Tool Kits

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This is a reference for the tools needed to work on Zeros. Some or many of these may be worth carrying with you on your bike, especially if you ride off-road or take trips far from home.

All "wrench" entries could be open-end, box, or even a socket. Torque values for most fasteners can be found in the owners' manuals. Add-on or aftermarket accessories (lights, windscreens, luggage, etc) may require additional tools.

Sample Tool kit:

Tool kit sample.jpg

2013-2014 S/SR/DS

Tool Items
Philips #1 Screwdriver Throttle assembly, turn signal lenses
Philips #2 Screwdriver Handlebar control switches, front brake fluid reservoir, misc plastics
Flathead Screwdriver Suspension adjustments
Hex key 3mm Body panels - side covers, tank plastics, front fender
Hex key 4mm Headlight, footguards, horn bracket, brake line clamps, misc
Hex key 5mm Front axle pinch bolts, brake rotors, left mirror perch clamp
Hex key 6mm Seat, front axle, battery box, motor mounts, fork clamps, misc structural
Hex key 7mm Side stand
Hex key 10mm Swingarm
Wrench 8mm Brake lever perch clamps, brake caliper bleeders
Wrench 10mm Brake lever pivot bolt
Wrench 13mm Brake calipers, belt adjusters
Wrench 14mm Mirrors, brake line banjo bolts
Wrench 15mm Rear brake pedal pivot
Torx T25 Front brake pad retainer pin
Wrench 27mm Rear axle nut
Wrench 42mm Top triple clamp crown bolt
Castle nut (size ???) Top steering head bearing
Spoke wrench (DS ONLY) Wheel spokes
Belt tension gauge Drive Belt
Tire Pressure Gauge Tires

* Different years (2015+) and models (FX/FXS) may vary from the above list. For example, 2015+ seats have a torx T45 bolt, and the handlebars are a 7mm hex rather than 6mm. There may be additional differences as well.

Spare Parts

Here are some recommended spare parts to carry on your Zero:

* Low voltage fuses (10 amp, 5 amp ATC style)
* High voltage fuses (ABC20A, ABC4A, ATM30 - see your owners' manual)
* Spare Drive Belt (especially on pre-2017 models)

Tire Repair

You may also consider carrying a tire repair kit with the appropriate items to repair a tire (patch for tubes, plug for tubeless) and a pump or CO2 cartridge to refill the air.