Tool Kits¶
This is a reference for the tools needed to work on Zeros.
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.
| 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+) |
| Security Torx bit | T25 | Throttle assembly (2014+?) |
| 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 or keep in your garage.
- Low voltage fuses (10 amp, 5 amp ATC style)
- High voltage fuses (ABC20A, ABC4A, ATM30 - see your official 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.
Source: zeromanual.com/wiki/Tool_Kits · Wayback capture of 2025-03-12 · wiki last edited 31 March 2020 21:49. Community-written content from the Unofficial Zero Manual, reproduced for preservation; not written or verified by OpenZero. Links to pages that were not mirrored go to the Wayback Machine.