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Zero · Shim-adjusted overhead-cam four-stroke, wet sump, gearbox shares engine oil, belt drive

S

Library entry covers 2014-2025

16 factory 44 guideline

Published source

Zero S 2014 Owner's Manual, Maintenance Schedule 5.2-5.4 (ManualsLib 757905 page 74)

Factory owner's handbook. Covers 2014 Zero S/SR/DS owner manual; later editions (2018 and on) not checked.

60 items for a 2020 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Overhead cam, shim adjusted (incl. desmo)
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Fuel injection
Cooling: Air / oil cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Toothed belt
Front suspension: Telescopic fork
Rear suspension: Swingarm, single shock / cantilever
Front brake: Disc, hydraulic
Rear brake: Disc, hydraulic
Wheels: Cast / alloy, tubeless
Sidecar: No sidecar

Maintenance schedule

2020 Zero S

On the road: every 300 km

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 500 km

2 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline

Every 1,600 km or 6 months

1 item

Inspect tire tread, sidewalls and date codes

Wheels and tires

Guideline

Every 5,000 km or 12 months

7 items

Check throttle cable(s) free play and return

Fuel and air

Guideline
Check steering head bearing adjustment

Front end

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check brake pads and discs

Brakes

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 6,500 km or 12 months

2 items

Inspect, clean and gap spark plugs

Engine

Guideline
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Guideline

Every 7,000 km or 6 months

13 items

Chassis fasteners (check)

Engine

Factory

Factory: Maintenance schedule (5.2-5.4): check all chassis fasteners. Marked at 4K, 8K, 12K, 16K and 20K mi. Columns: every ride; initial 600 mi (1K km) or 1 month; then 4K mi (7K km) or 6 months, 8K mi or 12 months, 12K mi or 18 months, 16K mi or 24 months, 20K mi or 30 months, whichever comes first. From 24,000 mi (37,000 km) or 36 months, repeat the intervals starting from 8,000 mi or 12 months.
Throttle grip (check)

Engine

Factory

Factory: Maintenance schedule (5.2-5.4): check operation and free play. Marked every ride and at 4K, 8K, 12K, 16K and 20K mi. Columns: every ride; initial 600 mi (1K km) or 1 month; then 4K mi (7K km) or 6 months, 8K mi or 12 months, 12K mi or 18 months, 16K mi or 24 months, 20K mi or 30 months, whichever comes first. From 24,000 mi (37,000 km) or 36 months, repeat the intervals starting from 8,000 mi or 12 months.
Front fork (check)

Front end

Factory

Factory: Maintenance schedule (5.2-5.4): check operation and for oil leakage; service or rebuild if necessary. Marked every ride and at 4K, 8K, 12K, 16K and 20K mi. Columns: every ride; initial 600 mi (1K km) or 1 month; then 4K mi (7K km) or 6 months, 8K mi or 12 months, 12K mi or 18 months, 16K mi or 24 months, 20K mi or 30 months, whichever comes first. From 24,000 mi (37,000 km) or 36 months, repeat the intervals starting from 8,000 mi or 12 months.
Steering bearings (check)

Front end

Factory

Factory: Maintenance schedule (5.2-5.4): check all chassis fittings and fasteners; correct if necessary. Marked initial, 4K, 8K, 12K and 20K mi; "Repack" is printed in the 16K mi column. Columns: every ride; initial 600 mi (1K km) or 1 month; then 4K mi (7K km) or 6 months, 8K mi or 12 months, 12K mi or 18 months, 16K mi or 24 months, 20K mi or 30 months, whichever comes first. From 24,000 mi (37,000 km) or 36 months, repeat the intervals starting from 8,000 mi or 12 months.
Kickstand pivots (check, grease)

Rear suspension and frame

Factory

Factory: Maintenance schedule (5.2-5.4): check operation; apply silicone grease lightly. Marked at 4K, 8K, 12K, 16K and 20K mi. Columns: every ride; initial 600 mi (1K km) or 1 month; then 4K mi (7K km) or 6 months, 8K mi or 12 months, 12K mi or 18 months, 16K mi or 24 months, 20K mi or 30 months, whichever comes first. From 24,000 mi (37,000 km) or 36 months, repeat the intervals starting from 8,000 mi or 12 months.
Kickstand switch (check)

Rear suspension and frame

Factory

Factory: Maintenance schedule (5.2-5.4): check operation and replace if necessary. Marked initial and at 4K, 8K, 12K, 16K and 20K mi. Columns: every ride; initial 600 mi (1K km) or 1 month; then 4K mi (7K km) or 6 months, 8K mi or 12 months, 12K mi or 18 months, 16K mi or 24 months, 20K mi or 30 months, whichever comes first. From 24,000 mi (37,000 km) or 36 months, repeat the intervals starting from 8,000 mi or 12 months.
Rear shock absorber (check)

Rear suspension and frame

Factory

Factory: Maintenance schedule (5.2-5.4): check operation and for oil leakage; replace if necessary. Marked every ride and at 4K, 8K, 12K, 16K and 20K mi. Columns: every ride; initial 600 mi (1K km) or 1 month; then 4K mi (7K km) or 6 months, 8K mi or 12 months, 12K mi or 18 months, 16K mi or 24 months, 20K mi or 30 months, whichever comes first. From 24,000 mi (37,000 km) or 36 months, repeat the intervals starting from 8,000 mi or 12 months.
Front brake (check)

Brakes

Factory

Factory: Maintenance schedule (5.2-5.4): check operation and for fluid leakage; replace brake pads if necessary. Marked every ride, initial and at 4K, 8K, 12K, 16K and 20K mi. Columns: every ride; initial 600 mi (1K km) or 1 month; then 4K mi (7K km) or 6 months, 8K mi or 12 months, 12K mi or 18 months, 16K mi or 24 months, 20K mi or 30 months, whichever comes first. From 24,000 mi (37,000 km) or 36 months, repeat the intervals starting from 8,000 mi or 12 months.
Front brake lever pivot (grease, check)

Brakes

Factory

Factory: Maintenance schedule (5.2-5.4): apply silicone grease lightly; check operation and for oil leakage; service or rebuild if necessary. Marked initial and at 4K, 8K, 12K, 16K and 20K mi. Columns: every ride; initial 600 mi (1K km) or 1 month; then 4K mi (7K km) or 6 months, 8K mi or 12 months, 12K mi or 18 months, 16K mi or 24 months, 20K mi or 30 months, whichever comes first. From 24,000 mi (37,000 km) or 36 months, repeat the intervals starting from 8,000 mi or 12 months.
Rear brake (check)

Brakes

Factory

Factory: Maintenance schedule (5.2-5.4): check operation and for fluid leakage; replace brake pads if necessary. Marked every ride, initial and at 4K, 8K, 12K, 16K and 20K mi. Columns: every ride; initial 600 mi (1K km) or 1 month; then 4K mi (7K km) or 6 months, 8K mi or 12 months, 12K mi or 18 months, 16K mi or 24 months, 20K mi or 30 months, whichever comes first. From 24,000 mi (37,000 km) or 36 months, repeat the intervals starting from 8,000 mi or 12 months.
Tires (check)

Wheels and tires

Factory

Factory: Maintenance schedule (5.2-5.4): check tread depth and for damage, replace if necessary; check air pressure and correct if necessary. Marked every ride and at 4K, 8K, 12K, 16K and 20K mi. Columns: every ride; initial 600 mi (1K km) or 1 month; then 4K mi (7K km) or 6 months, 8K mi or 12 months, 12K mi or 18 months, 16K mi or 24 months, 20K mi or 30 months, whichever comes first. From 24,000 mi (37,000 km) or 36 months, repeat the intervals starting from 8,000 mi or 12 months.
Wheel bearings (check)

Wheels and tires

Factory

Factory: Maintenance schedule (5.2-5.4): check bearings for smooth operation; replace if necessary. Marked initial and at 4K, 8K, 12K, 16K and 20K mi. Columns: every ride; initial 600 mi (1K km) or 1 month; then 4K mi (7K km) or 6 months, 8K mi or 12 months, 12K mi or 18 months, 16K mi or 24 months, 20K mi or 30 months, whichever comes first. From 24,000 mi (37,000 km) or 36 months, repeat the intervals starting from 8,000 mi or 12 months.
Wheels (check)

Wheels and tires

Factory

Factory: Maintenance schedule (5.2-5.4): check run-out and for damage; replace if necessary. Marked at 4K, 8K, 12K, 16K and 20K mi. Columns: every ride; initial 600 mi (1K km) or 1 month; then 4K mi (7K km) or 6 months, 8K mi or 12 months, 12K mi or 18 months, 16K mi or 24 months, 20K mi or 30 months, whichever comes first. From 24,000 mi (37,000 km) or 36 months, repeat the intervals starting from 8,000 mi or 12 months.

Every 8,000 km or 12 months

3 items

Change engine oil

Engine

Guideline

Pre-1970 machines: many owners run non-detergent or classic-spec oil with no filter, so short intervals matter. Dry sump: drain the tank and the crankcase/sump, flush the tank and clean the feed and return screens.
Replace oil filter

Engine

Guideline
Inspect drive belt, pulleys and tension

Final drive

Guideline

Every 9,500 km or 12 months

6 items

Clean / inspect air filter

Fuel and air

Guideline

Mesh or oiled foam: clean and re-oil. Paper: blow out or replace. Some very early machines have no filter at all.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline
Lubricate control cables and lever pivots

Controls and cables

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 16,000 km or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 19,500 km or 2 years

4 items

Replace air filter element

Fuel and air

Guideline
Synchronize throttle bodies

Fuel and air

Guideline
Clean and grease rear suspension linkage

Rear suspension and frame

Guideline
Grease swingarm pivot

Rear suspension and frame

Guideline

Every 24,000 km or 3 years

1 item

Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 24,000 km or 4 years

1 item

Check valve clearances (shim adjusted)

Engine

Guideline

Every 25,000 km or 2 years

1 item

Steering bearings (repack)

Front end

Factory

Factory: Maintenance schedule (5.3): "Repack" printed in the 16K mi (25K km) or 24 months column. Columns: every ride; initial 600 mi (1K km) or 1 month; then 4K mi (7K km) or 6 months, 8K mi or 12 months, 12K mi or 18 months, 16K mi or 24 months, 20K mi or 30 months, whichever comes first. From 24,000 mi (37,000 km) or 36 months, repeat the intervals starting from 8,000 mi or 12 months.

Every 25,500 km or 4 years

1 item

Replace spark plugs

Engine

Guideline

Every 32,000 km or 4 years

2 items

Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 38,500 km or 4 years

1 item

Replace fuel filter

Fuel and air

Guideline

Every 40,000 km or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 40,000 km

1 item

Drive belt (replace)

Engine

Factory

Factory: Maintenance schedule (5.3): replace the belt every 40K km (25K mi). Columns: every ride; initial 600 mi (1K km) or 1 month; then 4K mi (7K km) or 6 months, 8K mi or 12 months, 12K mi or 18 months, 16K mi or 24 months, 20K mi or 30 months, whichever comes first. From 24,000 mi (37,000 km) or 36 months, repeat the intervals starting from 8,000 mi or 12 months.

Every 48,500 km or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 80,500 km

1 item

Replace drive belt (wear or damage based)

Final drive

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 2 years

3 items

Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Replace brake fluid

Brakes

Guideline

Every 4 years

3 items

Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.
Inspect brake hoses; replace old rubber

Brakes

Guideline
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

1 item

Replace tires on age (regardless of tread)

Wheels and tires

Guideline

No interval set

1 item

Drive belt (check)

Engine

Factory

Factory: Maintenance schedule (5.3): check belt slack and condition, and for cracking; replace a worn or damaged belt. Marked every ride. Columns: every ride; initial 600 mi (1K km) or 1 month; then 4K mi (7K km) or 6 months, 8K mi or 12 months, 12K mi or 18 months, 16K mi or 24 months, 20K mi or 30 months, whichever comes first. From 24,000 mi (37,000 km) or 36 months, repeat the intervals starting from 8,000 mi or 12 months.

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.

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Other 2020 Zero models

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