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Wow.  I sure appreciate all this informnation.  Thank you very much.  I just got the Zero Service Manual.  I wasn't aware there was one and had been using the unofficial manual.

I got the new pulley and spacer and unfortunately I didn't read your helpful posts before I worked on it today. 

The new pulley slipped on nicely and doesn't appear to have any slop or play in it.  The spacer matches the back surface of the pulley but its I.D. is larger than the motor shaft O.D..  I used some red and tacky grease to get it aligned on the pulley for installation.  Otherwise, it could be tightened off-center.  This seems a little jankity to me but that is the way it is.  I didn't use anything on the splines - when I took the pulley off before installing the chain kit, it was clean, i.e., no evidence of any Loctite 680 on it.  It came off with no pressure or tools needed.  I wonder if the use of Loctite 680 is a new thing.  I used blue loctite on the T50 M10X25-10.9 countersunk head screw.  I was able to torque it to 50 NM.  When I trid to torque it to 60, it was too difficult to hold the pulley and I was concerned I might damage the torx fitting.  It is really awkward doing it through the swing arm pivot holes in the frame and difficult to hold the pulley.  I don't have an old drive belt to make the tool the manual shows for holding the pulley.  I think the drive belts are pretty expensive.

I'm going to take it for a short test drive tomorrow to check it out.  I'll get some Loctite 680 and work on a way of holding the pulley better and go back through the process of installing the pulley again.

The dealer did tell me when he looked it up, that it called for the 18T.  The parts manual I have (think I downloaded it from here or from Zero) calles for 20T and the part number is stamped into the part.  I prefer the 20T and that is what I ordered.

I didn't know there was a dongle for adjusting the speedo. Back when I installed the chain kit, Zero told me to take it to the dealer to get the speedo correct; they wouldn't give me the password to change it in the interface when I connect a laptop to it.  I think someone did eventually post the password on this forum but I haven't gone back to try using it.

When I put it back on after the chain kit, I used the newer Torx screw (rather than the original allen head) and used blue loctite.  It was snug when I removed it and there was no evidence of it being loose, e.g., paint scraped off.

When I get the replacement installed I think I will check the screw every few thousand miles just in case.

A new fuse didn't make any difference.

The piece with the spring that holds the fuse looks like new and I used a light to look inside the fuse holder and don't see any corrosion or do-dah.  I may get a new fuse holder but it looks like there would more dis-assembly in order to install it.  I put the side cover back on for now and will see what happens for a while.  From looking around the forum, it seems like a lot of OBCs fail.  This bike started showing these symptoms right at the 5 year mark and I intially thought it was the battery going down hill but it seems like there is more experience suggesting it is the OBC or this fuse holder.

Got it - thank you very much.

They are 6204-2RS - single row ball bearings.  I replaced with Xike bearings purchased on Amazon.  Remove the seals and clean thoroughly then pack with high quality grease.  Others have used really expensive bearings.  I'll see how these do; it is easy enough now to replace them.

The design is different from most other swing arm bearings I know of.  I don't know if it is good or not so but, I think zero should have used a larger bearing, a double row ball bearing, or needle bearing or some combination instead of what they did.

The front sprocket in my chain kit was JT - looks just like the diagram except 12 teeth.   Maybe Zero has other suppliers.  I had about 100 hours of off road/dirt bike use when I changed the sprocket and the wear was easily noticeable but it was still serviceable.

I have never known of a sprocket to shatter.

Know it is off topic but, the swing arm bearings are toast now and need replacing.  As discussed elsewhere on the forum, they are a problem.  I'm hoping better quality bearings packed with good grease will help longevity.  Most bearing suppliers don't properly lube the bearings and it is unlikely Zero would have done so either.

I have the chain kit on my 2017 FX and wanted options on the front sprocket.  After contacting several sprocket suppliers, JT sprockets told me they supply front sprockets to Zero; didn't know if anyone else was also supplying them and they do not supply rear sprockets.  Look closely at the chain kit front sprocket and you'll see it has the JT logo and is marked 565.  Here's a link to their JTF565 sprockets:

http://www.jtsprockets.com/catalogue/part/JTF565SC/

And to their spec drawing:


Sunstar told me their 325xx matches the JTF 565.

I put a 14 tooth on mine for street use and now the gearing is very close to stock and the speedometer is only off by a little.  I'll just keep the chain on now and not switch back to belt and pulley for street use.