5,366
edits
Changes
move Corbin's tail fender eliminator to the aftermarket. This page is for hacks.
Procedures on this page generally involve fabrication or some modifications to the motorcycle that involve some risk.
=Guides=
Youtube Video blogs that cover Zero customization
;Electric Terry
: [https://www.youtube.com/user/gasfreeearth/videos Electric Terry Hershner] illustrates his long and adventurous career breaking records with Zero motorcycles, involving adding batteries, chargers, streamlined fairings, and conventional fairings to a 2012 Zero S and then a 2015 Zero SR for touring.
; DoctorBass
: [https://www.youtube.com/channel/UCp1WbWrsdKV_XT-_Jr_7HpA DoctorBass] is a "wizard"-level electric motorcycle tinkerer from Quebec.
: Many of his videos cover battery pack teardowns and construction, as well as instrumented performance measurement and tuning of powertrains.
: [https://www.youtube.com/playlist?list=PLIKut_pH6iuiZrCWhxPIeT59nsKCM9tjo Electric race playlist] showcases electric motorcycle racing (drag, street, and track).
; [[DigiNow]]
: [https://www.youtube.com/channel/UCb5Tkxx5Xg5krDY5QQCRdqA DigiNow Inc] by [[DigiNow]] describes their products and shows some demonstrations.
;NewZeroland
: [https://www.youtube.com/playlist?list=PLj677QLSu64TDDE-KuYOb4Vd7X0VQ0X3n Zero Modifying playlist] by [https://www.youtube.com/channel/UCdEMqkiM5I-98gxZKJXQ65Q NewZeroland]
;Dump the Pump
: [https://www.youtube.com/channel/UCLZ9tcCrr_bq2tSdJ_a-0eg Dump the Pump] includes videos preparing a 2015 Zero DS for touring with a fairing and chargers.
;Zero Pionier
: [https://www.youtube.com/playlist?list=PLEVz4SEGjzJsMhtUmaC--CLiJtUDM0ar4 Zero Motorcycles by "Zero Pionier" in German] with a 2017 Zero SR.
: [https://www.youtube.com/playlist?list=PLEVz4SEGjzJsY7Sf-BGoGQ9rdtApndQCN 24h-Weltrekord-Fahrt 2018 by "Zero Pionier" in German] describes an effort to see what the maximum distance a Zero with OEM equipment can achieve in 24 hours.
=Ergonomics=
==Custom Windscreen Mount==
The OEM windscreens are all MRA windscreens mounted via two points to the handlebar risers. They're attached to the windscreens below their center of pressure (CP) so have a tendency to wobble in highway speed winds and sometimes even fold.
Alternatively, you may choose a larger windscreen not designed for the OEM mounts, and want to secure it so it doesn't have this problem.
;Windscreen mount improvement options
* Acquire a [http://www.twistedthrottle.com/shop-by-product/ergonomics-rider-comfort/windshields/mra-mount-kits longer set of MRA stalks] that go around the handlebars (they all match the OEM mount) and change the angle of the mount to balance the windscreen forces better.
*: For a mount with existing holes, you can pick the upper holes to re-use and make a new pair above those at the right distance, then secure the mount to those, to minimize the modifications to the screen.
* Brace the windscreen at a third point (or second pair of points) near the headlamp.
*: A little metal bracket from the headlamp mount bolts up to the screen with a little clip or such might do the trick.
;NOTE
: If you drill through the windscreen to make a mount point, use drill bits meant for plastic so they won't catch and crack the plastic.
==[[SDS Platform/Create Quick Seat Release|Quick Seat Release]]==
{{:SDS Platform/Create Quick Seat Release}}
==Footpegs==
===[[Footpegs|Footpeg]] Relocation===
[http://electricmotorcycleforum.com/boards/index.php?topic=5956.0 Footpeg Relocator Adaptors] for the FX model.
===Dual Sport Footpeg Rubber===
[https://www.electricmotorcycleforum.com/boards/index.php?topic=9819 KuRi reports at EMF] that he's designed a 3d-printable footpeg rubber.
: [https://www.thingiverse.com/thing:4141991 Footpeg Rubber for Zero Motorcycles DS DSR] on Thingiverse
==[[Adapting Footpegs|Larger Rubber-Capped Footpegs]]==
{{:Adapting Footpegs}}
==Left Hand Controls==
===[[Gen2/High Beam Switch Toggle Sculpting|High Beam Switch Toggle Sculpting]]===
{{:Gen2/High Beam Switch Toggle Sculpting}}
==Handlebar Riser Adapters==
[http://electricmotorcycleforum.com/boards/index.php?topic=5019.0 Handlebar Riser Adaptors]
These adaptors tilt the risers 20° to move the bar-clamp centers back about 45mm from the OEM location, and up @ 10mm or so. They also greatly reduce the steering-stem-to-riser-bolt offset on the '14 FX, from 34mm to 12mm (all my ICE bikes have 14mm to 18mm offsets). Modern MX/offroad bars tend to be low and straight for the most part, and adding a bit more rise and setback allows me a greater choice than before. It's hard to tell from the photos at the Zero site, but it looks like these should work on any Zero that has removable risers with M10 riser bolts.
==[[SDS Platform/Install Tank Lock As Tail Helmet Lock|Helmet Lock Relocation]]==
{{:SDS Platform/Install Tank Lock As Tail Helmet Lock}}
==Throttle Upgrade==
Ted Dillard tried out and prefers the Domino throttle to the stock 2013-2014 Magura to reduce wrist twist for ergonomic reasons, published with a howto:
* [https://evmc2.wordpress.com/2014/03/30/5k-ohm-throttles-domino-vs-magura/ 5kOhm Throttles: Domino vs. Magura]
* [http://electricmotorcycleforum.com/boards/index.php?topic=4481 Domino Premium throttle to replace stock Magura throttle]
* [http://www.electricmotorsport.com/ev-parts/throttles/domino-twist-grip-throttle-with-microswitch.html Domino Twist-Grip Throttle with Microswitch product page at ElectricMotorSports]
* [http://electricmotorcycleforum.com/boards/index.php?topic=5252.0 Domino Throttle Installation] by Ray Ivers
Models from 2015 and onwards (for reasons that were published but need citation) have an incompatible throttle interface and require Sevcon controller reprogramming to switch throttles.
=Aesthetics=
==Tail Eliminator==
[https://www.thingiverse.com/BenTheRighteous/about BenTheRighteous] has created a [https://www.thingiverse.com/thing:3136698 3D-printable rear fender eliminator] for S/SR models. [http://electricmotorcycleforum.com/boards/index.php?topic=8359.0 EMF thread]
=Frame=
==[[Gen2/Fabricate Rear Axle Sliders|Rear Axle Sliders]]==
{{:Gen2/Fabricate Rear Axle Sliders}}
=Braking=
==[[Gen2/Replace Rear Brake Pedal With Lever|Left Hand Rear Brake]]==
{{:Gen2/Replace Rear Brake Pedal With Lever}}
== Better right hand lever ==
*: Yamaha lever, reportedly less harsh: http://electricmotorcycleforum.com/boards/index.php?topic=4949.msg58200#msg58200
=Powertrain=
==[[Gen2/Implement Variable Regen|Variable Regen]]==
{{:Gen2/Implement Variable Regen}}
==[[Gen2/Create Variable Regen Lever|Left Hand Variable Regen Lever]]==
{{:Gen2/Create Variable Regen Lever}}
==[[Gen2/Implement Reverse Mode|Reverse Mode]]==
{{:Gen2/Implement Reverse Mode}}
==Wide Belt for Pre-2017 Models==
[http://electricmotorcycleforum.com/boards/index.php?topic=6538 Big belt Kits for pre-2017 bikes.]
This involves designing and machining a front sprocket to adapt to the older keyed shaft.
It will also change the gear ratio (without making a different rear sprocket choice) to reduce top speed and raise torque.
=Electrical Accessories=
==[[Gen2/Always-On Accessory Power Supply|Always-On Accessory Power Supply]]==
{{:Gen2/Always-On Accessory Power Supply}}
==Givi Top Case RGB LED==
This uses an Arduino + WS2812 custom RGB LEDs to add brake lighting to a [https://www.givi.it/cases/Monokey/V47NN%20TECH Givi V47NN Tech Top Case]
: [[File:Givi-topcase-LED-mod.jpeg|thumb|LEDs in the case]] [[File:Givi-topcase-LED-mod-arduino.jpeg|thumb|Wiring and Arduino board]]
: The Givi V47 series top case has an optional [https://www.givi.it/cases/Monokey/V47NN%20TECH?o=E135 LED kit] that adds an extra stop light.
: This is a DIY version of the same.
;Parts and Tools
* hot glue
* a soldering iron
* an Arduino to hook it up to the bikes wiring and make it all light up.
; References
* [https://www.youtube.com/watch?v=gVIXSBNNbzE Zero S 2016 Givi Topcase LED MOD video on YouTube]:
*: {{#ev:youtube|gVIXSBNNbzE}}
==[[Sound System]]==
{{:Sound System}}
=Diagnostics=
==[[Cycle Analyst]]==
This allows datalogging of a variety of parameters tracking voltage, current, and regen for trips.
{{warning|This requires a great deal of skills and knowledge to install and calibrate correctly on a Zero, and is not intended for casual customers.}}
See our [[Cycle Analyst]] page for details.
=[[Gen2/Front Wheel Swap|Front Wheel Swap]]=
{{:Gen2/Front Wheel Swap}}
=Charging=
==Top Case Charger Install==
;[http://electricmotorcycleforum.com/boards/index.php?topic=6713.0 Diginow 6.6kw Supercharger in top case install project]
==[[Install Charging Circuit At Controller|Charging Through Sevcon Controller Lugs]]==
{{:Install Charging Circuit At Controller}}
==Hard-Mounting Chargers==
;[http://electricmotorcycleforum.com/boards/index.php?topic=4698 Impersonating a Beemer with QuiQ Chargers]
: Mount QuiQ chargers on the side of the S platform power pack in the lower forward quarter to get the "BMW boxer" look.
==[[SDS Platform/Fabricate Permanent Onboard Power Cable|Leave-In Kettle Cord]]==
{{:SDS Platform/Fabricate Permanent Onboard Power Cable}}
==[[Gen2/Fabricate Charger Y-Cable|Charger Y-Cable]]==
{{:Gen2/Fabricate Charger Y-Cable}}
==Type2 to 3x regular power outlets adapter==
[[File:type2 adapter.jpg|400px]]
: Using your Quiq chargers while on the road :) Get 3x 230V connections out of a Type2 connection/charging station with this adapter.
: [http://www.instructables.com/id/Type2-Mennekes-to-3-230V-Sockets-under-Constructio/ Type 2 to 3x 230V Sockets Instructable]
==[[XMX Platform/Charging Off-Bike|Charging Off Bike]]==
{{:XMX Platform/Charging Off-Bike}}
=Battery=
==Battery Rebuild==
===[[Gen1/Battery Rebuild|Pre-2013 Battery Rebuild]]===
{{:Gen1/Battery Rebuild}}
=Guides=
Youtube Video blogs that cover Zero customization
;Electric Terry
: [https://www.youtube.com/user/gasfreeearth/videos Electric Terry Hershner] illustrates his long and adventurous career breaking records with Zero motorcycles, involving adding batteries, chargers, streamlined fairings, and conventional fairings to a 2012 Zero S and then a 2015 Zero SR for touring.
; DoctorBass
: [https://www.youtube.com/channel/UCp1WbWrsdKV_XT-_Jr_7HpA DoctorBass] is a "wizard"-level electric motorcycle tinkerer from Quebec.
: Many of his videos cover battery pack teardowns and construction, as well as instrumented performance measurement and tuning of powertrains.
: [https://www.youtube.com/playlist?list=PLIKut_pH6iuiZrCWhxPIeT59nsKCM9tjo Electric race playlist] showcases electric motorcycle racing (drag, street, and track).
; [[DigiNow]]
: [https://www.youtube.com/channel/UCb5Tkxx5Xg5krDY5QQCRdqA DigiNow Inc] by [[DigiNow]] describes their products and shows some demonstrations.
;NewZeroland
: [https://www.youtube.com/playlist?list=PLj677QLSu64TDDE-KuYOb4Vd7X0VQ0X3n Zero Modifying playlist] by [https://www.youtube.com/channel/UCdEMqkiM5I-98gxZKJXQ65Q NewZeroland]
;Dump the Pump
: [https://www.youtube.com/channel/UCLZ9tcCrr_bq2tSdJ_a-0eg Dump the Pump] includes videos preparing a 2015 Zero DS for touring with a fairing and chargers.
;Zero Pionier
: [https://www.youtube.com/playlist?list=PLEVz4SEGjzJsMhtUmaC--CLiJtUDM0ar4 Zero Motorcycles by "Zero Pionier" in German] with a 2017 Zero SR.
: [https://www.youtube.com/playlist?list=PLEVz4SEGjzJsY7Sf-BGoGQ9rdtApndQCN 24h-Weltrekord-Fahrt 2018 by "Zero Pionier" in German] describes an effort to see what the maximum distance a Zero with OEM equipment can achieve in 24 hours.
=Ergonomics=
==Custom Windscreen Mount==
The OEM windscreens are all MRA windscreens mounted via two points to the handlebar risers. They're attached to the windscreens below their center of pressure (CP) so have a tendency to wobble in highway speed winds and sometimes even fold.
Alternatively, you may choose a larger windscreen not designed for the OEM mounts, and want to secure it so it doesn't have this problem.
;Windscreen mount improvement options
* Acquire a [http://www.twistedthrottle.com/shop-by-product/ergonomics-rider-comfort/windshields/mra-mount-kits longer set of MRA stalks] that go around the handlebars (they all match the OEM mount) and change the angle of the mount to balance the windscreen forces better.
*: For a mount with existing holes, you can pick the upper holes to re-use and make a new pair above those at the right distance, then secure the mount to those, to minimize the modifications to the screen.
* Brace the windscreen at a third point (or second pair of points) near the headlamp.
*: A little metal bracket from the headlamp mount bolts up to the screen with a little clip or such might do the trick.
;NOTE
: If you drill through the windscreen to make a mount point, use drill bits meant for plastic so they won't catch and crack the plastic.
==[[SDS Platform/Create Quick Seat Release|Quick Seat Release]]==
{{:SDS Platform/Create Quick Seat Release}}
==Footpegs==
===[[Footpegs|Footpeg]] Relocation===
[http://electricmotorcycleforum.com/boards/index.php?topic=5956.0 Footpeg Relocator Adaptors] for the FX model.
===Dual Sport Footpeg Rubber===
[https://www.electricmotorcycleforum.com/boards/index.php?topic=9819 KuRi reports at EMF] that he's designed a 3d-printable footpeg rubber.
: [https://www.thingiverse.com/thing:4141991 Footpeg Rubber for Zero Motorcycles DS DSR] on Thingiverse
==[[Adapting Footpegs|Larger Rubber-Capped Footpegs]]==
{{:Adapting Footpegs}}
==Left Hand Controls==
===[[Gen2/High Beam Switch Toggle Sculpting|High Beam Switch Toggle Sculpting]]===
{{:Gen2/High Beam Switch Toggle Sculpting}}
==Handlebar Riser Adapters==
[http://electricmotorcycleforum.com/boards/index.php?topic=5019.0 Handlebar Riser Adaptors]
These adaptors tilt the risers 20° to move the bar-clamp centers back about 45mm from the OEM location, and up @ 10mm or so. They also greatly reduce the steering-stem-to-riser-bolt offset on the '14 FX, from 34mm to 12mm (all my ICE bikes have 14mm to 18mm offsets). Modern MX/offroad bars tend to be low and straight for the most part, and adding a bit more rise and setback allows me a greater choice than before. It's hard to tell from the photos at the Zero site, but it looks like these should work on any Zero that has removable risers with M10 riser bolts.
==[[SDS Platform/Install Tank Lock As Tail Helmet Lock|Helmet Lock Relocation]]==
{{:SDS Platform/Install Tank Lock As Tail Helmet Lock}}
==Throttle Upgrade==
Ted Dillard tried out and prefers the Domino throttle to the stock 2013-2014 Magura to reduce wrist twist for ergonomic reasons, published with a howto:
* [https://evmc2.wordpress.com/2014/03/30/5k-ohm-throttles-domino-vs-magura/ 5kOhm Throttles: Domino vs. Magura]
* [http://electricmotorcycleforum.com/boards/index.php?topic=4481 Domino Premium throttle to replace stock Magura throttle]
* [http://www.electricmotorsport.com/ev-parts/throttles/domino-twist-grip-throttle-with-microswitch.html Domino Twist-Grip Throttle with Microswitch product page at ElectricMotorSports]
* [http://electricmotorcycleforum.com/boards/index.php?topic=5252.0 Domino Throttle Installation] by Ray Ivers
Models from 2015 and onwards (for reasons that were published but need citation) have an incompatible throttle interface and require Sevcon controller reprogramming to switch throttles.
=Aesthetics=
==Tail Eliminator==
[https://www.thingiverse.com/BenTheRighteous/about BenTheRighteous] has created a [https://www.thingiverse.com/thing:3136698 3D-printable rear fender eliminator] for S/SR models. [http://electricmotorcycleforum.com/boards/index.php?topic=8359.0 EMF thread]
=Frame=
==[[Gen2/Fabricate Rear Axle Sliders|Rear Axle Sliders]]==
{{:Gen2/Fabricate Rear Axle Sliders}}
=Braking=
==[[Gen2/Replace Rear Brake Pedal With Lever|Left Hand Rear Brake]]==
{{:Gen2/Replace Rear Brake Pedal With Lever}}
== Better right hand lever ==
*: Yamaha lever, reportedly less harsh: http://electricmotorcycleforum.com/boards/index.php?topic=4949.msg58200#msg58200
=Powertrain=
==[[Gen2/Implement Variable Regen|Variable Regen]]==
{{:Gen2/Implement Variable Regen}}
==[[Gen2/Create Variable Regen Lever|Left Hand Variable Regen Lever]]==
{{:Gen2/Create Variable Regen Lever}}
==[[Gen2/Implement Reverse Mode|Reverse Mode]]==
{{:Gen2/Implement Reverse Mode}}
==Wide Belt for Pre-2017 Models==
[http://electricmotorcycleforum.com/boards/index.php?topic=6538 Big belt Kits for pre-2017 bikes.]
This involves designing and machining a front sprocket to adapt to the older keyed shaft.
It will also change the gear ratio (without making a different rear sprocket choice) to reduce top speed and raise torque.
=Electrical Accessories=
==[[Gen2/Always-On Accessory Power Supply|Always-On Accessory Power Supply]]==
{{:Gen2/Always-On Accessory Power Supply}}
==Givi Top Case RGB LED==
This uses an Arduino + WS2812 custom RGB LEDs to add brake lighting to a [https://www.givi.it/cases/Monokey/V47NN%20TECH Givi V47NN Tech Top Case]
: [[File:Givi-topcase-LED-mod.jpeg|thumb|LEDs in the case]] [[File:Givi-topcase-LED-mod-arduino.jpeg|thumb|Wiring and Arduino board]]
: The Givi V47 series top case has an optional [https://www.givi.it/cases/Monokey/V47NN%20TECH?o=E135 LED kit] that adds an extra stop light.
: This is a DIY version of the same.
;Parts and Tools
* hot glue
* a soldering iron
* an Arduino to hook it up to the bikes wiring and make it all light up.
; References
* [https://www.youtube.com/watch?v=gVIXSBNNbzE Zero S 2016 Givi Topcase LED MOD video on YouTube]:
*: {{#ev:youtube|gVIXSBNNbzE}}
==[[Sound System]]==
{{:Sound System}}
=Diagnostics=
==[[Cycle Analyst]]==
This allows datalogging of a variety of parameters tracking voltage, current, and regen for trips.
{{warning|This requires a great deal of skills and knowledge to install and calibrate correctly on a Zero, and is not intended for casual customers.}}
See our [[Cycle Analyst]] page for details.
=[[Gen2/Front Wheel Swap|Front Wheel Swap]]=
{{:Gen2/Front Wheel Swap}}
=Charging=
==Top Case Charger Install==
;[http://electricmotorcycleforum.com/boards/index.php?topic=6713.0 Diginow 6.6kw Supercharger in top case install project]
==[[Install Charging Circuit At Controller|Charging Through Sevcon Controller Lugs]]==
{{:Install Charging Circuit At Controller}}
==Hard-Mounting Chargers==
;[http://electricmotorcycleforum.com/boards/index.php?topic=4698 Impersonating a Beemer with QuiQ Chargers]
: Mount QuiQ chargers on the side of the S platform power pack in the lower forward quarter to get the "BMW boxer" look.
==[[SDS Platform/Fabricate Permanent Onboard Power Cable|Leave-In Kettle Cord]]==
{{:SDS Platform/Fabricate Permanent Onboard Power Cable}}
==[[Gen2/Fabricate Charger Y-Cable|Charger Y-Cable]]==
{{:Gen2/Fabricate Charger Y-Cable}}
==Type2 to 3x regular power outlets adapter==
[[File:type2 adapter.jpg|400px]]
: Using your Quiq chargers while on the road :) Get 3x 230V connections out of a Type2 connection/charging station with this adapter.
: [http://www.instructables.com/id/Type2-Mennekes-to-3-230V-Sockets-under-Constructio/ Type 2 to 3x 230V Sockets Instructable]
==[[XMX Platform/Charging Off-Bike|Charging Off Bike]]==
{{:XMX Platform/Charging Off-Bike}}
=Battery=
==Battery Rebuild==
===[[Gen1/Battery Rebuild|Pre-2013 Battery Rebuild]]===
{{:Gen1/Battery Rebuild}}
