Zap DX Owner'S Manual Download

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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

)

...................................................6-7

EASY INSTALLATION GUIDE

....................................................................................................................8-9

ENGAGEMENT LEVER OPERATION

............................................................................................................10

OPERATION MANUAL & CHARGING GUIDE

................................................................................................11

SAFETY WARNINGS

...........................................................................................................................12-13

PRE-RIDE CHECKLIST

..............................................................................................................................14

BATTERY CARE

.......................................................................................................................................15

TROUBLESHOOTING GUIDE

.....................................................................................................................16

TORQUE RATINGS

...................................................................................................................................17

WARRANTY FORM

.............................................................................................................................17-18

Summary of Contents for DX

Page 1: ...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 2001 ZAPWORLD COM All Rights Reserv...

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: ...LD CONTACT YOUR INSURANCE COMPANY OR INSURANCE AGENT TO DETERMINE IF COVERAGE IS PROVIDED ALONG WITH YOUR KIT WE VE INCLUDED AN INVOICE OWNER S MANUAL AND A WARRAN TY FORM PLEASE READ THE WARRANTY CAR...

Page 4: ...t of peoples daily transportation and cause most of our air pollution Your ZAP can even be quicker than a car in some instances Leave your car at home and ride your ZAP Not only will you get more exer...

Page 5: ...AIL OF ZAP POWERBIKE 5 RE ASSEMBLY INSTRUCTIONS FOR PRE ASSEMBLED ELECTRICRUIZERS 6 7 EASY INSTALLATION GUIDE 8 9 ENGAGEMENT LEVER OPERATION 10 OPERATION MANUAL CHARGING GUIDE 11 SAFETY WARNINGS 12 13...

Page 6: ...mps 10 Battery Charger 11 4mm Allen Wrench 12 Motor Mount Bolts 13 Bridge Mount 14 Threaded Plate 15 Cam Ramp 16 Double Sided Tape 17 Cam Lever 18 Hinge Bracket 19 Spacer Tube 20 Zip Ties 21 Battery P...

Page 7: ...PowerBike MINIMUM FIT DIMENSIONS FOR ZAP POWER SYSTEM TRAY MODEL Do not use ZAP System on bikes without metal seat stays 13 5 DX DRIVE SYSTEMS 4 5 SX DRIVE SYSTEMS IMPORTANT PLEASE NOTE The standard...

Page 8: ...ot twist the saddle out of alignment after the quick release is engaged 4b HOW TO FASTEN THE SEAT QUICK RELEASE Open and close the quick release lever with your right hand while gradually tightening t...

Page 9: ...cket to make sure that they are tight The front reflector should be perpen dicular with the ground 10 TIRE PRESSURE All ZAP bicycle tires should be inflated to the maximum recom mended pressure printe...

Page 10: ...ttery tray is held firmly in place Be sure not to clamp any cables to the frame Route throttle switch wire along the left side of the bicycle down tube and Auxiliary Power Alternate Charging Jack alon...

Page 11: ...out 1 16 into the tire If the Cam forces the roller into the tire more than 1 16 remove the Cam Ramp which is adhered to the motor under the Cam using a flat head screwdriver or pliers Engage the Cam...

Page 12: ...handlebar causes the motor to swing into contact with the tire and engage The motor then auto matically adjusts itself to maximum efficiency at lower torque levels Fig 2 Full Time Power Assisted After...

Page 13: ...ur times as much energy to accelerate from a dead stop in high speed than low speed The rider must always pedal to start and use the Throttle Switch in the low position and move to the high speed as n...

Page 14: ...uct the vents on the battery container Read the instructions supplied with your charger before attempting to charge your battery CHARGER WARNINGS 1 Before using the battery charger read all instructio...

Page 15: ...regarding electric bicycles OTHER SAFETY WARNINGS 1 Keep your ZAP Power System in good working condition Only your authorized service dealer should perform any repair or maintenance procedures that ar...

Page 16: ...compresses the tire by approximately 1 16 when the cam lever is in the down position If it is more or less loosen the motor mount bolts and adjust by moving the sys tem up if more than 1 16 or down if...

Page 17: ...f properly Local state or federal laws may prohibit disposal of lead acid batteries in ordinary trash Consult your local waste authority for information regarding available recycling and or disposal o...

Page 18: ...or incline Action to be Taken Inflate to maximum tire rating Pedal more while riding especially when starting Check Easy Installation Guide Tune brakes bearings true wheels If you don t know how to tu...

Page 19: ...5 in lbs Cable Carrier Nut 50 70 in lbs Brake Lever Clamp Screwdriver 22 30 in lbs Hex Wrench 50 70 in lbs Bottom Bracket Fixed Cup Lockring Steel Bottom Bracket 600 690 in lbs Alloy bottom bracket se...

Page 20: ...5472 USA tel 707 824 4150 fax 707 824 4159 e mail zap zapworld com Stock Symbol ZAPP ZAP is a Publicly Traded Company 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 2001 ZAP...

Page 21: ...________________________________________________ Buyer s Name Print If buyer is under 18 years of age the buyer s guardian must sign TO ACTIVATE WARRANTY PLEASE INITIAL AND SIGN THE BUYER S CHECKLIST...

Page 22: ...s operation performance or durability or that has been altered or modified so as to change its intended use This war ranty does not extend to repairs made necessary by normal wear or by the use of pa...

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