Difference between revisions of "OEM Drop Bars Install"

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(parts measurements and revised part number)
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: [[File:Crash-bars.jpg|thumb|300px|Drop bars, shoulder brackets, and crossmember layed out in installation form]]
: [[File:Crash-bars.jpg|thumb|300px|Drop bars, shoulder brackets, and crossmember layed out in installation form]]
# (2) Side bars (left and right).
# (2) Side bars (left and right).
# One crossmember piece.
# (1) Crossmember piece.
# (2) Shoulder brackets (left and right).
# (2) Shoulder brackets (left and right).
# (2) Heavy hex head M10x70mm stay bolts - 30mm thread with 40mm shoulder.
# (2) Heavy hex head M10x70mm stay bolts - 30mm thread with 40mm shoulder.

Revision as of 22:31, 21 July 2018

The police models (SP/DSP) include some broad crash bars.

The width is about 7 inches on the top half, but they taper to the bottom so lean angle is not affected (see photos).
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.
Part Number Name Price Notes
Police Drop Bars
Includes mounts for siren and lights
10-08062XX Dual Sport Drop Bars $250
part number
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
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.
Non-police drop bar parts
Drop bars, shoulder brackets, and crossmember layed out in installation form
  1. (2) Side bars (left and right).
  2. (1) Crossmember piece.
  3. (2) Shoulder brackets (left and right).
  4. (2) Heavy hex head M10x70mm stay bolts - 30mm thread with 40mm shoulder.
    These join the crossmember to the bars through the shoulder brackets.
  5. (4) Shoulder mount bolts: M4x20mm cap head bolts (replacements can have a 5mm long shoulder that is 6mm diameter).
  6. (5) Wide washers: 6mm ID, 14mm OD
  7. (4) Narrow washers: 6.5mm ID, 12mm OD
  8. (2) Toothed lock washers: 5mm ID
  9. (4) Lower mount bolts: M6?x15mm hex head bolts.
  • Allen wrenches for M4 and M6 bolts (depends on what is chosen).
  • 10mm hex socket wrench for the stay bolts.
  1. (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.
  2. (2015+) 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.
  3. Install the small shoulder brackets on each side of the frame shoulder area, using the pair of holes to anchor the brackets.
    Do not tighten the bolts until all pieces are in place.
  4. Detach the horn and the bracket holding it and set it aside.
    You may relocate it closer into the front of the frame or move it to the side (no recommendation here).
    For the DS/DSR, the front fender will interfere with this and the next step. Detach it and set it aside.
  5. 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 shoulder brackets might be under tension once the bar is in between the brackets. This is normal.
  6. Hold the cross member in place by running the M10x70mm bolts through the main holes.
  7. Attach each crash guard bar to the M10 bolt and fasten the lower end to the side of the bash plate using a pair of bolts.
    Tighten the bolts in concert.
  8. Once both crash guard bars are fastened tightly, check and tighten the bolts holding the small shoulder brackets.
    For the DS/DSR, replace the front fender if you removed it before.