Zap DX Owner's Manual

Zap bicycle owner's manual dx zap

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$2.00

REV 5/15/00

OWNER'S MANUAL

ZAP POWER SYSTEM

MADE IN THE USA

Patent #5,491,390 #5,671,821

Other Patents Pending

•

Z A P W O R L D . C O M

w h e r e t r a n s p o r t a t i o n i s g o i n g

One ZAP Drive •117 Morris Street • Sebastopol

California 95472 U.S.A.

tel (707) 824-4150 • fax (707) 824-4159

e-mail: zap@zapworld.com • Stock Symbol:ZAPP

is a registered trademark.

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Page 1 Z A P W O R L D . C O M w h e r e t r a n s p o r t a t i o n i s g o i n g One ZAP Drive •117 Morris Street • Sebastopol California 95472 U.S.A.
Page 2 YOUR INSURANCE POLICIES MAY NOT PROVIDE COVERAGE FOR ACCIDENTS INVOLVING THE USE OF THIS BICYCLE. TO DETERMINE IF COVERAGE IS PROVIDED, YOU SHOULD CONTACT YOUR INSURANCE COMPANY OR AGENT.
Page 3: Your Bike
ALONG WITH YOUR KIT, WE’VE INCLUDED AN INVOICE, OWNER’S MANUAL, AND A WARRAN- TY FORM. PLEASE READ THE WARRANTY CAREFULLY AND FILL OUT THE FORM ON THE BACK. YOU MUST MAIL THE WARRANTY FORM WITHIN 10 DAYS OF RECEIVING YOUR ZAP POWER SYSTEM IN ORDER TO ACTIVATE THE WARRANTY.
Page 4: Introduction
Since vir- tually all of the world’s one billion bicycles are upgrad- able with a ZAP, it is truly an invention that can change the world. The global population is increasing at an alarming rate, and the future seems to promise only more traffic congestion and air pollution.
Page 5: Table Of Contents
Table of Contents BEFORE YOU BEGIN ...1 INTRODUCTION ...2 TABLE OF CONTENTS ...3 DESCRIPTION OF SYSTEM ...4 DETAIL OF ZAP POWERBIKE ...5 RE-ASSEMBLY INSTRUCTIONS (FOR PRE-ASSEMBLED ELECTRICRUIZERS EASY INSTALLATION GUIDE ...8-9 ENGAGEMENT LEVER OPERATION OPERATION MANUAL & CHARGING GUIDE SAFETY WARNINGS ...12-13 PRE-RIDE CHECKLIST ...14...
Page 6: Description Of System
Description of System NOTE: The items referred to on this page are important when installing your ZAP. ZAP Motor Unit Battery Pack Throttle Switch Assembly Battery Tray Main Power Switch Motor / Controller Leads Controller Power Connector Auxiliary Power / Alternate...
Page 7: Detail Of Zap Powerbike
SEAT STAY SEAT BRIDGE STAYS ZAP MOTOR CHAIN STAYS UNIT MINIMUM FIT DIMENSIONS FOR ZAP POWER SYSTEM (TRAY MODEL) Do not use ZAP System on bikes without metal seat stays!!! TOP TUBE 13” SEAT DOWN BATTERY TUBE PACK TUBE CRANK...
Page 8: Re-Assembly Instructions
INTRODUCTION Welcome electric bicycle owner! Thank you for pur- chasing your ZAP Electric Bicycle - we are confident that you will love it. The innovative ZAP Power System you have pur- chased will bring you many hours of fun and enjoyment.
Page 9 11) FINAL BICYCLE INSPECTION Give your ZAP Electric Bicycle a mechanical safety check. Correct procedure for a safety check can be found in your ZAP Owner’s Manual Supplemental. Step 1) At the rear brake assembly, located at the...
Page 10: Easy Installation Guide
3) Mounting Motor Unit NOTE: If you buy a bike directly from ZAP, your bike may have a welded bridge plate instead of a seat stay bridge. IF YOUR BIKE DOES NOT HAVE THE WELDED PLATE, START HERE...
Page 11 Threaded Plate. MOUNTING MOTOR UNIT • Slide the slot of the Hinge Bracket (attached to the ZAP Motor Unit) around the Motor Mount Bolt, between the inside of the seat stays and the Threaded Plate. Deflating the tire may be necessary to get the motor in place.
Page 12: Engagement Lever Operation
Engagement Lever Operation Rider Power Only The engagement cam is in the “up” position, and the motors are off and hang free, just clearing the tire. This mode is for riding when power is not needed and allows the rider to pedal without any drag from the motor. Fig.1 Motor-Assisted After pedaling has initiated, activation of the throttle switch on the handlebar causes the motor to swing into...
Page 13: Operation Manual & Charging Guide
Cam Lever The Cam Lever on your ZAP Motor Unit can either be in the up (disengaged) or down (engaged) position. Your ZAP Power System will operate with the lever in the engaged position. The Cam Lever in the disengaged position is used for full time non- electric assist (pedaling only).
Page 14: Safety Warnings
2. In order to prevent damages or injuries, do not attempt to regenerate a fully charged battery. 3. The ZAP Power System is an electrical assistance for your leg power. Overloading the motor will cause the motor to shut off. This may happen when climbing hills, crossing traffic or during any situation.
Page 15: Other Safety Warnings
2. Do not attempt to touch the motor while it is rotating. 3. Always remain alert. To prevent injury to yourself and to others, do not operate your ZAP Power System if you are fatigued or on medication. 4. Do not operate your ZAP Power System while under the influence of drugs, alcohol, or medication.
Page 16: Pre-Ride Checklist
Pre-Ride Checklist It is a good idea to periodically go through this checklist to make sure that your ZAP Power System and your bike are in proper adjustment for safety and optimal performance. It is imperative that you review this checklist before...
Page 17: Battery Care
1) Your ZAP Power System should be stored and charged at temperatures between 50° F (10° C) and 100° F (38° C). 2) Keep your battery charged. Batteries stored for long periods of time will self-discharge. The higher the temperature, the greater the rate of self-discharge.
Page 18: Troubleshooting Guide
Read the following section carefully. This guide will help your ZAP Power System achieve maximum performance. If you cannot adjust your electric bike using this guide, call ZAP at (707) 824-4150. Our customer service representatives will be glad to help you.
Page 19: Torque Ratings
Multiply Foot pounds Foot pounds Foot pounds Inch pounds Inch pounds Inch pounds Kgf-cm Kgf-cm Kgf-cm Pedals 350 in. lbs. Seat Post Bolt Clamp 75-100 in. lbs. Seat Clamp Single Bolt 120-145 in. lbs. Double Bolt 72-96 in. lbs. Headset Topnut 300 in.
Page 20 ©2001 ZAPWORLD.COM. All rights reserved. is a registered trademark. ® ZAPWORLD.COM • One ZAP Drive 117 Morris Street, Sebastopol CA 95472 USA tel (707) 824-4150 fax (707) 824-4159 e-mail: zap@zapworld.com • Stock Symbol:ZAPP ZAP is a Publicly Traded Company...
Page 21 (wheels, seatpost and brakes) as well as any wheel retention devices and the ZAP motor system and controls on this electric bicycle. Please initial ___________ 4) I am aware that riding an electric bicycle involves certain TO ACTIVATE WARRANTY, PLEASE INITIAL AND SIGN THE BUYER’S CHECKLIST ABOVE AND RETURN WITHIN 10 DAYS OF PURCHASE...
Page 22: Warranty Form
ZAP Owner's Manual. This warranty does not apply to any damage to the ZAP Product that is the result of improper maintenance or to any ZAP Product that has been altered or modified so as to adversely affect the product's operation, performance or durability or that has been altered or modified so as to change its intended use.