Zero Motocycles. DSR 2017 Exploded Views

Transcription

1 Zero Motocycles DSR 207 Exploded Views

2 ZEV003 - Lighting

3 ZEV003 - Lighting Callout Part Number Part Name Qty. per Motorcycle HEADLIGHT BRACKET HEADLIGHT MOUNTING WASHER 4 HEXAGON SOCKET BUTTON HEAD SCREWS ISO M6X2-8.8 ZM-F-0 REV 03 ZM-L-0 REV 0 4 PA-335 TURN SIGNAL LENS 5 PA-336 TURN SIGNAL LENS SCREW TURN SIGNAL BULB TURN SIGNAL FR-RH RR-LH HEADLIGHT MOUNT RIGHT FOR ABS V ACCESSORY COVER, SMALL HEADLIGHT ASSY, 60/55W, TRIOM TURN SIGNAL BULB 2 PA-337 RUNNING LAMP BULB SOCKET/HARNESS HEXAGON THIN NUT ISO 4035 M0-04 ZM-F-0 REV 02 TOOTHED LOCK WASHER WITH EXTERNAL TEETH DIN A M0-B85 ZM-F-0 REV HEADLIGHT MOUNT LEFT FOR ABS 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 TURN SIGNAL FR-LH RR-RH 2 PA-338 HEADLAMP BULB SEAL 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 02 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

4 WASHER M5 X X NYLON 6/6 BLACK 35 Not Applicable to this Bike Model LICENSE PLATE BRACKET EXTENSION LOWER NOTE: ONLY USED IN EU/AUS REGION WASHER ISO HV ZM-F-0 REV 02 0 HEXAGON SOCKET BUTTON HEAD SCREWS ISO M6X2-8.8 ZM-F-0 REV 03 ZM-L-0 REV 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 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 SR TAIL FRAME

5

6 ZEV Braking

7 ZEV 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 JJUAN FRONT MC RESERVOIR CAP SERVICE KIT SDS FRONT MASTER CYLINDER BRAKE LIGHT SWITCH SDS JJUAN CALIPER/MASTER CYLINDER BLEED SCREW SDS/XMX JJUAN FRONT MASTER CYLINDER PISTON KIT SDS JJUAN FRONT MASTER CYLINDER CIRCLIP SDS/XMX 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 9 PA-237 MASTER CYLINDER BANJO BOLT 0 PA-30 BRAKE LEVER PIVOT BOLT NUT BRAKE LINE/WHEEL SPEED SENSOR WIRE DOUBLE C CLIP 2 PA-80 BANJO BOLT 3 PA-28 BANJO GASKET 4 PA-28 BANJO GASKET DS FRONT BRAKE LINE HCU TO CALIPER 6 PA-28 BANJO GASKET 7 PA-28 BANJO GASKET 8 PA-28 BANJO GASKET 9 PA-28 BANJO GASKET CUSTOM ROTOR BOLT M8X23MM SHOULDER SCREW MPI WHEEL SPEED SENSOR 22 PA-30 BRAKE LEVER PIVOT BOLT NUT 23 PA-82 BLEEDER VALVE JJUAN 32/30MM FRONT CALIPER SDS HEXAGON HEAD SCREW ISO 4762 M0-.25X ZM-F-0 REV03 ZM-L-0 REV ABS MAGNET RING 27 PA-28 BANJO GASKET BRAKE PADS SET FRONT SDS ABS MAGNET RING 30 PA-28 BANJO GASKET

8 3 PA-28 BANJO GASKET 32 PA-28 BANJO GASKET LOOP CLAMP NYLON 3/4" BLK 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 PA-28 BANJO GASKET 37 PA-86 BANJO BOLT AT REAR CALIPER 38 PA-28 BANJO GASKET BRAKE PAD SET SDS REAR 40 PA-89 ANTI RATTLE CLIP 4 PA-28 BANJO GASKET 42 PA-90 CALIPER SLIDE BOLT CLIP JJUAN 34MM REAR CALIPER REAR BRAKE ROTOR BOLT NOTE: Supersedes DS FRONT BRAKE LINE HCU TO CALIPER 46 PA-28 BANJO GASKET MPI WHEEL SPEED SENSOR 48 PA-28 BANJO GASKET 49 PA-28 BANJO GASKET 50 PA-28 BANJO GASKET IGLIDE BEARING GFM PA-28 BANJO GASKET SDS REAR BRAKE LINE MC TO HCU 54 PA-28 BANJO GASKET /4 X 3/4 CLEVIS PIN STEEL ZINC HEXAGON SOCKET HEAD CAP SCREW ISO 4762 M6X ZM-F-0 REV 03 ZM-L-0 REV WASHER ISO HV ZM-F-0 REV Not Applicable to this Bike Model IGLIDE BEARING GFM BRAKE PEDAL SPRING PREVAILING TORQUE TYPE NUT DIN 985 M6-8 ZM-F-0 REV X BRAKE PEDAL SPACER HEXAGON SOCKET HEAD CAP SCREW ISO 4762 M6X ZM-F-0 REV 03 ZM-L-0 REV 0 64 Not Applicable to this Bike Model 65 Not Applicable to this Bike Model BRAKE PEDAL BASE /4 X 3/4 CLEVIS PIN STEEL ZINC X BRAKE PEDAL SPACER 69 Not Applicable to this Bike Model

9 /4 X 3/4 CLEVIS PIN STEEL ZINC WASHER ISO HV ZM-F-0 REV WASHER ISO HV ZM-F-0 REV 02 MASTER CYLINDER GUARD FOR J-JUAN MASTER CYLINDER JJUAN 2MM REAR MASTER CYLINDER SDS JJUAN REAR MC PUSHROD SERVICE KIT SDS/XMX JJUAN REAR MC RESERVOIR HOSE SERVICE KIT SDS JJUAN REAR MASTER CYLINDER PISTON KIT SDS JJUAN REAR MASTER CYLINDER CIRCLIP SDS/XMX M6X ZM-F-0 REV 03 ZM-L-0 REV 0 76 PA-96 WASHER JJUAN REAR MC RESERVOIR CAP SERVICE KIT SDS/XMX WASHER ISO HV ZM-F-0 REV WASHER ISO HV ZM-F-0 REV PA-28 BANJO GASKET 8 PA-28 BANJO GASKET M6X6-8.8 ZM-F-0 REV 03 ZM-L-0 REV 0 83 PA-28 BANJO GASKET 84 PA-28 BANJO GASKET M6X6-8.8 ZM-F-0 REV 03 ZM-L-0 REV 0 86 PA-28 BANJO GASKET 87 PA-85 BANJO BOLT

10 ZEV Wheel Assy

11 ZEV 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 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

13

14 ZEV Steering Systems

15 ZEV Steering Systems Callout Part Number Part Name Qty. per Motorcycle HIGH RISE OFF-ROAD HANDLEBAR 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 STEERING HEAD BEARING KOYO SAC Not Applicable to this Bike Model SDS LOWER TRIPLE CLAMP ASSY HEXAGON SOCKET HEAD CAP SCREW ISO 4762 M8X ZM-F-0 REV 03 HEXAGON SOCKET HEAD CAP SCREW ISO 4762 M8X ZM-F-0 REV FRONT FENDER DIRT BRAKE LINE HOLE 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 DS FORK 4MM LEFT HOLLOW AXLE FRONT HEXAGON SOCKET HEAD CAP SCREW ISO 4762 M8X ZM-F-0 REV 03 ZM-L-0 REV DS FORK 4MM RIGHT

16 ZEV Body Trim

17 ZEV Body Trim Callout Part Number Part Name Qty. per Motorcycle RIDER INTERFACE MISCELLANEOUS COMPONENT HANDLEBAR END CAP MIRROR RH MIRROR LH HAND GRIP LEFT SIDE RIDER INTERFACE MISCELLANEOUS COMPONENT HANDLEBAR END CAP SEAT BOLT M8X NOTE: Supersedes SDS SEAT ASSEMBLY MY NOTE: replaces SEAT GAP FILLER RIGHT SEAT GAP FILLER LEFT HEXAGON SOCKET HEAD CAP SCREW ISO 4762 M4X WASHER UNIVERSAL (SIZE ) Option #: YELLOW Option #2: WHITE Option #3: ORANGE Option #4: BLACK Option #5: GRAPHITE Option #6: RED Option #: YELLOW Option #2: WHITE Option #3: RED Option #4: ORANGE Option #5: GRAPHITE Option #6: BLACK PHILIPS HEAD SHEET METAL SCREW 6 X / TRUNK PAN RIGHT COMPRESSION ADJUSTER TRIMMED SR TRUNK PAN LEFT FOR SIZE 6 CONTROLLER RIVET PUSH PUSH NYLON M6 SDS TAIL POD TOP NOTE: Top half only. Order bottom half PN: CLIP-ON U-NUT M5XDP WASHER M5 X X NYLON 6/6 BLACK HEXAGON SOCKET BUTTON HEAD SCREW ISO M5X SIZE 6 CONTROLLER FILLER 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

18 HEXAGON SOCKET BUTTON HEAD SCREW ISO M5X WASHER M5 X X NYLON 6/6 BLACK HEXAGON SOCKET BUTTON HEAD SCREW ISO M5X WASHER M5 X X NYLON 6/6 BLACK TRIMMED REAR INNER FENDER 30 Not Applicable to this Bike Model 3 Not Applicable to this Bike Model 32 Not Applicable to this Bike Model 33 Not Applicable to this Bike Model 34 Not Applicable to this Bike Model 35 Not Applicable to this Bike Model 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 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 46 Not Applicable to this Bike Model WASHER M5 X X NYLON 6/6 BLACK M5X6-8.8 ZM-F- REV WASHER M5 X X NYLON 6/6 BLACK CLIP-ON U-NUT M5XDP SDS STUBBY CHIN CENTER WASHER M5 X X NYLON 6/6 BLACK M5X6-8.8 ZM-F- REV FORK GUARD LEFT FORK GUARD RIGHT 56 Not Applicable to this Bike Model 57 Not Applicable to this Bike Model WASHER M5 X X NYLON 6/6 BLACK

19 PHILIPS HEAD SHEET METAL SCREW 0 X / M5X6-8.8 ZM-F- REV 0 ZM-L-0 REV 0 NOTE: Does not apply to DS HEADLIGHT MOUNTING WASHER FRONT FENDER DIRT BRAKE LINE HOLE 63 Not Applicable to this Bike Model 64 Not Applicable to this Bike Model 65 Not Applicable to this Bike Model SDS CHIN FAIRING RIGHT 67 Not Applicable to this Bike Model 68 Not Applicable to this Bike Model 69 Not Applicable to this Bike Model 70 Not Applicable to this Bike Model 7 Not Applicable to this Bike Model 72 Not Applicable to this Bike Model 73 Not Applicable to this Bike Model 74 Not Applicable to this Bike Model PHILIPS HEAD SHEET METAL SCREW 0 X / M5X6-8.8 ZM-F- REV WASHER M5 X X NYLON 6/6 BLACK Option #: WHITE Option #2: ORANGE Option #3: BLACK Option #4: GRAPHITE SDS FAIRING FRONT CENTER BLACK# HEADLIGHT MOUNT LEFT FOR ABS M5X6-8.8 ZM-F- REV WASHER M5 X X NYLON 6/6 BLACK HEADLIGHT MOUNT RIGHT FOR ABS V ACCESSORY COVER, SMALL HAND GRIP THROTTLE SIDE HEXAGON SOCKET HEAD CAP SCREW ISO 4762 M6X ZM-F-0 REV 03 ZM-L-0 REV MIRROR MOUNT CLAMP MIRROR LH MOUNT LOW PROFILE NOTE: Bottom part of the mirror mount LH Option #: WHITE Option #2: ORANGE Option #3: BLACK Option #4: GRAPHITE LATCH BOLT CYLINDER J772 INLET COVER WITH BADGE ASSEMBLY

20 92 PA-339 J772 INLET COVER BADGE LATCH BOLT SECURITY SCREW 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 Option #: WHITE Option #2: ORANGE Option #3: BLACK Option #4: GRAPHITE WASHER M5 X X NYLON 6/6 BLACK M5X6-8.8 ZM-F- REV LATCH CYLINDER NUT TANK TRUNK LID NOTE: Tank Trunk Lid Only. Please order the complete service kit if all parts are needed. Kit is not backward compatible with earlier model years. NOTE: For older model years, please order the entire replacement tank assembly with tank trunk STRIKER PLATE DEG TURN KEYLATCH CAP TANK TRUNK LID REPLACEMENT KIT NOTE: Kit includes TANK TRUNK LID ( ). Part Detail for #03. TANK TRUNK LID REPLACEMENT KIT Callout Part Number Part Name Qty. per Motorcycle ASYMMETRIC U-CHANNEL FOAM SEAL 3/6" WIDE HEX SOCKET HEAD CAP SCREW M3X WASHER ISO HV ZM-F-0 REV TANK TRUNK HINGE CAP TORSION SPRING FOR LID

21

22 ZEV Rear Suspension

23 ZEV Rear Suspension Callout Part Number Part Name Qty. per Motorcycle PREVAILING TORQUE TYPE NUT DIN 985 M0-8 ZM-F REV WASHER ISO HV ZM-F-0 REV 02 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) 2 in 205 and later models. NOTE: Manufacturer part number is RS STUB AXLE SDS STUB-PIVOT COVER TRIMMED REAR INNER FENDER 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 REAR AXLE 20MM HOLLOW, ROUNDED END HEXAGON HEAD SCREW DIN 933 M8X ZM-F-0 REV HEXAGON HEAD SCREW DIN 933 M8X ZM-F-0 REV HEXAGON FLANGE NUT DIN 6923 M8-.25 ZM-F-0 REV 03 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 STUB AXLE SDS STUB-PIVOT COVER LOWER SHOCK EYE BOLT M0-.5X60MM LOWER SHOCK EYE BOLT M0-.5X60MM

24 LOWER SHOCK EYE BOLT M0-.5X60MM WASHER ISO HV ZM-F-0 REV 02

25

26 ZEV Frame(Left)

27 ZEV 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 02 HEXAGON SOCKET HEAD CAP SCREW ISO 4762 M8X ZM-F-0 REV 03 ZM-L-0 REV 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 HEATSINK SUPPORT SR TAIL FRAME SEAT BOLT M8X NOTE: Supersedes HEX FLANGE BOLT M8X CLEVIS PIN CUSTOM 0MM X 45L CAVITY PLUG C SDS PASSENGER PEG BRKT L RETAINING RING 9MM SHAFT PASSENGER FOOTPEG LEFT SIDE 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 RETAINING RING 9MM SHAFT RETAINING RING 9MM SHAFT BUSHING FLANGE HEXAGON SOCKET THIN HEAD CAP SCREW DIN M0X ZM-F-0 REV 03 ZM-L-0 REV 0

28 CLEVIS FOOT PEG UNIVERSAL LEFT CLEVIS PIN CUSTOM 0MM X 45L FOOTPEG, LEFT TORSION SPRING,.678 OD.078 WIRE, CCW 37 Not Applicable to this Bike Model M5X6-8.8 ZM-F- REV WASHER M5 X X NYLON 6/6 BLACK SKID PAN BRACKET SDS FRAME MOUNTED HORN BRACKET HEX SOCKET BUTTON HEAD CAP SCREW M6X WASHER ISO HV ZM-F-0 REV WASHER ISO HV ZM-F-0 REV 02 PREVAILING TORQUE TYPE NUT DIN 985 M6-8 ZM-F-0 REV SR MAIN FRAME HEXAGON SOCKET HEAD CAP SCREW ISO 4762 M5X ZM-F-0 REV 03 ZM-L-0 REV HEADLIGHT MOUNTING WASHER S ELECTRICAL PANEL HEXAGON SOCKET HEAD CAP SCREW ISO 4762 M5X ZM-F-0 REV 03 ZM-L-0 REV HEADLIGHT MOUNTING WASHER

29

30 ZEV Frame(Right)

31 ZEV Frame(Right) Callout Part Number Part Name Qty. per Motorcycle HEX FLANGE BOLT M8X SR MAIN FRAME 3 Not Applicable to this Bike Model FOOTPEG, RIGHT NOTE: Does not apply to S and SR TORSION SPRING,.678 OD.078 WIRE, CCW 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 PASSENGER FOOTPEG RIGHT SIDE RETAINING RING 9MM SHAFT 7 Not Applicable to this Bike Model SDS AND FX PASSENGER PEG BRKT R

32 ZEV Motor and Drive System

33 ZEV Motor and Drive System Callout Part Number Part Name Qty. per Motorcycle WASHER ISO HV ZM-F-0 REV ZF75-7 R IPM MOTOR SPLINED SHAFT 3 Not Applicable to this Bike Model MOTOR JACK SCREW INNER WASHER ISO HV ZM-F-0 REV 02 4 HEXAGON SOCKET HEAD CAP SCREW ISO 4762 M8X ZM-F-0 REV 03 WHEEL SPROCKET 90T MM PITCH 7MM WIDE BELT COATED WASHER ISO HV ZM-F-0 REV 02 M8X30 HEXOBULAR SOCKET PAN HEAD ISO 4583 CLASS ZM-F-0 REV 04 ZM-L-02 REV BELT 58T MM PITCH 7MM WIDE MOTOR SPROCKET 20T MM PITCH 7MM WIDE BELT ASSEMBLED 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 HEXALOBULAR (6 LOBE) SOCKET FLAT HEAD COUNTERSUNK SCREW ISO 4582 M8X ZM-F-0 REV MOTOR MOUNTING LEFT FRONT TOP AND LEFT FRONT BOTTOM BOLT 04

34 ZEV Electronics ZF3.0 Power Pack

35 ZEV Electronics ZF3.0 Power Pack 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 BODYWORK MISC #6 CONTROLLER UN-SHIELDED COVER CONTROLLER FORMEX PAN HEAD PHILLIPS #6 SHEET METAL SCREW CONTROLLER LEAD BOLTS M8X6 9 Not Applicable to this Bike Model CONTROLLER, SIZE 6 GEN 4.5 SEVCON Not Applicable to this Bike Model HEATSINK #4 CONTROLLER SDS 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 ELECTRICAL COMPONENT EVC35 CONTACTOR HEADLIGHT MOUNTING WASHER HEXAGON SOCKET BUTTON HEAD SCREW ISO M5X ZM-F-0 REV 03 ZM-L-02 REV JUNCTION POST SMALL TRIMMED 9 Not Applicable to this Bike Model FUSE 300A 60VDC CLASS T WASHER ISO HV ZM-F-0 REV FUSE NUT INTERNAL 23 PA-20 CONTACTOR COVER 24 PA-225 LV FUSE HOLDER CONTROLLER, SIZE 6 GEN 4.5 SEVCON PREVAILING TORQUE TYPE NUT DIN 985 M6-8 ZM-F-0 REV DC-DC CONV 500W SEVCON ABS UNITS S ELECTRICAL PANEL ASSY MBB GENERIC POTTED 7MY IMPL MBB KW HEXAGON SOCKET HEAD CAP SCREW ISO 4762 M4X ZM-F-0 REV WASHER ISO HV ZM-F-0 REV 02 PREVAILING TORQUE TYPE NUT DIN 985 M8-0 ZM-F REV 02

36 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 ASSY BATTERY PACK MONOLITH 7MY IMPL 38 Not Applicable to this Bike Model WASHER UNIVERSAL (SIZE ) HEXAGON SOCKET HEAD CAP SCREW ISO 4762 M4X ZM-F-0 REV 03 ZM-L-02 REV MONOLITH BMS COVER 42 Not Applicable to this Bike Model BATTERY FRONT UPPER FILLER PLUG DISC HORN K70/H2 V WITH BLACK ZINC WASHER ISO HV ZM-F-0 REV M8X ZM-F-0 REV 03 HEXAGON SOCKET HEAD CAP SCREW ISO 4762 M6X ZM-F-0 REV 03 ZM-L-0 REV BATTERY FRONT UPPER FILLER PLUG M8X ZM-F-0 REV M8X ZM-F-0 REV M8X ZM-F-0 REV WASHER ISO HV ZM-F-0 REV BATTERY FRONT UPPER FILLER PLUG 54 Not Applicable to this Bike Model M8X ZM-F-0 REV 03 KEYSWITCH LOCK ZADI, IGNITION SWITCH NOTE: This part is the ignition switch and keys only. If you want a matching helmet lock for 6MY motorcycles and older, please order p/n If you want the key switch and a lock for a tank trunk, please order If you want a ignition and matching locks for tank trunk and storage trunks, please order part number PREVAILING TORQUE TYPE NUT DIN 985 M6-8 ZM-F-0 REV KEYSWITCH AND 90 DEG TURN PANEL LATCH KEYED ALIKE SET WASHER ISO HV ZM-F-0 REV 02

37 DASH LCD (ABS) BUG LOGO NOTE: Applicable 4MY-6MY 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] SDS TRIPLE CLAMP HARNESS SUPPORT HEXAGON SOCKET BUTTON HEAD SCREW ISO M5X6-8.8 HEXAGON SOCKET BUTTON HEAD SCREW ISO M5X BATTERY CASE CONT COVER FRONT 5MY IMPL

38 ZEV004 - Electronics ZF6.5 Power Pack

39 ZEV004 - Electronics ZF6.5 Power Pack Callout Part Number Part Name Qty. per Motorcycle HEXAGON SOCKET HEAD CAP SCREW ISO 4762 M4X ZM-F-0 REV 03 ZM-L-02 REV 0 2 Not Applicable to this Bike Model 3 Not Applicable to this Bike Model WASHER UNIVERSAL (SIZE ) HEXAGON NUT ISO 4032 M6-8 ZM-F-0 REV 02 6 Not Applicable to this Bike Model 7 Not Applicable to this Bike Model HEADLIGHT MOUNTING WASHER HEXAGON SOCKET BUTTON HEAD SCREW ISO 7380 M5X HEXAGON SOCKET BUTTON HEAD SCREW ISO 7380 M5X0 Not Applicable to this Bike Model ASSY MBB GENERIC POTTED 7MY IMPL BMS MOUNTING SCREW NEXT TO DIA CONNECTOR HEXAGON SOCKET HEAD CAP SCREW ISO 4762 M4X ZM-F-0 REV 03 ZM-L-02 REV 0 5 Not Applicable to this Bike Model BATTERY FRONT UPPER FILLER PLUG LEFT HAND SWITCHGEAR ECIE MBB TO FRAME FRONT 9 Not Applicable to this Bike Model HEXAGON SOCKET HEAD CAP SCREW ISO 4762 M4X ZM-F-0 REV 03 ZM-L-02 REV WASHER UNIVERSAL (SIZE ) 22 Not Applicable to this Bike Model 23 Not Applicable to this Bike Model WASHER UNIVERSAL (SIZE ) BATTERY LOW VOLTAGE FUSE COVER HEXAGON SOCKET HEAD CAP SCREW ISO 4762 M5X ZM-F-0 REV 03 ZM-L-0 REV DC-DC CONV 500W SEVCON ABS UNITS 28 Not Applicable to this Bike Model 29 Not Applicable to this Bike Model ASSY MBB GENERIC POTTED 7MY IMPL MBB KW HEXAGON SOCKET HEAD CAP SCREW ISO 4762 M4X ZM-F-0 REV WASHER ISO HV ZM-F-0 REV Not Applicable to this Bike Model WASHER ISO HV ZM-F-0 REV 02

40 35 Not Applicable to this Bike Model 36 Not Applicable to this Bike Model 37 Not Applicable to this Bike Model PREVAILING TORQUE TYPE NUT DIN 985 M8-0 ZM-F REV 02 HEXAGON SOCKET HEAD CAP SCREW ISO 4762 M8X ZM-F-0 REV 03 ZM-L-0 REV WASHER ISO HV ZM-F-0 REV 02 HEXAGON SOCKET HEAD CAP SCREW ISO 4762 M8X ZM-F-0 REV 03 ZM-L-0 REV WASHER ISO HV ZM-F-0 REV HEADLIGHT MOUNTING WASHER M5X2-8.8 ZM-F-0 REV M5X2-8.8 ZM-F-0 REV HEADLIGHT MOUNTING WASHER 47 Not Applicable to this Bike Model 48 Not Applicable to this Bike Model 49 Not Applicable to this Bike Model 50 Not Applicable to this Bike Model 5 Not Applicable to this Bike Model 52 Not Applicable to this Bike Model 53 Not Applicable to this Bike Model 54 Not Applicable to this Bike Model 55 Not Applicable to this Bike Model 56 Not Applicable to this Bike Model 57 Not Applicable to this Bike Model 58 Not Applicable to this Bike Model 59 Not Applicable to this Bike Model 60 Not Applicable to this Bike Model 6 Not Applicable to this Bike Model 62 Not Applicable to this Bike Model DISC HORN K70/H2 V WITH BLACK ZINC PREVAILING TORQUE TYPE NUT DIN 985 M8-0 ZM-F REV WASHER ISO HV ZM-F-0 REV WASHER ISO HV ZM-F-0 REV M8X ZM-F-0 REV 03 HEXAGON SOCKET HEAD CAP SCREW ISO 4762 M6X ZM-F-0 REV 03 ZM-L-0 REV WASHER ISO HV ZM-F-0 REV SDS FRAME MOUNTED HORN BRACKET PREVAILING TORQUE TYPE NUT DIN 985 M6-8 ZM-F-0 REV

41 WASHER ISO HV ZM-F-0 REV 02 M8X4MM BREAK AWAY HEX BOLT NOTE: One Time Use Bolt KEYSWITCH LOCK ZADI, IGNITION SWITCH NOTE: This part is the ignition switch and keys only. If you want a matching helmet lock for 6MY motorcycles and older, please order p/n If you want the key switch and a lock for a tank trunk, please order If you want a ignition and matching locks for tank trunk and storage trunks, please order part number KEYSWITCH AND 90 DEG TURN PANEL LATCH KEYED ALIKE SET PREVAILING TORQUE TYPE NUT DIN 985 M6-8 ZM-F-0 REV WASHER ISO HV ZM-F-0 REV 02 DASH LCD (ABS) BUG LOGO NOTE: Applicable 4MY-6MY 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] SDS TRIPLE CLAMP HARNESS SUPPORT THROTTLE BITRON HALL EFFECT PCB NOTE: Replaced PN KILL MODE START SWITCH