Difference between revisions of "Tool Kits"

Latest revision as of 21:49, 31 March 2020

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.

Sample: Zero's former toolkit for 2013-2014

Fastener Torques: See the owners' manuals, and the fastener specifications page.
Aftermarket: Add-on or aftermarket accessories (lights, windscreens, luggage, etc) may require additional tools.

2013+ S-Platform (S/DS/etc)
Tool	Spec	Items
Philips #1 Screwdriver	PH1	Throttle assembly, turn signal lenses
Philips #2 Screwdriver	PH2	Handlebar control switches, front brake fluid reservoir, misc plastics
Flathead Screwdriver	Size 1	Suspension adjustments
Allen key	3mm (H3)	Body panels side covers tank plastics front fender headlamp shoulders
	4mm (H4)	Headlight, footguards, horn bracket, brake line clamps, misc
	5mm (H5)	Front axle pinch bolts, brake rotors, left mirror perch clamp
	6mm (H6)	Misc Structural Seat bolts (with OEM side racks) front axle battery box motor mounts fork clamps
	7mm (H7)	Side stand, handlebars (2015+)
	10mm (H10)	Swingarm
Hex Open-end, box, or socket wrench	8mm	Brake lever perch clamps, brake caliper bleeders
	10mm	Brake lever pivot bolt
	13mm	Brake calipers, belt adjusters (open-end only)
	14mm	Mirrors, brake line banjo bolts
Torx bit	T25	Front brake pad retainer pin (2013-2014)
Torx bit	T45	Seat bolts (stock 2015+)
Security Torx bit	T25	Throttle assembly (2014+?)
Hex socket Wrench w/ at least 3/8" drive Torque setting advised	15mm	Rear brake pedal pivot
	27mm	Rear axle nut
	41mm (42mm?)	Top triple clamp crown bolt
Castle nut	(see manual)	Top steering head bearing
Spoke wrench		Wheel spokes (2013-2014 DS or FX)
Belt tension gauge	Gates Krikit	Drive Belt
Tire Pressure Gauge	Rated for 20-50psi	Tires

Here are some recommended spare parts to carry on your Zero or keep in your garage.

Low voltage fuses (10 amp, 5 amp ATC style)
High voltage fuses (ABC20A, ABC4A, ATM30 - see your official owners' manual)
Spare Drive Belt (especially on pre-2017 models)
Pre-ordering a belt can save replacement delivery delays when or if a belt snaps.
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.