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:
|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.
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)
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.