View source for SDS Platform/Unofficial Service Manual

=Overview=

This describes the Zero [[SDS Platform]] and includes as many service tasks not described (or incompletely described) in the [[Official Owners Manual]] as customers have identified.
: Relevant Models: [[S Model]], [[DS Model]], [[SR Model]], and [[DSR 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__

==[[SDS 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.
{{:SDS 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}}

==[[SDS Platform/Tools|Tools]]==
{{:SDS Platform/Tools}}

==[[Gen2/Consumables|Consumables]]==
{{:Gen2/Consumables}}

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

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

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

==[[SDS Platform/Tail Subassembly|Tail Subassembly]]==
{{:SDS Platform/Tail Subassembly}}

==[[SDS Platform/Tail Extension|Tail Extension]]==
{{:SDS Platform/Tail Extension}}

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

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

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

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

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

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

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

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

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

==[[Gen2/Bodywork Material|Panel Material]]==
{{:Gen2/Bodywork Material}}

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

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

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

==[[SDS Platform/Lower Plastics|Lower Plastics]]==
{{:SDS Platform/Lower Plastics}}

===[[SDS Platform/Lower Plastics Removal|Lower Plastics Removal]]===
{{:SDS Platform/Lower Plastics Removal}}

=Steering=

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

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

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

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

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

==[[Gen2/Triple Clamp|Triple Clamp]]==
{{:Gen2/Triple Clamp}}

==[[Gen2/Steering Head|Steering Head]]==
{{:Gen2/Steering Head}}

===[[Gen2/Steering Head Bearing|Steering Head Bearing]]===
{{:Gen2/Steering Head Bearing}}

==[[Gen2/Front Fender|Front Fender]]==
{{:Gen2/Front Fender}}

===[[Gen2/Low Front Fender|Low Front Fender]]===
{{:Gen2/Low Front Fender}}

===[[Gen2/High Front Fender|High Front Fender]]===
{{:Gen2/High Front Fender}}

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

==[[Gen2/Front Wheel|Front Wheel]]==
{{:Gen2/Front Wheel}}

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

===Front Axle===
;TODO measurements

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

===[[Gen2/Front Bearings|Front Bearings]]===
{{:Gen2/Front Bearings}}

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

==[[Gen2/Rear Wheel|Rear Wheel]]==
{{:Gen2/Rear Wheel}}

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

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

===[[Gen2/Rear Bearings|Rear Bearings]]===
{{:Gen2/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]] by an M10 bolt.

The upper mount reaches the frame centertube ahead of the [[#Controller_Heatsink|controller heatsink]] area so is difficult to access.

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

===[[Gen2/Rear Shock Substitutions|Rear Shock Substitions]]===
{{:Gen2/Rear Shock Substitutions}}

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

=Final Drive=

==[[Gen2/Swingarm|Swingarm]]==
{{:Gen2/Swingarm}}

===[[Gen2/Swingarm Tube|Swingarm Tube]]===
{{:Gen2/Swingarm Tube}}

===[[Gen2/Swingarm Bearings|Swingarm Bearings]]===
{{:Gen2/Swingarm Bearings}}

===[[Gen2/Swingarm Removal|Swingarm Removal]]===
{{:Gen2/Swingarm Removal}}

==[[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}}

===[[Gen2/Drive Belt Adjustment|Belt Adjustment]]===
{{:Gen2/Drive Belt Adjustment}}

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

===[[Gen2/Drive Belt Replacement Procedure|Belt Replacement]]===
{{:Gen2/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}}

=[[Gen2/Brakes|Brakes]]=
{{:Gen2/Brakes}}

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

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

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

==[[Gen2/Rear Brake Actuator|Rear Brake Actuator]]==
{{:Gen2/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}}

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

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

==[[Gen2/Regen|Regen]]==
{{:Gen2/Regen}}

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

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

===[[Gen1/Agni Motor|Agni Motor]]===
{{:Gen1/Agni Motor}}

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

====[[Z-Force Motor/75-7|Z-Force Motor 75-7]]====
{{:Z-Force Motor/75-7}}

====[[Z-Force Motor/75-7R|Z-Force Motor R-Variant]]====
{{:Z-Force Motor/75-7R}}

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

====[[Z-Force Motor/Splined Shaft Update|Z-Force Motor Mount/Torque Update]]====
{{:Z-Force Motor/Splined Shaft Update}}

===[[Gen2/Motor Mounting|Motor Mounting]]===
{{:Gen2/Motor Mounting}}

===[[Gen2/Motor Removal|Motor Removal]]===
{{:Gen2/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}}

===[[Gen2/Motor Alignment|Motor Alignment]]===
{{:Gen2/Motor Alignment}}

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

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

==[[Gen2/Motor Controller|Controller]]==
{{:Gen2/Motor Controller}}

===[[Gen2/Motor Controller/Operation|Controller Operation]]===
{{:Gen2/Motor Controller/Operation}}

===[[Gen2/Motor Controller/Alignment|Controller Alignment]]===
{{:Gen2/Motor Controller/Alignment}}

===[[Gen2/Motor Controller/Versions|Controller Versions]]===
{{:Gen2/Motor Controller/Versions}}

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

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

===[[Gen2/Motor Controller/Heatsink|Controller Heatsink]]===
{{:Gen2/Motor Controller/Heatsink}}

===[[Gen2/Motor Controller/Connections|Controller Connections]]===
{{:Gen2/Motor Controller/Connections}}

===[[Gen2/Motor Controller/Feature Usage|Controller Feature Usage]]===
{{:Gen2/Motor Controller/Feature Usage}}

===[[Gen2/Motor Controller/CAN Diagnostics|Controller CAN Diagnostics]]===
{{:Gen2/Motor Controller/CAN Diagnostics}}

===[[Gen2/Motor Controller/Configuration|Controller Configuration]]===
{{:Gen2/Motor Controller/Configuration}}

===[[Gen2/Motor Controller/Cover|Controller Cover]]===
{{:Gen2/Motor Controller/Cover}}

====[[Controller Uncovering|Controller Cover Removal]]====
{{:Controller Uncovering}}

====[[Controller Cover Replacement]]====
{{:Controller Cover Replacement}}

=Electronic Systems=

==Instrument Cluster==
Until 2014, Zero used branded versions of generic Koso instrument clusters, mapping the fuel level indicator to battery state of charge.

===[[Gen1/Koso XR-SR|Koso XR-SR]]===
{{:Gen1/Koso XR-SR}}

===[[Koso RX-1N]]===
{{:Koso RX-1N}}

===[[Gen2/Instrument Cluster|Zero 2014 Instrument Cluster]]===
{{:Gen2/Instrument Cluster}}

==[[Onboard Charger|Charger]]==
{{:Onboard Charger}}

===[[Gen2/Calex Charger|Calex Charger]]===
{{:Gen2/Calex Charger}}

====[[Gen2/Calex Charger/Behavior|Calex Charger Behavior]]====
{{:Gen2/Calex Charger/Behavior}}

===[[Gen2/Meanwell Charger|Meanwell Charger]]===
{{:Gen2/Meanwell Charger}}

====[[Gen2/Meanwell Charger/Behavior|Meanwell Charger Behavior]]====
{{:Gen2/Meanwell Charger/Behavior}}

===[[Gen2/Calex Charger/Operation|Charger Operation]]===
{{:Gen2/Calex Charger/Operation}}

===[[Gen2/Charger Power Cord|Charger Power Cord]]===
{{:Gen2/Charger Power Cord}}

===[[Gen2/Calex Charger/Connections|Charger Connections]]===
{{:Gen2/Calex Charger/Connections}}

===[[Calex Charger Replacement|Charger Replacement]]===
{{:Calex 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}}

==[[Gen2/Charging Control Unit|Charging Control Unit]]==
{{:Gen2/Charging Control Unit}}

==[[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==
===[[SDS Platform/Monolith Removal|Monolith Removal]]===
{{:SDS Platform/Monolith Removal}}

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

=[[Gen2/Charging|Charging]]=
{{:Gen2/Charging}}

==[[Gen2/Charging Indications|Charging Indications]]==
{{:Gen2/Charging Indications}}

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

==[[Gen2/Charging Inlet|On-board Charging Port]]==
{{:Gen2/Charging Inlet}}

==[[Gen2/Accessory Charging Port|Accessory Charging Port]]==
{{:Gen2/Accessory Charging Port}}

==[[Gen2/Charging Circuit Fuse|Charging Circuit Fuse]]==
{{:Gen2/Charging Circuit Fuse}}

=Electrical System=
==Lights and Signals==
===[[SDS Platform/Headlamp|Headlamp]]===
Zero's models ship with halogen bulbs.
{{:SDS Platform/Headlamp}}

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

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

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

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

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

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

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

==Routing==
===[[SDS Platform/Power Cable Routing|Power Cable Routing]]===
{{:SDS Platform/Power Cable Routing}}
===[[SDS Platform/Charging Cable Routing|Charging Cable Routing]]===
{{:SDS Platform/Charging Cable Routing}}
===[[SDS Platform/Electrical Routing|12V Routing]]===
{{:SDS Platform/Electrical Routing}}

=Troubleshooting=
==[[Gen2/Instrument Cluster/Troubleshooting|Dash Display]]==
{{:Gen2/Instrument Cluster/Troubleshooting}}

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

===[[Gen2/Error Codes|Error Codes]]===
How to use the [[Gen2/Instrument Cluster|2014+ instrument cluster]] to extract self-reported diagnostic codes from the bike.

{{:Gen2/Error Codes}}

==[[Gen2/Isolation_Faults|Isolation Faults]]==
{{:Gen2/Isolation_Faults}}

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

==Diagnostics==

<DynamicPageList>
category = Diagnostics
</DynamicPageList>