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[Lecram]

I bought the 25T HIGHER TORQUE GEARING OPTION for my 2015 DS. Any tips/instructions how to replace the current one?

http://www.zeromotorcycles.com/shop/index.php?main_page=product_info&cPath=15_6&products_id=182

[Burton]

What type of tips are you looking for ?

Typically this would require you to
1) put bike up on a stand
2) remove tension from belt
3) remove bolts holding motor in (Put a hydraulic jack under motor with a towel to support it for when it comes loose, bonus if it has wheels.)
4) remove key screws from existing pulley (might need a torch if they gob'ed green locktite on it) [you don't need to remove the wires at controller if you do this right, just rotate the motor into a direction you can more easily work on it BUT you might need to also remove the swing arm]
4a optional) remove swing arm by first loosing the key screws in each nut on the inside. These are tiny bastards but not hard to find. Don't try to remove these nuts without removing the set screws or loosing them first!
5) remove pulley (likely need a pneumatic wrench for this of at least 90 psi)
6) remove key screws (should be two) from old pulley, clean, put some blue locktite (at minimal) on them and put into new pulley
7) Place new pulley on the motor and screw in front with pneumatic wrench
screw in key screws with allen key
9) place motor back into frame and make sure belt is in place
10) tighten left side bolts into motor
11) tighten right side bolts into motor and adjust standoffs to properly transfer force
12) Adjust belt tension at rear wheel and check for alignment. (this should be 40 - 45 kg if you are running 25/132 or 25/98. With SR's you can strip teeth off the  belt if you run a lower tention than this. Not sure how it applies to size 4 bikes if at all, and if it doesn't go with 35kg)

These will help a lot!

I found these online - they seem quite good to me:
http://freepdfhosting.com/bb590a712d.pdf
http://freepdfhosting.com/3455cf1dcd.pdf

[Cortezdtv]

I would loosen the pulley bolt with the belt still on first that way you can use the belt and brake to hold the pulley in place otherwise you will most likely forced into using the wrong tools for the job,
This is much easier done on the fx platform vs the s platform as you cannot as easily disconnect the battery to remove motor from controller

[Lecram]

Thanks a lot, guys!

[mguw]

Hello

Is there a smaller pulley available than the 25T for the fx?

A+ Marcel

[Burton]

If you want "smaller" then you go chain instead of belt.

From Zero you won't get anything smaller than 25.

I think I have a 25, 28, 98, and 132 at home lol

[KrazyEd]

  As you go smaller on the motor sprocket, you put more stress on the drive source belt or chain. Probably worse on chain.
I agree with conversion to chain if you want more, go larger on the rear. Chain is easier to lengthen than belt.
I believe that I read on here that people were ripping teeth off of the belt with a 25 on SR. Keep in mind that the difference
in speed will be significant. Top speed will be 85 mph. Pretty impressive if you are only going a few hundred feet,
but, you will get spanked when the ICE bike hits 3rd gear. Pretty embarrassing to have a Ninja 250 walk away from you on the Freeway.
SR Top speed listed at 102, FX ( which is the gearing you end up with ) is 85. 17 mph may not be that much when you drop a
'Busa from top speed of 190 down to 173 but, percentage wise, it is around 17%. Doubtful that you would be able to take
full advantage anyway, probably just spin the tire. You can see this on Tesla videos that go past 60 mph. Very impressive off the
line, but, just about any performance vehicle passes it soon after ( unless Ludicrous Mode upgrade installed and enabled ). I can
guarantee that if you ran a 1/4 mile that your time would be much slower, since you are topped out well before half way.

[Lecram]

I am not so concerned about the higher stress on the belt, because the SR has much more torque with (I guess) the same belt. I don't care about the lower top speed. I barely go faster than 120 km/h. I try to avoid highways and rather stay on local roads. Especially with a passenger, I find the current torque too low.

[Cortezdtv]

If you get the chain kit you can then get a 12 tooth on the front instead of the 14, go karts sometimes use the 12s


If you want to make the fx snappier order a custom rear sprocket and/or custom front. But get the chain kit!!! It is going to make the bike loud but it's not something I ever regret, makes it more "motorcycle'y" if that makes sense

I believe McMaster has the front sprockets

[KrazyEd]

   Just making sure that you were aware of the trade off. I have changed my gearing twice on my FX. I first went to the 30 because I wanted higher top speed, and, when not going fast, greater range.
I switched shortly after to a 28, because of loss of some of the "fun" factor. The factory installed sprocket was very difficult. I tried heat, puller, and, other options available without damage to motor or
shaft. Eventually, I removed the motor and took to a local electric motor shop. They swapped sprockets in a couple minutes. Didn't even charge me, just wanted to see the bike once motor was back in.
Once you have the motor loosened. it is only a few more minutes to remove it. My feelings were that it was better to pay a professional who does this daily rather than save a few dollars and damage
something. Make sure that you apply appropriate torque, and something to make sure that it doesn't come loose when installing the new sprocket.

[rayivers]

Is there a smaller pulley available than the 25T for the fx?

That you can buy and put right on? No. Zero uses a non-standard 14mm belt width and 520 chain, so like every option I've found that drops gearing below 5.28:1 (belt) or 5.41:1 (chain), either machine / welding work or custom fabrication will be needed.

Here's a 22T pulley for a standard 21mm-wide version of the 8mm-pitch belt Zero uses:

http://www.ebay.com/itm/Gates-8MX-22S-21-1-Sprocket-8MX22S21-New-No-Box-/350428948756

My machinist told me he can definitely narrow this pulley to 14mm, and my welder told me he could then weld the flange end back on.  Neither gave me a price.

I'll be going with a 10/65 chain setup next time (20% more torque than the chain kit, with only minor machining of a Martin 50BS10-1 sprocket needed).

Ray

[grmarks]

I don't care about the lower top speed. I barely go faster than 120 km/h. I try to avoid highways and rather stay on local roads. Especially with a passenger, I find the current torque too low.

Another solution - buy an SR!  Sorry couldn't resist.

Note to future buyers of the S.
 
I had the choice of a discounted 2014 S or a 2015 SR. In the end I decided to go with the SR as I was worried I might end up feeling as you do now. I hardly ever use ALL its power but I certainly use more than the S can give, often. Even if Zero bought out a more powerful model, I wouldn't upgrade. On those rare occasions when I use all the power it has never struck me that it's not enough.

[Lecram]

Another solution - buy an SR!  Sorry couldn't resist.

The high torque option was much, much cheaper than trading my DS in for a SR 

[grmarks]

Well that is certainly true. The SR is so versatile, you can ride with plenty of power or speed or as economical you you like. I love it.

[Ndm]

How much more range does the high speed gearing offer? I'm not a torque or speed junkie either way,but a little added range would be helpful, 2013 s is good enough for me and my commute, but I do engage in a little throttle twisting every now and then!