Zero Motocycles. DS 2015 Exploded Views

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Chester Elliott
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1 Zero Motocycles DS 205 Exploded Views

2 ZEV00 - Lighting

3 ZEV00 - Lighting Callout Part Number Part Name Qty. per Motorcycle TURN SIGNAL FR-RH RR-LH HEADLIGHT MOUNT RIGHT SDS ACCESSORY OUTLET COVER HEADLIGHT ASSY, 60/55W, TRIOM TURN SIGNAL HEX NUT CAP HEXAGON THIN NUT ISO 4035 M0-04 ZM-F-0 REV 02 2 TOOTHED LOCK WASHER WITH EXTERNAL TEETH DIN A M0-B85 ZM-F-0 REV HEADLIGHT MOUNT LEFT M5X6-8.8 ZM-F- REV WASHER M5 X X NYLON 6/6 BLACK WASHER M5 X X NYLON 6/6 BLACK M5X6-8.8 ZM-F- REV TURN SIGNAL FR-LH RR-RH SDS HEADLIGHT BULB HEXAGON SOCKET BUTTON HEAD SCREWS ISO M6X2-8.8 ZM-F-0 REV 03 ZM-L-0 REV HEADLIGHT MOUNTING WASHER LED TAIL LIGHT TRIOM TURN SIGNAL FR-LH RR-RH TOOTHED LOCK WASHER WITH EXTERNAL TEETH DIN A M0-B85 ZM-F-0 REV HEXAGON THIN NUT ISO 4035 M0-04 ZM-F-0 REV TURN SIGNAL HEX NUT CAP 2 SDS TAIL POD TOP NOTE: Top half only. Order bottom half PN: LICENSE PLATE LIGHT REFLECTOR MOUNT BRACKET PHILIPS HEAD SHEET METAL SCREW 6 X / REFLECTOR, OVAL, ADH BACK, RED ECIE HEXAGON SOCKET COUNTERSUNK HEAD SCREW ISO M5X2-0.9 ZM-F-0 REV LICENSE PLATE BUMPER LICENSE PLATE BRACKET EXTENSIONS NOTE: UR ONLY HEXAGON SOCKET BUTTON HEAD SCREWS ISO M6X2-8.8 ZM-F-0 REV 03 ZM-L-0 REV WASHER ISO HV ZM-F-0 REV 02 0

4 WASHER M5 X X NYLON 6/6 BLACK 4 PREVAILING TORQUE TYPE NUT DIN 985 M5-08 ZM-F REV 02 LICENSE PLATE BRACKET EXTENSIONS NOTE: ONLY USED IN EU/AUS REGIONS LICENSE PLATE BRACKET EXTENSIONS NOTE: ONLY USED IN EU/AUS REGIONS SDS TAIL POD BOTTOM NOTE: Bottom half only. Order top half PN: BMS MOUNTING SCREW NEXT TO DIA CONNECTOR 4 PREVAILING TORQUE TYPE NUT DIN 985 M5-08 ZM-F REV TURN SIGNAL FR-RH RR-LH WASHER ISO HV ZM-F-0 REV 02 0 PREVAILING TORQUE TYPE NUT DIN 985 M6-8 ZM-F-0 REV SDS TAIL FRAME HEADLIGHT BRACKET HEADLIGHT MOUNTING WASHER BOLT M6 X 8

6 ZEV002 - Braking

7 ZEV002 - Braking Callout Part Number Part Name Qty. per Motorcycle SDS BRAKE JJUAN LEVER 2 PA-77 BRAKE LEVER PIVOT BOLT JJUAN 2.7MM FRONT MASTER CYLINDER SDS/FXS FRONT MASTER CYLINDER CLAMP KIT NOTE: SDS/XMX NOTE: Mount and Bolts NOTE: Upper Mirror Mount RH 5 PA-78 MIRROR POST BOLT 6M X 20 6 PA-28 BANJO GASKET SDS FRONT BRAKE LINE MC TO HCU 8 PA-28 BANJO GASKET BANJO BOLT 0 PA-30 BRAKE LEVER PIVOT BOLT NUT PA-79 BRAKE LINE CLIP BRAKE LINE GUIDE P CLAMP TO TRIPLE CLAMP BOLT 4 PA-80 BANJO BOLT 5 PA-28 BANJO GASKET 6 PA-28 BANJO GASKET S FRONT BRAKE LINE HCU TO CALIPER 8 PA-28 BANJO GASKET 9 PA-8 BANJO BOLT 20 PA-28 BANJO GASKET BRAKE ROTOR 320MM FIXED CUSTOM ROTOR BOLT M8X23MM SHOULDER SCREW MPI WHEEL SPEED SENSOR HEXAGON HEAD SCREW ISO 4762 M0-.25X ZM-F-0 REV03 ZM-L-0 REV0 25 PA-82 BLEEDER VALVE JJUAN 32/30MM FRONT CALIPER SDS HEXAGON HEAD SCREW ISO 4762 M0-.25X ZM-F-0 REV03 ZM-L-0 REV0 28 PA-83 ANTI RATTLE CLIP BRAKE PADS SET FRONT SDS 30 PA-85 BANJO BOLT 3 PA-28 BANJO GASKET SDS REAR BRAKE LINE HCU TO CALIPER NOTE: Supersedes part number PA-28 BANJO GASKET M5X6-8.8 ZM-F- REV 0 ZM-L-0 REV 0 NOTE: Does not apply to DS

8 WASHER ISO HV ZM-F-0 REV BRAKE LINE GUIDE 37 PA-28 BANJO GASKET 38 PA-86 BANJO BOLT AT REAR CALIPER 39 PA-87 CALIPER SLIDE BOLT BRAKE PAD SET SDS REAR 4 PA-89 ANTI RATTLE CLIP 42 PA-90 CALIPER SLIDE BOLT CLIP JJUAN 34MM REAR CALIPER SDS NOTE: replacing old p/n: MPI WHEEL SPEED SENSOR HEXAGON SOCKET BUTTON HEAD SCREW ISO M8X2-8.8 ZM-F-0 REV BRAKE ROTOR 240MM FIXED WITH COUNTERBORE 47 PA-9 BANJO BOLT AT HCU 48 PA-28 BANJO GASKET 49 PA-28 BANJO GASKET BRAKE LIGHT SWITCH 50 PA-92 NOTE: Not sold separately. Please order the Master Cylinder. 5 PA-28 BANJO GASKET SDS REAR BRAKE LINE MC TO HCU 53 PA-28 BANJO GASKET /4 X 3/4 CLEVIS PIN STEEL ZINC M0 WASHER IGLIDE BEARING GFM BUTTON CAP SCREW M6 X SPRING X BRAKE PEDAL IGLIDE BEARING GFM X BRAKE PEDAL /4 X 3/4 CLEVIS PIN STEEL ZINC X BRAKE PEDAL SPACER IGLIDE BEARING GFM PA-93 BRAKE PEDAL PIVOT BOLT 65 PA-94 BRAKE PEDAL PIVOT BOLT WASHER 66 PA-95 MASTER CYLINDER BOLT MASTER CYLINDER GUARD FOR J-JUAN MASTER CYLINDER JJUAN 2MM REAR MASTER CYLINDER SDS M6X6-8.8 ZM-F-0 REV 03 ZM-L-0 REV 0 70 PA-96 WASHER 7 PA-97 REAR MASTER CYLINDER RESERVOIR M6X6-8.8 ZM-F-0 REV 03 ZM-L-0 REV WASHER ISO HV ZM-F-0 REV 02

9 GROMMET VIBRATION ISOLATION M6 BOSCH ABS HCU FLUID FILLED 6 PROFILE VARIANTS NOTE: Supersedes part number and GROMMET VIBRATION ISOLATION M WASHER ISO HV ZM-F-0 REV M6X6-8.8 ZM-F-0 REV 03 ZM-L-0 REV 0 79 PA-28 BANJO GASKET 80 PA-28 BANJO GASKET 8 PA-85 BANJO BOLT

10 ZEV003 - Wheel Assy

11 ZEV003 - Wheel Assy Callout Part Number Part Name Qty. per Motorcycle MPI WHEEL SPEED SENSOR ABS MAGNET RING BEARING DUST SEAL 2 BEARING 6204 NOTE: Bearing used as swing arm bearing in some models and as the wheel bearing (qty of 5; 2 in front and three in rear wheel) 2 in 205 and later models. NOTE: Manufacturer part number is RS TIRE, FRONT, 00/ H, PIRELLI MT X9 DS FRONT CAST WHEEL ASSY NOTE: Supersedes part number FRONT WHEEL BEARING TUBE BEARING 6204 NOTE: Bearing used as swing arm bearing in some models and as the wheel bearing (qty of 5; 2 in front and three in rear wheel) 2 in 205 and later models. NOTE: Manufacturer part number is RS BEARING DUST SEAL HOLLOW AXLE FRONT Not Applicable to this Bike Model REAR AXLE 20MM HOLLOW, ROUNDED END WHEEL SPACER DRIVE SIDE REAR BEARING DUST SEAL 2 BEARING 6204 NOTE: Bearing used as swing arm bearing in some models and as the wheel bearing (qty of 5; 2 in front and three in rear wheel) 2 in 205 and later models. NOTE: Manufacturer part number is RS BEARING 6204 NOTE: Bearing used as swing arm bearing in some models and as the wheel bearing (qty of 5; 2 in front and three in rear wheel) 2 in 205 and later models. NOTE: Manufacturer part number is RS TIRE, REAR, 30/ H, PIRELLI MT-60 WHEEL 3.50X7 SDS REAR CAST WHEEL ASSY 6MY IMPL BLACK-SILVER C REAR WHEEL BEARING TUBE 5MY BEARING 6204 NOTE: Bearing used as swing arm bearing in some models and as the wheel bearing (qty of 5; 2 in front and three in rear wheel) 2 in 205 and later models. NOTE: Manufacturer part number is RS

12 ABS MAGNET RING MPI WHEEL SPEED SENSOR U-NUT M20X.5 FN 27S 5H (REAR AXLE NUT) NOTE: Rear Axle Nut

14 ZEV004 - Steering Systems

15 ZEV004 - Steering Systems Callout Part Number Part Name Qty. per Motorcycle HANDLEBAR LOW WIDE 5MY MOTOR MOUNTING LEFT FRONT TOP AND LEFT FRONT BOTTOM BOLT S HANDLEBAR CLAMP STEERING STEM THIN NUT M27 X.5 X 8MM WASHER X 2 MM SDS UPPER TRIPLE CLAMP 5MY IMP HEXAGON SOCKET HEAD CAP SCREW ISO 4762 M8X ZM-F-0 REV STEERING STEM LOCK NUT M 30 X.5 MM BEARING LIP SEAL OVERMOLDED 55MM OD NOTE: Supersedes part STEERING HEAD BEARING KOYO SAC STEERING HEAD BEARING KOYO SAC M5X2-8.8 ZM-F-0 REV HEADLIGHT MOUNTING WASHER HEADLIGHT BRACKET BEARING LIP SEAL OVERMOLDED 55MM OD NOTE: Supersedes part SDS LOWER TRIPLE CLAMP ASSY 5MY IMP NOTE: Superseded by WASHER ISO HV ZM-F-0 REV 02 HEXAGON SOCKET HEAD CAP SCREW ISO 4762 M8X ZM-F-0 REV 03 DS/X/MX FRONT FENDER XMX BLACK# NOTE: Does not apply to S and SR WASHER ISO HV ZM-F-0 REV NOTE: Does not apply to S and SR M5X6-8.8 ZM-F- REV 0 ZM-L-0 REV 0 NOTE: Does not apply to DS S FORK 4MM LEFT DS FORK 4MM LEFT 23 PA-204 INNER BEARING SPACER 24 PA-205 M8 X 30 BOLT HOLLOW AXLE FRONT S FORK 4MM RIGHT DS FORK 4MM RIGHT FRONT FENDER STREET TO WORK WITH SHOWA SUSPENSION BLACK #2

16 M5X6-8.8 ZM-F- REV 0 ZM-L-0 REV 0 NOTE: Does not apply to DS WASHER M5 X X NYLON 6/6 BLACK

18 ZEV005 - Body Trim

19 ZEV005 - Body Trim Callout Part Number Part Name Qty. per Motorcycle RIDER INTERFACE MISCELLANEOUS COMPONENT HANDLEBAR END CAP MIRROR RH NOTE: Supersedes part number MIRROR LH NOTE: Supersedes part number HAND GRIP LEFT SIDE RIDER INTERFACE MISCELLANEOUS COMPONENT HANDLEBAR END CAP M5X6-8.8 ZM-F- REV WASHER M5 X X NYLON 6/6 BLACK SEAT BOLT M8X NOTE: Supersedes SDS SEAT ASSEMBLY 0 PA-4 BOLT PA-42 WASHER SDS TAIL TOP WHITE#2 SDS TAIL TOP ORANGE # NOTE: MY5 DS SDS TAIL BOTTOM WHITE# NOTE: Superseded by SDS TAIL BOTTOM ORANGE #2 SDS TAIL BOTTOM BLACK/BASE NOTE: Black (unpainted) tail top bottom. Used as the base for the 7MY painted colors PHILIPS HEAD SHEET METAL SCREW 6 X /2 DS TANK ASSEMBLY BLACK NOTE: DS Tank Assembly no longer available in black. Owners should upgrade to 207 painted bodywork. DS TANK ASSEMBLY WHITE NOTE: Does not apply to SR DS TANK ASSEMBLY ORANGE # WASHER M5 X X NYLON 6/6 BLACK M5X6-8.8 ZM-F- REV TRUNK PAN RIGHT TRUNK PAN LEFT SDS TAIL POD TOP NOTE: Top half only. Order bottom half PN:

20 2 PA-43 NUT 22 PA-44 WASHER WASHER ISO HV ZM-F-0 REV 02 HEXAGON SOCKET BUTTON HEAD SCREWS ISO M6X2-8.8 ZM-F-0 REV 03 ZM-L-0 REV 0 25 PA-45 BOLT 26 PA-46 BOLT 27 PA-47 BOLT WASHER M5 X X NYLON 6/6 BLACK M5X6-8.8 ZM-F- REV PA-48 WASHER REAR INNER FENDER NOTE: Supersedes part number SDS STUBBY CHIN CENTER WASHER M5 X X NYLON 6/6 BLACK M5X6-8.8 ZM-F- REV WASHER M5 X X NYLON 6/6 BLACK M5X6-8.8 ZM-F- REV 03 SDS CHIN FAIRING LEFT NOTE: Please order GRAPHIC LABEL SANTA CRUZ separately M5X6-8.8 ZM-F- REV WASHER M5 X X NYLON 6/6 BLACK M5X6-8.8 ZM-F- REV M5X6-8.8 ZM-F- REV WASHER M5 X X NYLON 6/6 BLACK M5X6-8.8 ZM-F- REV WASHER M5 X X NYLON 6/6 BLACK 45 Not Applicable to this Bike Model 46 Not Applicable to this Bike Model 47 Not Applicable to this Bike Model FORK GUARD LEFT M5X6-8.8 ZM-F- REV 0 ZM-L-0 REV 0 NOTE: Does not apply to DS WASHER M5 X X NYLON 6/6 BLACK FORK GUARD RIGHT M5X6-8.8 ZM-F- REV 0 ZM-L-0 REV 0

21 NOTE: Does not apply to DS WASHER M5 X X NYLON 6/6 BLACK M5X6-8.8 ZM-F- REV 0 ZM-L-0 REV 0 NOTE: Does not apply to DS WASHER ISO HV ZM-F-0 REV NOTE: Does not apply to S and SR FRONT FENDER STREET TO WORK WITH SHOWA SUSPENSION BLACK #2 DS/X/MX FRONT FENDER XMX BLACK# NOTE: Does not apply to S and SR SDS CHIN FAIRING RIGHT NOTE: Please order GRAPHIC LABEL SANTA CRUZ or CRAFTED IN CALIFORNIA JEWEL. NOTE: Supersedes part number SDS FAIRING FRONT CENTER BLACK# PHILIPS HEAD SHEET METAL SCREW 6 X / MY5 PWER TANK ASSY> DS ORANGE MY5 PWER TANK ASSY> DS WHITE HEADLIGHT MOUNT LEFT M5X6-8.8 ZM-F- REV WASHER M5 X X NYLON 6/6 BLACK HEADLIGHT MOUNT RIGHT SDS ACCESSORY OUTLET COVER 2V ACCESSORY SOCKET KIT - SDS NOTE: Charge a GPS, smart phone or mp3 player using the Zero Motorcycles 2V Accessory Socket Kit. Designed to connect directly to your motorcycle{###}s power port harness, the accessory socket enables you to charge small devices that have a cigarette lighter plug. The accessory outlet is rated up to 0 amps/20 watts. This kit includes all mounting hardware for installation on the 204 and later Zero S, Zero DS and Zero SR motorcycles. NOTE: 204 [Zero SR, Zero S, Zero DS] 205 [Zero SR, Zero S, Zero DS] [Zero SR, Zero S, Zero DS, Zero DSR] HEXAGON SOCKET HEAD CAP SCREW ISO 4762 M6X ZM-F-0 REV 03 ZM-L-0 REV MIRROR MOUNT CLAMP MIRROR MOUNT BODY LH THREAD HAND GRIP THROTTLE SIDE

22 ZEV006 - Rear Suspension

23 ZEV006 - Rear Suspension Callout Part Number Part Name Qty. per Motorcycle PREVAILING TORQUE TYPE NUT DIN 985 M0-8 ZM-F REV M0 WASHER PREVAILING TORQUE TYPE NUT DIN 985 M0-8 ZM-F REV 02 BEARING 6204 NOTE: Bearing used as swing arm bearing in some models and as the wheel bearing (qty of 5; 2 in front and three in rear wheel) in 205 and later models. NOTE: Manufacturer part number is RS STUB AXLE SDS STUB-PIVOT COVER REAR INNER FENDER NOTE: Superseded by WASHER M5 X X NYLON 6/6 BLACK M5X2-8.8 ZM-F-0 REV HEXAGON FLANGE NUT DIN 6923 M8-.25 ZM-F-0 REV 03 HEXAGON HEAD SCREW DIN 933 M8X ZM-F-0 REV U-NUT M20X.5 FN 27S 5H (REAR AXLE NUT) NOTE: Rear Axle Nut REAR AXLE ADJUSTER PUSH BLOCK, NUT SIDE MPI WHEEL SPEED SENSOR WHEEL SPACER DRIVE SIDE REAR REAR AXLE ADJUSTER PUSH BLOCK, HEAD SIDE AXLE 20MM HOLLOW NOTE: Superseeded by pn: HEXAGON HEAD SCREW DIN 933 M8X ZM-F-0 REV HEXAGON FLANGE NUT DIN 6923 M8-.25 ZM-F-0 REV S SWINGARM BEARING 6204 NOTE: Bearing used as swing arm bearing in some models and as the wheel bearing (qty of 5; 2 in front and three in rear wheel) in 205 and later models. NOTE: Manufacturer part number is RS STUB AXLE SDS STUB-PIVOT COVER LOWER SHOCK EYE BOLT M0-.5X60MM

24 LOWER SHOCK EYE BOLT M0-.5X60MM DS SHOCK 40MM M0 WASHER

26 ZEV007 - Frame(Left)

27 ZEV007 - Frame(Left) Callout Part Number Part Name Qty. per Motorcycle WASHER ISO HV ZM-F-0 REV 02 PREVAILING TORQUE TYPE NUT DIN 985 M6-8 ZM-F-0 REV SDS SEAT FRAME WITH FUSEPANEL MOUNT M6X6-8.8 ZM-F-0 REV WASHER ISO HV ZM-F-0 REV TAIL FRAME BOLT HEX HEAD 8MM -.00 X 30MM WASHER ISO HV ZM-F-0 REV 02 PREVAILING TORQUE TYPE NUT DIN 985 M8-0 ZM-F REV WASHER ISO HV ZM-F-0 REV 02 0 Not Applicable to this Bike Model SDS TAIL FRAME TAIL FRAME BOLT HEX HEAD 8MM -.00 X 30MM 3 PA-50 PASSENGER CLEVIS BRACKET BOLT 8MM -.25 X 25MM CLEVIS PIN CUSTOM 0MM X 45L CAVITY PLUG C SDS PASSENGER PEG BRKT L RETAINING RING 9MM SHAFT FOOTPEG LT PASSENGER FOOTPEG DETENT PLATE FOOTPEG DETENT BALL MECHANISM HEXAGON SOCKET THIN HEAD CAP SCREW DIN M0X ZM-F-0 REV 03 ZM-L-0 REV BUSHING FLANGE KICKSTAND MOUNT CLEVIS PIN CUSTOM NOTE: Used to attach kickstand leg to mount MEDIUM KICKSTAND LEG W/MAGNET E CLIP S KS SPRING OUT HEXAGON SOCKET COUNTERSUNK HEAD SCREW ISO M8X ZM-F-0 REV 03 ZM-L-0 REV BUSHING FLANGE HEXAGON SOCKET THIN HEAD CAP SCREW DIN M0X ZM-F-0 REV 03 ZM-L-0 REV CLEVIS FOOT PEG UNIVERSAL LEFT CLEVIS PIN CUSTOM 0MM X 45L TORSION SPRING,.678 OD.078 WIRE, CCW

28 RETAINING RING 9MM SHAFT FOOTPEG, LEFT 36 Not Applicable to this Bike Model HEXAGON SOCKET HEAD CAP SCREW ISO 4762 M5X ZM-F-0 REV 03 ZM-L-0 REV 0 38 PA-5 M5 FLAT WASHER SKID PAN BRACKET SDS SKID PAN NOTE: Superseded by part number M5X2-8.8 ZM-F-0 REV SDS FRAME MOUNTED HORN BRACKET M8X ZM-F-0 REV 03 HEXAGON SOCKET BUTTON HEAD SCREWS ISO M6X2-8.8 ZM-F-0 REV 03 ZM-L-0 REV WASHER ISO HV ZM-F-0 REV 02 FRAME S NOTE: Must supply proof of destruction of old frame along with VIN# and/or Claim# for replacement. NOTE: Supersedes KEYSWITCH LOCK AND TANK BAG LOCK COMBO KIT NOTE: This Kit includes an ignition lock ( ) and a tank bag/helmet lock (p/n ) that have been keyed alike with two keys. ELECTRICAL PANEL MOUNT PLATE NOTE: Superseded by PA-52 ELECTRICAL BRACKET BOLT HEX HEAD M X 2MM 50 PA-53 ELECTRICAL BRACKET BOLT HEX HEAD M X 2MM 5 PA-54 ELECTRICAL PANEL BOLT WASHER, M5 FLAT WASHER

30 ZEV008 - Frame(Right)

31 ZEV008 - Frame(Right) Callout Part Number Part Name Qty. per Motorcycle CLEVIS PIN CUSTOM 0MM X 45L 2 PA-206 BATTERY RETAINING RAIL FRAME S NOTE: Must supply proof of destruction of old frame along with VIN# and/or Claim# for replacement. NOTE: Supersedes Not Applicable to this Bike Model TORSION SPRING,.678 OD.078 WIRE, CCW FOOTPEG, RIGHT NOTE: Does not apply to S and SR RETAINING RING 9MM SHAFT HEXAGON SOCKET THIN HEAD CAP SCREW DIN M0X ZM-F-0 REV 03 ZM-L-0 REV CLEVIS FOOT PEG UNIVERSAL RIGHT CLEVIS PIN CUSTOM 0MM X 45L MASTER CYLINDER GUARD FOR J-JUAN MASTER CYLINDER WASHER ISO HV ZM-F-0 REV M6X ZM-F-0 REV 03 ZM-L-0 REV FOOTPEG DETENT PLATE FOOTPEG DETENT BALL MECHANISM FOOTPEG RT PASSENGER RETAINING RING 9MM SHAFT SDS PASSENGER PEG BRKT R NOTE: superseded by

32 ZEV009 - Motor and Drive System

33 ZEV009 - Motor and Drive System Callout Part Number Part Name Qty. per Motorcycle SHAFT KEY.25 MOTOR SPROCKET NOTE: Motor Sprocket ZERO SDS 75-7 MOTOR REPLACEMENT KIT NOTE: Must Provide Warranty Claim and VIN# when ordering NOTE: Old Part# HEXAGON NUT ISO 4033 M4-2 ZM-F-0 REV MOTOR JACK SCREW INNER WASHER ISO HV ZM-F-0 REV 02 HEXAGON SOCKET HEAD CAP SCREW ISO 4762 M8X ZM-F-0 REV 03 SPROCKET REAR BELT DRIVE 32T, 8MM PITCH, 7MM WIDE CASTING NOTE: Please order SPROCKET REAR BELT DRIVE 32T, 8MM PITCH, 7MM WIDE FINISHED WASHER ISO HV ZM-F-0 REV 02 HEXAGON SOCKET THIN HEAD CAP SCREW DIN M8X ZM-F-0 REV 03 ZM-L-0 REV 0 NOTE: THIN HEAD CAP SCREW DIN 7984 M8X MOTOR SHAFT SPACER.5 MM FOR " SHAFT BELT DRIVE, 220T, 8MM PITCH, 4MM WIDE, NEW LOGO SPROCKET FRONT, BELT DRIVE 28T, 8MM PITCH, 5MM WIDE " BORE NOTE: Does not apply to SR LOW PROFILE BELT SPROCKET MOTOR SHAFT TOPHAT HEXAGON SOCKET COUNTERSUNK HEAD SCREW M0X MOTOR SHAFT NOTE: Bolt used to hold front sprocket in place onto the motor shaft. NOTE: Sprocket HEXAGON SOCKET SET SCREW CUP POINT KNURLED ISO TYPE V M4X6 ZM-F-0 REV 03 ZM-L-0 REV 0 NOTE: 2 set screws are needed for an SR motor. HEXALOBULAR (6 LOBE) SOCKET FLAT HEAD COUNTERSUNK SCREW ISO 4582 M8X ZM-F-0 REV NOTE: Used for both drive side rear motor mount or rear sprocket mounting depending on model. NOTE: Supersedes MOTOR MOUNTING LEFT FRONT TOP AND LEFT FRONT BOTTOM BOLT

34 WASHER ISO HV ZM-F-0 REV 02

36 ZEV Electronics

37 ZEV Electronics Callout Part Number Part Name Qty. per Motorcycle THROTTLE BITRON HALL EFFECT PCB NOTE: Replaced PN KILL MODE START SWITCH LEFT HAND SWITCHGEAR ECIE WASHER ISO HV ZM-F-0 REV HEXAGON NUT ISO 4032 M6-8 ZM-F-0 REV #4 CONTROLLER COVER SHIELDED CONTROLLER FORMEX PAN HEAD PHILLIPS #6 SHEET METAL SCREW CONTROLLER LEAD BOLTS M8X SDS SEVCON CONTROLLER MOUNT REAR BOLT SPACERS CONTROLLER SIZE 4 GEN 4 SEVCON NOTE: PLEASE INCLUDE VIN# OF BIKE FOR PROGRAMMING PURPOSES M8 X 50MM S/DS/SR HEAT SINK HEXAGON SOCKET HEAD CAP SCREW ISO 4762 M6X ZM-F-0 REV 03 HEXAGON SOCKET HEAD CAP SCREW ISO 4762 M8X ZM-F-0 REV 03 ZM-L-0 REV CONTACTOR GIGAVAC GX 2/40VDC COIL HEADLIGHT MOUNTING WASHER M5 X 30 MM 8 PA-207 FUSE MOUNT PA-208 FUSE MOUNT BOLT FUSE 300A 60VDC CLASS T 2 PA-209 FUSE WASHER FUSE NUT INTERNAL 23 PA-20 CONTACTOR COVER 24 PA-2 LV FUSE WASHER 25 PA-22 LV FUSE HOLDER PA-23 BATTERY BOX SCREW PREVAILING TORQUE TYPE NUT DIN 985 M6-8 ZM-F-0 REV DC-DC CONV 500W SEVCON ABS UNITS ELECTRICAL PANEL MOUNT PLATE NOTE: Superseded by ASSY MBB GENERIC 5MY IMPL NOTE: NOTE: Need to provide motorcycle VIN in shipping notes. HEXAGON SOCKET HEAD CAP SCREW ISO 4762 M4X ZM-F-0 REV 03

38 WASHER ISO HV ZM-F-0 REV 02 PREVAILING TORQUE TYPE NUT DIN 985 M8-0 ZM-F REV 02 HEXAGON SOCKET HEAD CAP SCREW ISO 4762 M8X ZM-F-0 REV WASHER ISO HV ZM-F-0 REV M5X2-8.8 ZM-F-0 REV 03 CALEX CHARGER ASSEMBLY 300W REG 0.5 EMC COMPLIANT NOTE: Supersedes and ASSY BATTERY SDS 4-MOD 6MY IMPL NOTE: Motorcycle VIN#, Case# or Claim# must be provided when ordering NOTE: Supersedes part number NOTE: NOTE: FOR INSTALLING IN 204 MODELS, INCLUDE IN THE ORDER. IN CASE OF THE BIKE HAVING A POWER TANK, ALSO INCLUDE BMS PCB ASSY POTTED 7MY IMPL NOTE: PLEASE INCLUDE VIN# OF BIKE AND BATTERY SERIAL # FOR PROGRAMMING PURPOSES NOTE: FOR FX/FXP, IF BATTERY SERIAL NUMBER STARTS WITH 4SG**** PLEASE ORDER NOTE: Super seeded pn: WASHER UNIVERSAL (SIZE ) HEXAGON SOCKET HEAD CAP SCREW M4X NOTE: BMS SCREW S/DS/SR BATTERY CASE FRONT PLUG DIAG PORT THRU MM 2MY IMPL 44 PA-25 BATTERY FRONT UPPER FILLER PLUG PREVAILING TORQUE TYPE NUT DIN 985 M6-8 ZM-F-0 REV DISC HORN K70/H2 V WITH BLACK ZINC M8X ZM-F-0 REV SDS FRAME MOUNTED HORN BRACKET 49 PA-26 BATTERY BOX SCREW M8X4MM BREAK AWAY HEX BOLT NOTE: One Time Use Bolt KEYSWITCH LOCK AND TANK BAG LOCK COMBO KIT NOTE: This Kit includes an ignition lock ( ) and a tank bag/helmet lock (p/n ) that have been keyed alike with two keys. 52 PA-27 BATTERY CONTACTOR TOP COVER PA-28 BATTERY BOX SCREW

39 54 PA-29 BATTERY BOX SCREW SDS TRIPLE CLAMP HARNESS SUPPORT 2V ACCESSORY SOCKET KIT - SDS NOTE: Charge a GPS, smart phone or mp3 player using the Zero Motorcycles 2V Accessory Socket Kit. Designed to connect directly to your motorcycle{###}s power port harness, the accessory socket enables you to charge small devices that have a cigarette lighter plug. The accessory outlet is rated up to 0 amps/20 watts. This kit includes all mounting hardware for installation on the 204 and later Zero S, Zero DS and Zero SR motorcycles. NOTE: 204 [Zero SR, Zero S, Zero DS] 205 [Zero SR, Zero S, Zero DS] [Zero SR, Zero S, Zero DS, Zero DSR] M6 X 8MM NUT WASHER ISO HV ZM-F-0 REV 02 DASH LCD (ABS) BUG LOGO NOTE: Applicable 4MY-6MY 60 PA-220 BRAKE LIGHT SWITCH SCREW BRAKE LIGHT SWITCH 6 PA-22 NOTE: Not sold separately. Please order the Master Cylinder.

Zero Motocycles. S 2017 Exploded Views

Zero Motocycles. S 2017 Exploded Views Zero Motocycles S 207 Exploded Views ZEV003 - Lighting ZEV003 - Lighting Callout Part Number Part Name Qty. per Motorcycle 20-0590 HEADLIGHT BRACKET 2 90-020 HEADLIGHT MOUNTING WASHER 4 HEXAGON SOCKET