View source for SDS Platform/Zero Drop Bars/Install

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The police models (SP/DSP) include some [[SDS Platform/Zero Drop Bars|drop bars]] with bracketing to mount law enforcement specific equipment like a siren and flashing lights.
: [[File:drop-bars-installed-sr.jpg|thumb|Installed on an SR (front)]][[File:drop-bars-installed-sr-side.jpg|thumb|Installed on an SR (side)]]
: Both the police versions of these drop bars and less expensive drop bars without the bracketing are available to all owners.
: The width is broad; about 7 inches on the top half (for a total 26" width around the frame there), but they taper to the bottom so lean angle is not affected.
: Zero does not list all drop bar options on their website, but dealers can request them by part number.
: Instructions have not been observed included yet.

; Construction
: Steel tube of 1" outer diameter with a black finish.
; Upper Fastening
: The bars attach to each other via a crosspiece just in front of the frame.
: The crosspiece is held to the frame by shoulder brackets on each side.
; Lower Fastening
: The bars have a flange that bolts directly to collared inserts in the metal skid plate.
: The metal skid plate is provided on the DS/DSR.
: The plastic skid plate provided on the S/SR is swapped for the DS/DSR metal skid plate during installation.

{| class="wikitable"
|+ Options
!Part Number
!Name
!Price
!Notes
|-
|
|Police Drop Bars
: Includes mounts for siren and lights
|$450
|
|-
|10-08062XX
|Dual Sport Drop Bars
| rowspan="2"|$250
| [[File:MY2016DSR_dropbarsnonpolice_pnXX.jpg|100px|part number]]
|-
|10-0806203
: Rev. 10-08123XX
|Frame Protection Bar Accessories Kit, Non-Police, 13-16 MY
: Rev. Frame Protection Bar Accessories Kit, Non-Mat(?)
: Includes 20-07053-01 skid plate 1PCS PO10224
| [[File:MY2016DSR_dropbarsnonpolice_pn03.jpg|100px|part number]]
: [[File:drop bar parts label.png|100px|Rev. part number]]
|-
|10-08028
|Zero FX Drop Bars
|$175
|
|}

;Install Variations
: '''2015+:''' the frame is predrilled to mount them, but the lower mount varies slightly per model year and may require modification to the belly pan.
: '''2014:''' the belly pan required drilling, and use of Rivnuts. Zero was not cooperative in acquiring, but parts from a downconverted SP were found.
: '''2015+ DS,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.

; Parts
: [[File:MY2016DSR_dropbarsnonpolice_partscontents.jpg|thumb|300px|Non-police drop bar parts]]
: [[File:drop bar parts.png|thumb|Drop bar fasteners]]
: [[File:drop-bars-fasteners.jpg|thumb|Included fasteners]]
: [[File:Crash-bars.jpg|thumb|300px|Structure layed out in installation form]]
* (2) Side bars (left and right).
* (1) Crossmember piece.
* (1) Metal skid plate; identical to DS/DSR original skid plate, and must replace an S/SR plastic skid plate.
* (2) Shoulder brackets (left and right).
* (2) Heavy hex head M10x70mm stay bolts - 30mm thread with 40mm shoulder.  Stamped "FMI 10.9" on the head.
*: These join the crossmember to the bars through the shoulder brackets.
* (4) Shoulder mount bolts: M5x20mm cap head bolts (replacements can have a 5mm long shoulder that is 6mm diameter).
* (5) Wide washers: 6mm ID, 14mm OD
* (4) Narrow washers: 6.5mm ID, 12mm OD
* (2) Toothed lock washers: 5mm ID
*: These may be mistakenly included when recorded? No known application
* (4) Lower mount bolts: M6?x15mm hex head bolts.

;Tools
: [[File:drop-bars-tools.jpg|200px|Tools (suggestion)]]
* Allen wrenches for M5 and M6 bolts (depends on what is chosen).
* 10mm hex socket wrench for the stay bolts.
* ''Optional:'' Plastic rivet removal tool
*: [[File:Drop Bars - Plastic Rivet Removal Tool.jpg|200px|Plastic rivet removal tool]]

;Steps
# '''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.
# '''S/SR:''' [[Belly Pan Removal|Remove the original plastic skid plate]] and install the included metal skid plate.
#: [[File:drop-bars-skid-plate-removal.jpg|200px|Plastic skid plate removal]]
# 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.
# Detach the horn bracket (via a hex nut and lock nut) and set it aside.
#: You may relocate it closer into the front of the frame or move it to the side (no recommendation here).
#: '''DS/DSR:''' The front fender will interfere with this and the next step. Detach it and set it aside.
# Install the small shoulder brackets on each side of the frame shoulder area, using the pair of holes to anchor the brackets.
#: Each side will have a pair of collared holes in the frame arms near the front of the tank plastics.
#: Slide the brackets in from below and behind.
#: The holes for the bars will be in front of the frame arms on the outside.
#: Do not tighten the bolts until all pieces are in place.
#: [[File:drop-bars-shoulder-bracket-fastening.jpg|200px|Right shoulder bracket fastening]] [[File:Drop Bars - Left Shoulder Bracket with Ground Lead.jpg|200px|Left shoulder bracket with ground lead]]
# 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 bar will be very close to the plastics covering the front of the battery, and recessed upward.
#: The shoulder brackets might be under tension once the bar is in between the brackets. This is normal.
#:[[File:drop-bars-crosspiece-mount.jpg|200px|Crosspiece mounted]][[File:Crash-bar-crossmember.jpg|200px|Crosspiece]][[File:Crash-bar-shoulder-mount.jpg|200px|Shoulder mount]]
# Hold the cross member in place by running the M10x70mm bolts through the main holes.
# Attach each drop bar:
## Place the bar against the shoulder bracket with the lower end hanging back but under the bike.
## Thread the M10 bolt through the shoulder bracket into the bar's top opening to support the bar.
## Rotate the supported bar's bottom end to cover the skid plate.
## Thread M6 bolts through the lower end's flange into the collared holes on the side of the skid plate.
##: [[File:drop-bars-lower-mount.jpg|200px|thumb|none|Lower mount]]
# Tighten the bolts (M10 at top and M6 at bottom) in concert.
#: The M10 bolt at top could benefit from either a telescoping socket across the bike behind the forks, or a shallow side socket wrench.
#: The M6 bolts below can use a hex socket with an extension.
#: [[File:drop-bars-crosspiece-tightening.jpg|200px|thumb|none|Tightening the crosspiece bolts]]
# Re-mount the horn by either:
#* Re-attaching the horn bracket:
#*: [[File:drop-bars-horn-reinstall.jpg|200px|Reinstalling the horn bracket]]
#* Attaching the horn to the left bar bracket:
#*: [[File:Drop Bars - Left Side Horn Front.jpg|200px|Horn on left bar (front)]] [[File:Drop Bars - Left Side Horn Rear.jpg|200px|Horn on left bar (rear)]]
# Once both crash guard bars are fastened tightly, check and tighten the bolts holding the small shoulder brackets.
#: [[File:drop-bars-shoulder-bracket-fastened.jpg|200px|thumb|none|Shoulder bracket fastened]]
# '''DS/DSR:''' replace the front fender if you removed it before.

;References
* [https://www.electricmotorcycleforum.com/boards/index.php?topic=8358 Zero Drop Bar Installation on DSR with Pics]
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[[Category:Install]]