View source for FST Platform/Unofficial Service Manual

=Overview=

This describes the Zero [[FST Platform]] and includes as many service tasks not described (or incompletely described) in the [[Official Owners Manual]] as customers have identified.
: Relevant Models: [[SRF Model]] and [[SRS Model]].
: Some information might be hearsay or not completely communicated, but attempts have been made to verify as much as possible.
: As with anything in a wiki environment, whatever you undertake with this as a guide is your own responsibility.

__TOC__

==[[FST Platform|Platform]]==
Zero motorcycles benefit from some commonality around the powertrain. The [[#Motor|motor]], [[#Controller|controller]], [[#Battery_Management_System|BMS]] and [[#Main_Bike_Board|MBB]] are more or less shared across all models, along with handlebars and controls.
{{:FST Platform}}

[[Category:Service Manual]]

=General Information=
==VIN==
The [[Wikipedia:Vehicle identification number|VIN]] is inscribed on the front head tube of the frame per the official manual.

See the [[VIN Guide]] to understand how the VIN describes your vehicle, as compiled across manual revisions.

==Systems==
This is a very simplified way of looking at the bike’s systems functions and general purposes, linking to relevant sections.

===Mechanical Systems===
* [[#Frame|Frame]]
* [[#Steering|Steering]]
* [[#Suspension|Suspension]]
* [[#Wheels|Wheels]]
* [[#Final_Drive|Final Drive]]
* [[#Brakes|Brakes]]
===Powertrain Systems===
* [[#Throttle|Throttle]]
* [[#Main_Bike_Board|MBB]]
* [[#Controller|Controller]]
* [[#Motor|Motor]]
===Energy Systems===
* [[#Battery|Battery]]
** [[#Battery_Management_System|BMS]]
** [[#Contactor|Contactor]]
* [[#Charging_Control_Unit|CCU]]
* [[#Charger|Charger]]
===Electrical Systems===
* [[#DC-DC_12V_converter|DC-DC 12V Converter]]
* [[#Fuse_Block|Fuse Block]]

=General Maintenance=
Mostly, refer to the [[Official Owners Manual]] for regular and general maintenance.

==[[Lift]]==
{{:Lift}}

==[[Front Stand]]==
{{:Front Stand}}

==[[Rear Stand]]==
{{:Rear Stand}}

==Tools==
See the separate [[Tool Kits]] article for a curated short list of tools with their purposes.
: NOTE: integrate or meld notes below with that article.

[http://electricmotorcycleforum.com/boards/index.php?topic=5878 Tools and parts to support your bike]

A travel kit for a motorcycle is always a good idea, but Zero doesn't include a default set. They do sell a [http://www.zeromotorcycles.com/shop/index.php?main_page=product_info&cPath=15_4&products_id=128 tool kit] which covers many common tasks.

;Tools for Everyday Riding
* Torx T45 for MY2015+ to remove the [[#Seat|seat]] for [[#Fuse_Block|fuse block]] access.
* 3mm allen key for [[#Tank_Plastics|tank plastics]] and [[#Headlamp|headlamp]] upper mount screws.
* 4mm allen key for [[#Headlamp|headlamp]] lower mount screws.
* 5mm allen key for the [[#Front_Brake_Lever|front brake lever]] and front wheel pinch bolt.
* Tire pressure gauge.
* 10mm, 13mm wrench (or monkey wrench) for [[#Belt_Tension_Adjustment|belt tension adjustment]] and front brake calipers.

==[[FST Platform/Consumables|Consumables]]==
{{:FST Platform/Consumables}}

==[[Pre-Ride Checklist]]==
{{:Pre-Ride Checklist}}

==[[Fastener Maintenance]]==
{{:Fastener Maintenance}}

=Frame/Bodywork=
==[[FST Platform/Frame|Frame]]==
{{:FST Platform/Frame}}

===[[FST Platform/Forward Frame|Forward Frame]]===
{{:FST Platform/Forward Frame}}

===[[FST Platform/Tail Subframe|Tail Subframe]]===
{{:FST Platform/Tail Subframe}}

===[[FST Platform/Frame Doubler|Frame Doubler]]===
{{:FST Platform/Frame Doubler}}

==[[Kickstand]]==
{{:Kickstand}}

==[[Footpegs]]==
{{:Footpegs}}

===[[Rider Footpegs]]===
{{:Rider Footpegs}}

====[[Rider Footpeg Removal]]====
{{:Rider Footpeg Removal}}

===[[Passenger Footpegs]]===
{{:Passenger Footpegs}}

====[[Passenger Footpeg Removal]]====
{{:Passenger Footpeg Removal}}

==[[FST Platform/Seat|Seat]]==
{{:FST Platform/Seat}}

===[[Seat Removal]]===
{{:Seat Removal}}

===[[Seat Install]]===
{{:Seat Install}}

==[[FST Platform/Bodywork Material|Panel Material]]==
{{:FST Platform/Bodywork Material}}

==[[FST Platform/Tank Plastics|Tank Plastics]]==
{{:FST Platform/Tank Plastics}}

==[[FST Platform/Tail Plastics|Tail Plastics]]==
{{:FST Platform/Tail Plastics}}

===[[FST Platform/Tail Plastics Removal|Tail Plastics Removal]]===
{{:FST Platform/Tail Plastics Removal}}

=Steering=

==[[Ignition Lock]]<span id="Ignition"></span>==
{{:Ignition Lock}}

==[[FST Platform/Tank Lock|Tank Lock]]<span id="Lock"></span>==
{{:FST Platform/Tank Lock}}

==[[Mirrors]]==
{{:Mirrors}}

==[[Handlebar]]<span id="Handlebars"></span>==
{{:Handlebar}}

==[[Front Brake Lever|Brake Lever]]==
{{:Front Brake Lever}}

==[[FST Platform/Triple Clamp|Triple Clamp]]==
{{:FST Platform/Triple Clamp}}

==[[FST Platform/Steering Head|Steering Head]]==
{{:FST Platform/Steering Head}}

===[[FST Platform/Steering Head Bearing|Steering Head Bearing]]===
{{:FST Platform/Steering Head Bearing}}

==[[FST Platform/Front Fender|Front Fender]]==
{{:FST Platform/Front Fender}}

=Wheels=
==Wheel Maintenance==
===[[Tire Pressure Check]]===
{{:Tire Pressure Check}}

==[[FST Platform/Front Wheel|Front Wheel]]==
{{:FST Platform/Front Wheel}}

===[[Front Wheel Removal]]===
{{:Front Wheel Removal}}

===Front Axle===
;TODO measurements

===Front Tire===
See [[Stock Tires]].

===[[FST Platform/Front Bearings|Front Bearings]]===
{{:FST Platform/Front Bearings}}

===[[Front Bearing Replacement]]===
{{:Front Bearing Replacement}}

==[[FST Platform/Rear Wheel|Rear Wheel]]==
{{:FST Platform/Rear Wheel}}

===Rear Tire===
See [[Stock Tires]].
===[[Rear Wheel Removal]]===
{{:Rear Wheel Removal}}

===[[Rear Wheel Install]]===
{{:Rear Wheel Install}}

===[[FST Platform/Rear Bearings|Rear Bearings]]===
{{:FST Platform/Rear Bearings}}

===[[Rear Bearings Replacement]]===
{{:Rear Bearings Replacement}}

=Suspension=
==Front Suspension<span id="Front Forks"></span>==
Zero's motorcycles all feature [[wikipedia:Telescopic_fork|telescoping fork]] front suspension.

===[[Front Suspension Specifications|Front Suspension Specs]]===
{{:Front Suspension Specifications}}

===[[Fork Oil Change and Spring Replacement]]===
{{:Fork Oil Change and Spring Replacement}}

===Fork Cartridge Revalving===
[http://electricmotorcycleforum.com/boards/index.php?topic=7737 Fast Ace fork revalving] by Ray Ivers

The procedure is described in great detail for FastAce (2013-2014) suspension but could be adapted for the newer Showa suspension.

===[[Fork Spring Rate Verification|Verify Fork Spring Rate]]===
{{:Fork Spring Rate Verification}}

==[[Rear Shock]]==
{{:Rear Shock}}

===Rear Shock Mounting===
The rear shock fastens to the [[#Swingarm|Swingarm]]'s right side arched arm.

The upper mount reaches the frame ahead of the tail area.

===[[Rear Shock Specifications]]===
{{:Rear Shock Specifications}}

===[[Rear Shock Adjustment]]===
{{:Rear Shock Adjustment}}

=Final Drive=

==[[FST Platform/Swingarm|Swingarm]]==
{{:FST Platform/Swingarm}}

==[[Rear Axle]]==
{{:Rear Axle}}

==[[Drive Belt|Belt]]==
{{:Drive Belt}}

===[[Drive Belt/Risks|Belt Risks]]===
{{:Drive Belt/Risks}}

===[[Drive Belt/Specifications|Belt Specifications]]===
{{:Drive Belt/Specifications}}

===[[Drive Belt/Tension Check|Belt Tension Check]]===
{{:Drive Belt/Tension Check}}

===[[FST Platform/Drive Belt Adjustment|Belt Adjustment]]===
{{:FST Platform/Drive Belt Adjustment}}

===[[Drive Belt/Wear|Belt Wear]]===
{{:Drive Belt/Wear}}

===[[FST Platform/Drive Belt Replacement Procedure|Belt Replacement]]===
{{:FST Platform/Drive Belt Replacement Procedure}}

==Sprocket==

===[[Sprocket Specifications]]===
{{:Sprocket Specifications}}

===[[Drive Belt/Wear From Sprocket Debris|Sprocket Wear On Belt]]===
{{:Drive Belt/Wear From Sprocket Debris}}

===[[Front Sprocket Replacement|Front Sprocket Removal / Swap]]===
{{:Front Sprocket Replacement}}

=[[FST Platform/Brakes|Brakes]]=
{{:FST Platform/Brakes}}

==[[Brake Maintenance]]==
{{:Brake Maintenance}}

==[[Brake Systems]]==
{{:Brake Systems}}

==[[Brake Hydraulics]]==
{{:Brake Hydraulics}}

==[[FST Platform/Rear Brake Actuator|Rear Brake Actuator]]==
{{:FST Platform/Rear Brake Actuator}}

==ABS System==
2015+ models have a Bosch ABS system installed.

===ABS Unit===

===ABS Wheel Sensors===

==[[Brake Pads]]==
{{:Brake Pads}}

===[[Brake Problems]]===
{{:Brake Problems}}

===[[Brake Pad Fitment|Brake Pad Fit]]===
{{:Brake Pad Fitment}}

===[[Front Brake Pad Replacement]]===
{{:Front Brake Pad Replacement}}

===[[Rear Brake Pad Replacement]]===
{{:Rear Brake Pad Replacement}}

=Powertrain=
The powertrain includes all of Zero's power storage and delivery components including the battery, but this section focuses on the [[#Motor|motor]], power delivery via the [[#Controller|controller]], and their inputs via [[#Throttle|throttle]] and drive mode configurations.

;Licensing
* For a time, Zero openly offered powertrain components in a licensed manner for prototyping and other uses.
* Currently, probably for reasons of liability and support overhead, this is not publicly offered but does seem available on request for companies wanting to develop products where Zero's powertrain is a good fit.
* See Zero's [https://www.zeromotorcycles.com/powertrains/ Z-Force Powertrain Solutions] page which has a contact form.

==[[Throttle]]==
{{:Throttle}}

===[[Bitron Throttle]]===
{{:Bitron Throttle}}

==[[FST Platform/Regen|Regen]]==
{{:FST Platform/Regen}}

==[[Drive Modes]]==
{{:Drive Modes}}

==[[Motor]]==
{{:Motor}}

===[[Z-Force Motor]]===
{{:Z-Force Motor}}

===[[Z-Force Motor/75-10|Z-Force Motor 75-10]]===
{{:Z-Force Motor/75-10}}

===[[FST Platform/Motor Mounting|Motor Mounting]]===
{{:FST Platform/Motor Mounting}}

===[[FST Platform/Motor Removal|Motor Removal]]===
{{:FST Platform/Motor Removal}}

===[[Motor Bearing Replacement]]===
{{:Motor Bearing Replacement}}

===[[Z-Force Motor/Shaft|Motor Shaft]]===
{{:Z-Force Motor/Shaft}}

===Motor Sounds===

====[[Motor Whirring]]====
:{{:Motor Whirring}}

====[[Motor Whine]]====
{{:Motor Whine}}

===[[Z-Force Motor/Electrical Connections|Motor Wiring]]===
{{:Z-Force Motor/Electrical Connections}}

===[[FST Platform/Motor Alignment|Motor Alignment]]===
{{:FST Platform/Motor Alignment}}

===[[Motor Commissioning]]===
{{:Motor Commissioning}}

===[[Z-Force Motor/Limits|Motor Limits]]===
{{:Z-Force Motor/Limits}}

==[[FST Platform/Motor Controller|Controller]]==
{{:FST Platform/Motor Controller}}

===[[FST Platform/Motor Controller/Operation|Controller Operation]]===
{{:FST Platform/Motor Controller/Operation}}

===[[FST Platform/Motor Controller/Alignment|Controller Alignment]]===
{{:FST Platform/Motor Controller/Alignment}}

===[[FST Platform/Motor Controller/Versions|Controller Versions]]===
{{:FST Platform/Motor Controller/Versions}}

===[[FST Platform/Controller Mounting|Controller Mounting]]===
{{:FST Platform/Controller Mounting}}

===[[FST Platform/Controller Uncovering|Controller Uncovering]]===
{{:FST Platform/Controller Uncovering}}

===[[FST Platform/Motor Controller/Heatsink|Controller Heatsink]]===
{{:FST Platform/Motor Controller/Heatsink}}

===[[FST Platform/Motor Controller/Connections|Controller Connections]]===
{{:FST Platform/Motor Controller/Connections}}

===[[FST Platform/Motor Controller/Feature Usage|Controller Feature Usage]]===
{{:FST Platform/Motor Controller/Feature Usage}}

===[[FST Platform/Motor Controller/CAN Diagnostics|Controller CAN Diagnostics]]===
{{:FST Platform/Motor Controller/CAN Diagnostics}}

===[[FST Platform/Motor Controller/Configuration|Controller Configuration]]===
{{:FST Platform/Motor Controller/Configuration}}

===[[FST Platform/Motor Controller/Cover|Controller Cover]]===
{{:FST Platform/Motor Controller/Cover}}

====[[FST Platform/Controller Uncovering|Controller Cover Removal]]====
{{:FST Platform/Controller Uncovering}}

=Electronic Systems=

==[[FST Platform/Instrument Cluster|Instrument Cluster]]==
{{:FST Platform/Instrument Cluster}}

==[[FST Platform/Onboard Charger|Charger]]==
{{:FST Platform/Onboard Charger}}

===[[FST Platform/Rapid Charge Module|Rapid Charge Module]]===
{{:FST Platform/Rapid Charge Module}}

====[[FST Platform/Onboard Charger/Behavior|Charger Behavior]]====
{{:FST Platform/Onboard Charger/Behavior}}

===[[FST Platform/Onboard Charger/Operation|Charger Operation]]===
{{:FST Platform/Onboard Charger/Operation}}

===[[FST Platform/Charger Power Cord|Charger Power Cord]]===
{{:FST Platform/Charger Power Cord}}

===[[FST Platform/Onboard Charger/Connections|Charger Connections]]===
{{:FST Platform/Onboard Charger/Connections}}

===[[FST Platform/Onboard Charger/Replacement|Charger Replacement]]===
{{:FST Platform/Onboard Charger/Replacement}}

==[[Gen2/Main Bike Board|Main Bike Board]]==
{{:Gen2/Main Bike Board}}

===[[Gen2/Main Bike Board/Limitations|Main Bike Board Limitations]]===
{{:Gen2/Main Bike Board/Limitations}}

===[[Gen2/Main Bike Board/Connections|Main Bike Board Connections]]===
{{:Gen2/Main Bike Board/Connections}}

==[[DC-DC 12V Converter|DC-DC 12V converter]]==
{{:DC-DC 12V Converter}}

==Power Harness==
The power cables and signal wiring that connects the MBB to the BMS units intended for that platform and year are collectively bundled and referred to as a “power harness”.

===[[Loopback Blanking Plug]]===
{{:Loopback Blanking Plug}}

===[[BMS CANBus Loopback|Loopback]]===
{{:BMS CANBus Loopback}}

==[[Firmware Update]]==
{{:Firmware Update}}

==[[Firmware Versions]]==
{{:Firmware Versions}}

=Battery=
The following guidance includes advice adapted from [http://electricmotorcycleforum.com/boards/index.php?topic=4280.0 MostlyBonkers' research summary] and [http://electricmotorcycleforum.com/boards/index.php?topic=5314 Battery Notes from a Farasis Engineer].

==[[Battery/Concepts|Battery Concepts]]==
{{:Battery/Concepts}}

==[[Battery/Charge Tips|Charge Tips]]==
{{:Battery/Charge Tips}}

==[[Battery/Capacity|Battery Capacity]]==
{{:Battery/Capacity}}

==[[Battery/Cells|Cells]]==
{{:Battery/Cells}}

==[[Battery/Cell Arrangement|Cell Arrangement]]==
{{:Battery/Cell Arrangement}}

===[[Battery/Brick|Brick]]===
{{:Battery/Brick}}

===[[Battery/Monolith|Monolith]]===
{{:Battery/Monolith}}

===[[Battery/Long Brick|Long Brick]]===
{{:Battery/Long Brick}}

==[[Battery Management System]]==
{{:Battery Management System}}

===[[BMS/Architecture|BMS Architecture]]===
{{:BMS/Architecture}}

===[[BMS Reset Procedure|BMS Reset]]===
{{:BMS Reset Procedure}}

===[[BMS/Cell Balancing|Cell Balancing]]===
{{:BMS/Cell Balancing}}

===[[BMS/Precharge|Precharge]]===
{{:BMS/Precharge}}

==[[State of Charge]]==
{{:State of Charge}}

===[[BMS/SoC Estimation|BMS SoC Estimation]]===
{{:BMS/SoC Estimation}}

===[[BMS/SoC Calibration|SoC Calibration]]===
{{:BMS/SoC Calibration}}

==[[Battery/Storage and Capacity with Age|Battery Storage and Capacity with Age]]==
{{:Battery/Storage and Capacity with Age}}

==[[Battery/Temperature Effects|Battery Temperature Effects]]==
{{:Battery/Temperature Effects}}

==[[Battery/Memory Effects|Battery Memory Effects]]==
{{:Battery/Memory Effects}}

==[[Battery/Rate of Charging and Discharging|Rate of Charging and Discharging]]==
{{:Battery/Rate of Charging and Discharging}}

==Protections==

===[[Main Contactor|Contactor]]===
{{:Main Contactor}}

===[[Battery/Internal Fuse|Battery Fuse]]===
{{:Battery/Internal Fuse}}

==[[Battery/Stress Factors|Battery Stress Factors]]==
{{:Battery/Stress Factors}}

==[[Battery/Longevity|Battery Longevity]]==
{{:Battery/Longevity}}

==[[Battery/Progress|Battery Future]]==
{{:Battery/Progress}}

==[[Battery/Best Practices|Battery Best Practices]]==
{{:Battery/Best Practices}}

==[[Battery/Construction|Battery Construction]]==
{{:Battery/Construction}}

==Battery Removal==
===[[FST Platform/Monolith Removal|Monolith Removal]]===
{{:FST Platform/Monolith Removal}}

==[[Battery/Pack Rebuild|Battery Pack Rebuild]]==
{{:Battery/Pack Rebuild}}

=[[FST Platform/Charging|Charging]]=
{{:FST Platform/Charging}}

==[[FST Platform/Charging Indications|Charging Indications]]==
{{:FST Platform/Charging Indications}}

==[[Charging Heat]]==
{{:Charging Heat}}

==[[FST Platform/Charging Inlet|On-board Charging Port]]==
{{:FST Platform/Charging Inlet}}

==[[FST Platform/Charging Circuit Fuse|Charging Circuit Fuse]]==
{{:FST Platform/Charging Circuit Fuse}}

=Electrical System=
==Lights and Signals==
===[[FST Platform/Headlamp|Headlamp]]===
{{:FST Platform/Headlamp}}

====[[SRF Model/Headlamp|Headlamp]]====
{{:SRF Model/Headlamp}}

====[[SRS Model/Headlamp|Headlamp]]====
{{:SRS Model/Headlamp}}

===[[Turn Signals]]===
{{:Turn Signals}}

===[[Turn Signal Flasher]]===
{{:Turn Signal Flasher}}

====[[FST Platform/Turn Signal Flasher Replacement|Turn Signal Flasher Replacement]]====
{{:FST Platform/Turn Signal Flasher Replacement}}

===[[Tail Light]]===
{{:Tail Light}}

===[[Horn]]===
{{:Horn}}

==Switchgear==

===[[12V Fuse Block|Fuse Block]]===
{{:12V Fuse Block}}

===[[Ignition Switch]]===
{{:Ignition Switch}}

===Handlebar Switch Housing===
The handlebar switch housing assemblies seem generic but have Torx T22 security bolt fasteners making inspection and maintenance more difficult than average.

===[[Kill Switch]]===
{{:Kill Switch}}

===[[Kickstand Switch]]===
{{:Kickstand Switch}}

===[[FST Platform/Tail Wiring|Tail Wiring]]===
{{:FST Platform/Tail Wiring}}

==[[FST Platform/Schematic|Schematic]]==
{{:FST Platform/Schematic}}

==[[OBD-II Port]]==
{{:OBD-II Port}}

===[[OBD-II Port Location]]<span id="OBD Location"></span>===
{{:OBD-II Port Location}}

==[[FST Platform/Electrical Routing|Routing]]==
{{:FST Platform/Electrical Routing}}

=Troubleshooting=
==[[FST Platform/Instrument Cluster/Troubleshooting|Dash Display]]==
{{:FST Platform/Instrument Cluster/Troubleshooting}}

===[[System Warning Sequences]]===
{{:System Warning Sequences}}

===[[Gen3/Error Codes|Error Codes]]===
{{:Gen3/Error Codes}}

==[[FST Platform/Isolation_Faults|Isolation Faults]]==
{{:FST Platform/Isolation_Faults}}

==Using Mobile App==
See the [[Official Mobile Application]] article.

==Diagnostics==

<DynamicPageList>
category = Diagnostics
</DynamicPageList>

[[Category:Under construction]]