Steering¶

Ignition Lock ¶

The ignition lock operates the Ignition Switch.

Location

The ignition lock is mounted on the tripe clamp top in the center between the steering head and the dash.

The Ignition Switch connects to a ZADI motorcycle lock with a steering lock feature and parking light enable (although the parking light enable is not connected on the Zero).

Key Blanks

Key blanks can typically be ordered from a dealer.

Key blanks appear to be available generically as JMA ZA9P1 FOR ZADI ZD23RCP.

In USA, calling them "Triumph" keys may help a locksmith find the right blank.

Maintenance

Occasional lock lubrication is recommended, and inspection of the wires for startup enable on the underside of the lock for reliability.

Troubleshooting

See the faulty ignition switch troubleshooting guide for issues with this.

Tank Lock ¶

The lock for the tank bag (2013-2016) or tank compartment (2017+) and possibly a helmet is keyed the same as the Ignition Lock.

Mounting

The tank bag lock (2013-2016) is mounted to the frame by two (M5?) bolts under the steering head.

It's very difficult to access without taking much of the frontend apart (as it should be, for theft deterrence).

References

ZADI lock re-pin

Mirrors ¶


2012-2014 Mirrors (side) on a DS	2015+ mirrors (side) on a DSR

Design

Pre-2015 (Gen1) Zeros use an angular mirror with a ball mount joint that allows rotating the mirrors 360 degrees.

Many riders turn the mirrors upside down for a little wider visibility around the shoulder/arms.

2015+ (Gen2 and Gen3) Zeros use a mirror stalk with an inboard ball mount with about 30 degrees of freedom from the stalk.

Mount

Zero mirrors are mounted from the handlebars with Yamaha/Ducati-style bolt fitting.

The bolt/thread specification is M10x1.25, left-hand-threaded on the right side and standard right-hand-threaded on the left side.

Maintenance

(pre-2015) Check that the set screw holding mirror position holds it firmly.

Use a corrosion inhibitor or thread-locker for the set screws and the mount threading since these are weather-exposed.

See Third-Party Mirrors for workable/tested replacements.

Handlebar ¶

Zero's models all steer with a handlebar.

S/SR and FXS models share a shorter, sportier handlebar shape.

DS/DSR and FX models share a wider, straighter handlebar shape.

Both S/FXS and DS/FX style handlebars are standard through-bars.

Diameters

1 1/8" (28mm) ⌀ center bar.
7/8" (22mm) ⌀ outer bar.

Models	Years	Width	Rise	Pullback
S,SR,FXS	2013-present
DS,DSR,FX	2013-present
SRF,SRS	2020-present

Control-Indexing Holes

(1) 3/16" ⌀ on the left for the switchgear, 6.5" from the end of the bar.
(1) 3/16" ⌀ on the right inner for the throttle, 7 3/16" from the bar end.
(1) 5/32" ⌀ on the right outer for the switches, 6" from the bar end.

References

Changing to non OEM handlebars (‘15 FX)

Handlebar Clamps¶

The SDS and XMX platform handlebar clamps are 2" by 1 1/8" (28mm) for the entire line of models, clamped with M10 cap screw bolts (35mm length; possibly 50mm?).

Handlebar Switch Assemblies¶

The switch assemblies are fastened with TT20 (1/4") tamper-resistant Torx bolts through the underside.

Handgrips¶

Handgrips have a Zero logo on them but otherwise are reasonably good stock grips for the 7/8" (22mm) handlebar width at the end of the bars.

Bar Ends¶

For 2014+ models, any bar end accessories that match the 14mm inner diameter will fit.

2014+ stock bar end plugs

The stock bar ends are round plastic bumpers held in by plastic threads, so can be removed with a little twisting and pulling.

2013 models

Bar ends are covered by the grip so are not easily changed without changing the grips.

Zero did offer heated grips for these models but dropped them after changing the bars in 2014.

Brake Lever ¶

Zero motorcycles have a right-hand lever for the front brake, as is common for motorcycle designs.

Brake Lever

Brake Lever Switch

Primary adjustment

The brake lever has a dial for adjusting the lever position relative to pad pressure and rider finger reach.

Set it however lets you operate it comfortably and safely.

Brake Light and Regen Switch

A set screw on the inside of the lever adjusts how a micro-switch is depressed.

The micro-switch is what activates the rear brake light and the "braking regen" mode at the same time.

Any adjustment or replacement of the brake lever should be followed by recalibrating this set screw to get the desired effect.

Too much free play and the switch will activate when going over bumps and result in a slightly jerky ride.

There is some guidance on how to adjust this: Brake Lever Adjustment to Regen Before Pad Contact.

NOTE: It seems like there's small difference in how this set screw is secured in stock lever compared to replacement lever (2016 SR), even though they look identical.

I wasn't able to adjust this screw on stock lever, however replacement lever adjusts with no issues.

You will need 7/64 SAE hex key to adjust.

Use some light threadlock compound (Blue Loctite will do) to fix the set screw in the desired position if it seems to move too freely out of the desired range.

References

Front brake tightness?

Adjustment

See Front Brake Lever Adjustment

Removal, Repair

See Front Brake Lever Replacement

Triple Clamp ¶

The triple clamp tree attaches the fork tubes to the frame via the steering head bearing.

The design and fitment changed from MY 2013-2014 to MY 2015+, when the forks changed from FastAce to Showa.

Upper Assembly

This sits atop the steering head, joining the forks at the top, and supports the handlebars, ignition switch, dash, and headlamp.

Lower Assembly

This inserts upward through the steering head tube, joining the forks below the tube, and supports the headlamp bracket and the high fender for DS/DSR/FX models.

The upper assembly and lower assembly join around/through the steering head.

Steering Head ¶

The steering head is the tube in the head position of the frame that mounts the fork steerer tube.

For 2014+ S and X-platform Zeros, the inner diameter of the steering head is 55mm for a steering tube size of 1in (25.4mm).

Steering head fastener stack (top to bottom)

Steering Stem Thin Nut (M27⨉1.5mm, 8mm depth); apply a 41mm hex socket.
Washer 41 - 27.5mm⌀, 2mm thickness (reportedly not present on 2018+ models)
Steering Stem Lock Nut (M30⨉1.5mm)
Bearing Lip Seal (55mm OD)
Steering Head Bearing (facing up)
Lower Triple Clamp Assembly Tube
Steering Head Bearing (facing down)
Bearing Lip Seal (55mm OD)

Steering Head Bearing ¶

The steering head bearing is a tapered roller bearing in the frame's steering head tube.

Troubleshooting

Steering stickiness or wobble may indicate an inadequately greased steering head bearing or a worn bearing.

Platform	Years	Dimensions	Stock Model	Part #	Description
S,X	2014-2018	ID: 30mm OD: 55mm Width: 17mm	Koyo SAC3055-1	ZM20-06068	Angular-contact caged ball bearings

Replacement

See Steering stem bearing replacement ('14-'17, all models) described for a 2014FX.

Reference

ZeroDS head bearing (2015)

DSR 17 steering head bearings

Steering stem bearing replacement ('14-'17, all models)

Front Fender ¶

The front fender covers the front wheel and acts as a mudguard against the front electrics and the front panel of the battery casing.

The S/SR front fender is a sporty low fender colored or painted panel like the tank plastics that hugs the tire.
The DS/DSR/FX/FXS front fender is an ABS plastic dual sport high fender.

Low Front Fender ¶

The S and SR models have a low front fender.

The low front fender is a colored or painted panel like the tank plastics that hugs the (17") front tire.

Mounting

The low front fender bolts onto the lower front fork cast aluminum bracketing.

The mounting uses 4 (2 per side) M5x15 bolts with a black finish, with a 3mm Allen/hex key (H3) drive with black plastic washers.

The holes are 85mm apart (centerline-to-centerline), and the width across the brackets measured from the outside face is 192mm across the wheel (taken from a 2020 DSR).

Transfer to other models

It bolts directly onto the FXS' lower forks around its tire even though the FXS comes with a dual sport fender.

See Low Front Fender Swap for how to adapt this to the DS and DSR models.

High Front Fender ¶

The DS, DSR, and FXS models have a dual sport / high front fender.

The dual sport fender attaches to the underside of the front fork triple tree.

Mounting

4 holes in a rectangular shape 58mm (2.3in) wide and 50mm (1.95in) front to back (center to center).

The bolts are (at least through 2016) M5x15mm button head socket screw for a 3mm Allen key.

The bolts on 2017?-present models are M5x15mm flanged socket head screws for a T25 Torx key.

Transfer

This fender also fits a S/SR model.

A Honda or Yamaha dual sport fender should fit this pattern without modification.

Source: zeromanual.com/wiki/Unofficial_Service_Manual · Wayback capture of 2025-02-26 · wiki last edited 10 July 2020 00:05. 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.