2024 BILTWELL 100
Patrick Flynn
Marketing Automation and Email Manager
April 22, 2024
Proving What’s Possible in the Dirt
Zero returns to the Biltwell 100, TAKING ELECTRIC ADVENTURE TO NEW EXTREMES
After an unforgettable ride (and a first-place finish) at the 2023 Biltwell 100 in Ridgecrest, California, a few of us at Zero couldn’t wait to line up again. For 2024 we doubled down, entering two racers on Zero DSR/Xs. Thanks to the bike’s size, both competed in the ADV Heavy class, but with a twist: one in the novice ranks, the other in expert. The main difference? Novices tackle three 25-mile laps (75 miles total), while experts go the full 100 miles.
Our chief test rider, Trevor Doniak, took on the expert class, while Kyle Hernandez, Senior Powertrain Technician, carried the flag in novice. Both are seasoned off-road riders, but racing the DSR/X in an event like this is uncharted territory.
There's just something special about a race bike
Planning for the 100-Mile Challenge
Years of testing have proven the DSR/X can comfortably cover 100 miles in typical riding conditions. But tackling a full 100-mile desert race course at race pace? That’s a different story—especially in Ridgecrest, where deep sand, rocky climbs, and wide-open desert all conspire to drain the battery faster than usual.
To go the distance, we came up with a plan: attempt Zero’s first-ever mid-race battery swap. The DS Line doesn’t have a built-in quick-swap system, so we had to improvise. The process? Unbolt the battery from the frame, slide in a fresh one, and button everything back up...fast. It was a high-stakes experiment, but we've been eager to have a reason to give it a shot.
Perfecting the Battery Swap
The first priority was to refine the swap process itself. We broke it down into precise steps and then practiced until the team could execute it efficiently. In controlled conditions, we got the swap time under five minutes—comparable to the time it takes an ICE racer to refuel and grab a quick drink. But we knew pulling it off mid-race, in the middle of the desert, would come with unforeseen challenges and push everyone to the limit.
Tuning the DSR/X for Racing
We began by testing Jenny’s class-winning DSR/X from the previous year's race before building a second race-prepped bike. Key modifications included a lighter subframe, more aggressive footpegs, ProTaper handlebars, shedding some weight, and a tuned suspension setup. After multiple test sessions at Hollister Hills, we found that a stiffer shock spring and firmer fork springs transformed the bike into a serious competitor for the Biltwell 100.
Ready for battle
Race Weekend: Facing Tough Competition
With plenty of practice behind us, we headed to Ridgecrest, ready to race. In the 'ADV Heavy' class we’d be competing in a field consisting of 900cc+ gas-powered adventure bikes built for extreme terrain and long-distance travel. These were some of the most capable machines in the event, making for a tough and exciting challenge.
The day before the race brought brutal conditions. Winds exceeded 40 mph, making even basic riding a challenge. Race day, on the other hand, delivered perfect conditions: blue skies and temperatures in the 50s.
Kyle and Trevor lined up at the start, waiting for the chaotic launch to begin. A surge of riders in a cloud of dust, all funneling to one narrow passage under a railroad track 200 yards away. It’s high-adrenaline and pure mayhem.
Kyle Hernandez with his eyes on the prize
Kyle’s Novice Class Victory
Thanks to the DSR/X's Extended Range Charging feature, Kyle kicked off the race with his dash reading 108% state of charge (SOC). By the end of Lap 1, he was down to 75%; after Lap 2, 43%. Confident in his pace and energy management, Kyle pushed through to the final lap without letting up. He kept his throttle in check, picked clean lines, and stayed smooth on the power.
Kyle rolled into the pits with just 7% SOC left, taking first place in his class!
"The second loop I felt really confident on the bike and knew what to expect on the trails. I was able to find smoother lines that required less energy and allowed me to be more consistent on the throttle. The bike performed amazingly overall."
Kyle silently ripping through the open desert
Trevor Takes on the 100-Mile Expert Class
Trevor lined up with the expert pack. In a bid to get a good launch off the line, he twisted the throttle wide open, breaking traction on the loose terrain. The DSR/X’s 169 lb-ft of torque is instant and relentless, making throttle control key. After two laps, he came into the pits for the team’s long-anticipated battery swap.
Trevor blasting off the start line
Executing a live battery swap under race conditions was no small feat. The uneven desert floor added a new layer of difficulty, but the crew got the bike back in action in just 10 minutes. With a fresh battery, Trevor powered through the final two laps and secured a hard-fought 3rd place podium finish.
Some quick napkin math showed that if we’d hit our sub-5-minute battery swap goal, Trevor would have finished 2nd. Lesson learned—and even more reason to come back next year and do it faster!
"The last 50 miles were awesome. I wasn’t tired and felt like I had a great pace. It was an incredibly fun and challenging race—and even more special to do it on a Zero DSR/X after spending so much time on the bike's development process."
A Weekend to Remember
Months of preparation flashed by in what felt like seconds. Taking home podiums in both classes was an incredible reward for the team’s hard work. As the sun set on race weekend, we gathered around the campfire with tacos and cold drinks, swapping stories from the trails.
Competing in a sandy desert race like the Biltwell 100 with electric motorcycles was a challenge, but our team’s passion and dedication made it a reality. And just like that, we’re already looking ahead to do it again in 2025.
Trevor (214) and Kyle (212) enjoying that post-race feeling
Special thanks to: Brian Wismann, Rodrigo Villalta, Michael Mattoch, Joshua Roton, David Mucci, Jenny Brookes, Dylan Andrako, Trevor Doniak, Kyle Hernandez, Patrick Flynn, Dylan Andrako, Davin Wirtanen, Mike “Otto” Deutsch, the whole Biltwell crew, and everyone else who made this possible!
EV Blood Biking
