for some discussions about how to wire an upgraded horn in.

Lighting

Headlamp

S-Platform Headlamp

Replacement Specification
H4 specifically for motorcycle tolerance fit, but 9003 generally will fit.
Brighter Halogen (often marketed as HID)
Generally, these offer much greater light spread and brightness with the same power requirement as the OEM bulb (55W/60W).
SYLVANIA 9003 (also fits H4) SilverStar zXe High Performance Halogen Headlight Bulb (only need one)
Whiter - Brighter & Safer Headlights For Your Zero - Mike Mas covers the broad issues with motorcycle headlight choices, recommends and reviews the zXe.
Cree LED
Fanless; uses braided metal filaments for heat dissipation instead of a fan unit.
Seems easier to fit behind the headlamp assembly while still keeping the lamp cool.
Cree seems to generate some noise on the CAN bus, which can lead to start errors.
OPT7 LED
Fan-cooled, but practically silent even for the Zero.
It's brighter than the stock bulb but has an unusual light pattern.
These appear to be more CAN-bus-friendly.
  • OPT7 at 20/40W. Choose the H4 (9003) Single.
    The cooling element does stick out a bit which might require some gymnastics with the rubber boot meant to protect the headlamp from moisture.
    Some fit and light pattern notes
Replacement
Video guide: Zero SR - How to swap a headlight bulb
Suggestion: Unbolt the headlamp assembly (with 3mm and 4mm allen wrenches) from the metal brackets to get enough room to work.
...unless you have very small hands and move the existing cabling out of the way.
  1. Detach the existing bulb's cable at the plug.
  2. Pull the rubber cover away from the headlamp.
  3. Twist the retaining bracket to release the bulb.
    NOTE: Avoid touching the bulb; oil and dirt from your fingers can cause the bulb's surface to heat up while operating and could age the bulb prematurely. Keep the bulb clean.
  4. Place the retaining bracket and rubber cover around the new bulb and press and rotate to fix it in place.
NOTE: For a 2013-2014 model, the plastic retaining bracket might require some filing to fit another bulb with its assembly to hold it in and lock properly. Later models have an easier shape to fit.
Calibration
When replacing the headlamp, check the light pattern emitted and adjust the set screw in the headlamp housing to get a suitable projection angle.
Wiring
If you need anything even slightly customized about the wiring, Eastern Beaver's various H4 kits cover many possibilities.

X-Platform Headlamp

Replacement Specification
H3 with dual projectors
S7 fanless H3 LEDs
Fits well and works well, just have to decide how to deal with the braid vs the rubber dust cups. Very affordable on Amazon.
These are the right length, from base to element, to focus properly and provide a sharp and accurate cutoff on the low beam. (The high beam still looks like a flashlight.)
They are brighter than even a 50W halogen and white without being blue.

71KhOe1hj4L. SL1000 .jpgMounted.jpgDustboots.jpg

Headlamp Running light

Replacement Specification
Any W3W or W5W bulb easily swaps.
The license plate bulbs have the same spec but LEDs don't work as well there.
Options

A number of LED and HID headlamp replacements are available that fit the Zero. The orientation and direction of the LEDs needs to match the stock headlamp's bulb to get as good a light pattern.

Running Lights

Turn Signals

Turn signal lamps are standard 1156 bulbs. There are many LED options for replacement; the usual concern is to make sure the LED turn signal has a compensator for the flasher relay. The Zero stock flasher relay (like most stock relays) changes its frequency/period of flashing based on the resistive load on its circuit, so a compensator adds a resistor which negates the (tiny) efficiency savings.

LED turn signal flasher relay that doesn't need a resistor, with some instructions.

Replace the stock relay with a relay with three prongs. The orientation is specific: look at the pins with the middle L (load) pin on top. The left pin should be B1+ (battery positive) and the right should be E1- (battery negative, maybe "emitter"?).

Many relays are oriented with E-, L, then B+ which will reverse-bias the LED signals so won't light them up. Reversing the polarity of the wire-up can make it work.

WeiserTechnik offers LED turn signals with in-built resistive compensating loads that are known-fits for Zero's models.

For the FX, WeiserTechnik made a howto video for installing their turn signals in German with English subtitles that illustrates how to get at everything.

Brake Light

The stock tail/brake light assembly is an integrated unit with LEDs.

However, a GearBrake unit is available that connects easily into the Zero lighting wiring harness and provides a flashing function or allows regen to trigger the brake light by orienting it so its accelerometer picks up on the deceleration correctly. The product page list Zero models up to 2015 model year and will likely be updated for 2016+ when the owner gets to it. It's very easy to instal under the seat behind the motor controller.

Seat

Corbin offers a gunfighter saddle for the 2013+ Zero S/DS/SR/DSR models.

It offers easier standover height via narrow sculpting in front, and a firm supportive area in back for longer rides. The support in back works well for leaning into the wind comfortably and getting one's legs tucked closer to the frame out of the wind.

Forum thread that includes reviews: Corbin Seat available for 2013-2016 Zero's now

Braking

Zero offers a 2013 rear brake upgrade kit to retrofit the more effective J Juan model on 2014 models.

Brake Levers

Zero brake lever fit is generally unconfirmed, but the fit changes with the front brake systems, so 2013-2014 models have a different fit than 2015-2016 models.

The lever fit for a 1990-1999 Suzuki DR350SE is confirmed against a 2014 FX per this facebook comment thread.

Master Cylinder Replacement

One strategy is to replace the assembly around the handbrake. Searching for 7/8" master cylinder kit can yield some options (reported for a 2011 model).

Parking Brake

Brake lever locks
Zero offers a brake lever lock for a basic parking brake.
This is a cheap solution but can strain the hydraulic system over time, and has been known to slip in hot weather.
It appears to be a branded version of a part available through other sites at comparable prices.
The Grip-Lock is similar, but features more as a simple security device and is a little more expensive.
OEM Parking Brake
As of 2017, the Zero Owner's Manual refers to a parking brake lever accessory that installs a paddle on the right handlebar that uses a cable to clamp on the rear brake disc for a parking brake. This roughly resembles the Honda Silverwing parking brake system.
Dealers report that they can order it, but installations are not confirmed yet.
Maintenance
The cable does represent a low-frequency maintenance task - cables on motorcycles should be periodically (yearly?) oiled and adjusted; the manual does have recommendations on this.
Compatibility
J Juan lists a parking brake product which is likely the same thing since Zero's brake systems are sourced from them. This implies that the Zero parking brake is compatible with 2015+ models.
Fit against previous year models is unconfirmed, but physically the 2014+ models with the J Juan "240 x 4.5 mm disc" (and 2013 models that have received the rear brake upgrade) should work with it.

Drivetrain

Gearing

Zero offers a Higher Speed Gearing Option for the 2013 S and DS bikes:

"Converts from original gearing of 132/28 (95 mph, 321 ft-lbs) to 98/25 (107 mph, 267 ft-lbs). Kit consists of a 98T wheel sprocket, 25T motor sprocket and 200T belt."

There was a higher torque option but it's apparently discontinued.

Resources
Zero FX Gearing calculator

Suspension

Zero offers a Fox rear shock upgrade for the 2013-2014 Zero FX models.

Report your suspension upgrades here.

Suspension Tuning

Many recommend a professional suspension tuning job, reporting it accomplishes a lot with the stock suspension, and should be attempted before investigating replacement options.

At the very least, learning to tune your suspension yourself will make the bike more suitable for your local road conditions and loading. The rear shock preload is easily adjustable and worth dialing up or down switching to or from 2-up riding or carrying a luggage load.

Rear Shock

Hollywood Electrics
Penske Shock (contact for details)
2015+ models seem to be supported now, and soon older (2013-2014) models.
They're certainly able to answer customization questions.
Ikon Shocks USA
An Ikon Shocks representative indicates they've made a Zero-appropriate rear shock for a 2016 FXS that can be ordered.
It should be appropriate for 2015 year model onwards, but ask in any case if interested.
Wilbers
They offer a rear shock upgrade for the 2013-2014 S and SR models. Shock absorber Type 640 Road
JRI Shocks, Double Adjustable
Confirmed working on a 2014 Zero SR.
Sunny 10 1/4" 260MM Pit Dirt Bike Motorcycle ATV Suspension Air Shock Absorber
via Facebook report: "It's bigger, but don't have the same adjustment capabilities. I needed to install it upside down and grind ~1mm of the width down to get it to sit in there comfortably."

Front Forks

Hollywood Electrics
GP Suspension Fork Cartridge Kit for track-oriented riding.
Wilbers
Wilbers Forkspring Kit for 2013+ S/SR models.

Security

Zeros are not yet widely attractive targets for theft because of limited numbers and specialized parts, but local circumstances can make it a risk.

Secure Power Supply

Wire in an always-on power supply by tapping the always-on DC-DC converter's input, and use a switching power supply to convert the battery DC voltage there to 12V or 5V to power a location-tracking device or alarm.

Disc Lock

Perfect Alarm Disc Lock for Zero bikes recommends an Urban UR-10 lock with an Artago 30X Alarm Disc Lock Support Kit which can mounts the lock while riding behind the rider's left leg, after a little sanding to fit the Zero frame.

Misc

Motorcycle Covers

Confirmed Fits
Dowco Guardian Hi-Viz in size Large for a 2016 DSR with OEM top and side cases.
Size medium should fit Zero bikes without cases or an FX/FXS.
Discussions
Has anyone found a bike cover that they liked? (popup shelter suggestions)
Anyone know the best size cover to get with saddle bags and top box?

Dash/Handlebar Mounts

For your phone, tablet, or GPS device:

Patrick Truchon's handlebar accessories are worth considering:

  • RAM handlebar base with U-bolt (fits 0.5-1.12" bar).
  • Double-socket arm for 1" ball mount.
  • RAM X-Grip holder.
  • Incredibell for low-speed interactions with cyclists and pedestrians, because the Zero makes no noise and the horn would be too alarming.

Regular maintenance

Belt tension measurement

  • OEM recommended belt tension meter GATES KRIKIT I V-BELT TENSION GAUGE is listed on Amazon retailer as a Gates 91107 Belt Tension Tester ($12 usd).
  • Krikit modification/hack to make it easier to read:
    1. Place a straight edge perpendicular to the scale at 25kg, which is middle of the range.
      Place straight edge
    2. Push needle up until it touches straight edge.
      Push needle up to edge
    3. Carefully scribe a line on the side of the needle.
      Scribe a line
    4. Wipe some white paint into the line you scribed.
      Permanently mark it
      Now it is easier to see when you have achieved the correct tension when the line is parallel to the scale.

Diagnostics

OBD-II Diagnostics

MBB Console via Diginow Reaper Dongle

DigiNow Reaper Dongle
This dongle attaches to the OBD-II port (above the motor for pre-2015 model years, and under the seat for 2016) and offers a bluetooth serial port profile interface that connects to the Main Bike Board (MBB).
It currently uses Bluetooth's Serial Port Profile instead of Bluetooth Low Energy (which can handle serial in a custom service) but does mean that iOS can't interact with the current shipping version.
Product page at Hollywood Electrics. It is also sold by Grand Canyon Cycles.
documentation including terminal software that works with the reaper

CANBUS access

Some success decoding CANBUS signals from the OBD-II is reported.

Electrical Measurements

Cycle Analyst
This allows data logging of a variety of parameters tracking voltage, current, and regen for trips.
See this Cycle Analyst install howto.