To unlock Zero in Super Smash Flash, you have to beat Adventure Mode on at least Normal Difficulty without getting a Game Over as Megaman.
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while on menu choose samus then hold minus then press plus
When you are Samus, aquire the smash ball, thus shooting a massive beam destroying your chozo Armour and leaving you with Zero suit Samus. then im pretty sure you can switch between the two at the character selection screen, but you must hold a button, but im not too sure.
Samus can only change back and forth between Samus and Zero Suit Samus by using her final smash.
i awnsered that last night...well just use samus' final smash