Tool Kits

From Unofficial Zero Manual
Jump to: navigation, search

This is a reference for the tools needed to work on Zeros, collated from the unofficial manual.

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)
T45 Seat bolts (stock 2015+)
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

Consumables

Here are some recommended spare parts to carry on your Zero. See also the consumables section of the unofficial manual.

  • 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)
    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.