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SR/S
Zero SR/S User Manual
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10-14
Motor Control
ler Firmware Update
Maintenance and Safety
10
Motor Con
troller
Firmwar
e Update
Motor Controller Firmware Update
Process
1.
To update the Motor Controller Firmware,
contact Zero Motorcycles Customer
Service
department for assistance.
•
North America:
support@zeromotorcycles.co
m
•
Zero Motorcycles Europe:
service.eu@zeromotorcycles.com
23
25
Table of Contents
Default Chapter
3
Default Chapter
3
Table of Contents
3
General Information
7
How to Use this Manual
7
Important Repair Information
8
Lockout Procedure
11
Maintenance and Safety
11
Adjust Drive Belt
12
Brake Bleeding Procedure (Front)
15
Brake Maintenance Procedures
15
Brake Bleeding Procedure (Rear)
16
Brake Bedding
17
Key Programming
18
Motor Commissioning
20
Motor Controller Firmware Update
24
Power Pack
30
BMS (Battery Management System) [Before 2022MY]
30
Battery Management Unit (BMU) [22MY Onwards]
38
Power Pack Battery Signal Harness [Before 2022MY]
39
Power Pack Accessory Power Bus [Before 2022MY]
44
Power Pack Heat Sink Skins [Before 2022MY]
52
Front Cover [22MY Onwards]
55
Service Cover [22MY Onwards]
55
MID Pack Protection Unit [22MY Onwards]
56
Rear Cover [22MY Onwards]
56
Top Cover [22MY Onwards]
57
Cooling Fan [22MY Onwards]
58
Assembly Cell Management Unit (CMU) [22MY Onwards]
59
Power Leads - Positive & Negative [22MY Onwards]
61
Contactor [22MY Onwards]
62
Controller BUS Set [22MY Onwards]
63
Volt Harness [22MY Onwards]
65
BCB Main BUS Set [22MY Onwards]
66
Charging System
69
Chargers
69
3KW Rapid Charger (Front) [Before 2022MY]
69
3KW Rapid Charger (Front and Rear) [Before 2022MY]
75
6KW Charger [22MY Onwards]
82
Charge Inlet Harness
85
DC/DC Converter
88
Motor and Drive System
91
Motor
91
Motor Stop Switch
104
Throttle
108
Throttle (Without Heated Grips)
108
Throttle (with Heated Grips)
112
Controller
117
Motor Controller [Before 2022MY]
117
Motor Controller Carrier [Before 2022MY]
129
Motor Controller with Heatsink [22MY Onwards]
132
Rear Sprocket
133
Suspension
137
Wheel Speed Sensor (WSS)
137
Wheel Speed Sensor (Front)
137
Wheel Speed Sensor (Rear)
142
Front Suspension
147
Steering Stem
147
Rear Shock
152
Rear Suspension
152
Swingarm
155
Doubler Plate Seals
165
Replace Drive Belt
171
Adjust Drive Belt
175
Brakes
179
Front Wheel
203
Wheels
203
Front Wheel
203
Rear Wheel
206
Body Trim
211
Rider's Seat
211
Body
211
Headlight Upper Fairing
212
Headlight Inner Fairing
213
Hela Bracket
216
Tank Removal
220
Side Fairings (Outer)
224
Side Fairings (Inner)
229
Tank (Disassembly and Reassembly)
232
For this Procedure, There will be References to Screws Securing Body Panels, that Are
237
Different Sized Screws
237
Small Screws: Designated on Photos with Yellow Arrows
237
Large Screws: Designated on Photos with Pink Arrows
237
Screwdriver. Torque: Hand Tighten - Do Not
238
Over-Tighten
238
Grab Handles (Right and Left)
242
Tank Storage Liner
244
Tail
246
Tail Assembly
246
Electrical
249
High Voltage Fuses
249
12 Volt Battery
251
Volt Battery (Disconnect)
251
Headlight
256
Lighting
256
Tail Light
258
Turn Signal (Left Front)
259
Turn Signal (Right Front)
260
Turn Signal (Rear)
264
Instruments
267
Dash
267
Key Switch
269
Mode Switch
271
Mode Switch (Without Heated Grips)
271
Mode Switch (with Heated Grips)
272
Heated Grip
277
Heated Grips (Left)
277
Kickstand Switch
281
Cellular Connectivity Module (CCM)
284
Main Bike Board (MBB)
287
4
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Zero SR/S Specifications
General
Brand
Zero
Model
SR/S
Category
Motorcycle
Language
English
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