$2.00 REV 5/15/00 OWNER’S MANUAL DX ZAP POWER SYSTEM MADE IN THE USA Patent #5,491,390 #5,671,821 • Other Patents Pending ZAPWORLD.COM where transportation is going 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 Reserved. ZAP ® is a registered trademark.
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.
STOP BEFORE YOU ZAP YOUR BIKE! IMPORTANT! PLEASE READ CAREFULLY: SINCE YOUR EXISTING INSURANCE POLICY MAY NOT PROVIDE COVERAGE FOR ELECTRIC BICYCLES, YOU SHOULD 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 WARRANTY FORM. PLEASE READ THE WARRANTY CAREFULLY AND FILL OUT THE FORM ON THE BACK.
Introduction C ongratulations on your purchase of a ZAP Electric Bike or Power System. In the coming years you will find many ways to use your ZAP — commuting, exercise, errands, or simply for fun! 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 exercise, fresh air and fun, but you can feel good because you are doing something positive for the planet. Imagine that...
Table of Contents BEFORE YOU BEGIN ..................................................................................................................................1 INTRODUCTION .......................................................................................................................................2 TABLE OF CONTENTS ................................................................................................................................3 DESCRIPTION OF SYSTEM .........................
Description of System NOTE: The items referred to on this page are important when installing your ZAP. Use this page as a reference guide.
Detail of ZAP PowerBike® SEAT SEAT STAYS TUBE SEAT STAY BRIDGE ZAP MOTOR UNIT CHAIN STAYS BATTERY PACK CRANK THROTTLE SWITCH BATTERY TRAY MINIMUM FIT DIMENSIONS FOR ZAP POWER SYSTEM (TRAY MODEL) Do not use ZAP System on bikes without metal seat stays!!! TOP TUBE DOWN TUBE “MONOSTAY” SEAT STAYS 5” -- DX DRIVE SYSTEMS (4.5” - SX DRIVE SYSTEMS) REAR WHEEL 13” IMPORTANT! PLEASE NOTE The standard ZAP Power System will not fit on a monostay bike.
RE-ASSEMBLY INSTRUCTIONS FOR A PRE-ASSEMBLED, BOXED ZAP ELECTRICRUIZER ® INTRODUCTION Welcome electric bicycle owner! Thank you for purchasing your ZAP Electric Bicycle - we are confident that you will love it. The innovative ZAP Power System you have purchased will bring you many hours of fun and enjoyment. However, before you start enjoying your bike, some assembly is required. We strongly suggest that your ZAP Electric Bike be assembled and tuned by a professional bike mechanic.
7) CONNECTING THE REAR BRAKE CABLE (The front fork crown is located immediately above the front wheel). Inspect the front reflector and reflector bracket to make sure that they are tight. The front reflector should be perpendicular with the ground. 10) TIRE PRESSURE All ZAP bicycle tires should be inflated to the maximum recommended pressure printed on the tires. It is normal for bicycle tires to lose a little tire pressure every week.
Easy Installation Guide IMPORTANT! PLEASE READ CAREFULLY: which should be removed once the tray is installed. • Route the Motor / Controller lead marked with a white dot along the right side of the bicycle seat tube and the other Motor / Controller lead along the left side of the bicycle seat tube. (Right and left are relative to a person sitting on the bicycle). Along with your kit, we’ve included an invoice, owner’s manual, and a warranty form.
• Take the Bridge Mount and position it on the seat stay bridge, centered and aligned with the seat stays. • Insert one of the motor mount bolts through the bottom hole of the Bridge Mount and finger-tighten it into the bottom hole of the Threaded Plate. Critical Setup Distance (CSD) for Different Tire Pressures 3/4” 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.
Engagement Lever Operation Rider Power Only Fig.1 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 Fig.2 After pedaling has initiated, activation of the throttle switch on the handlebar causes the motor to swing into contact with the tire and engage.
OPERATIONS AND FEATURES CHARGING Speed Selection Your ZAP Power System is equipped with a 2-speed controller. This controller has speeds of Low (10 mph maximum) and High (18 mph maximum). You must pedal to start. Your actual speed depends on a number of variables such as how much you pedal, rider weight, tire pressure, incline angle, wind resistance, etc.(see page 13). The low speed is used for slow acceleration and is the most efficient of the speeds (i.e. it uses less energy for distance traveled).
SAFETY WARNINGS BATTERY WARNINGS 1. To reduce the risk of injury, use only ZAP batteries. Other batteries may explode causing personal injury and damage. THE PURPOSE OF SAFETY SYMBOLS IS TO ATTRACT YOUR ATTENTION TO POSSIBLE DANGERS. THE SAFETY SYMBOLS, AND THE EXPLANATIONS WITH THEM , DESERVE YOUR CAREFUL ATTENTION AND UNDERSTANDING. THE SAFETY WARNINGS BY THEMSELVES DO NOT ELIMINATE ANY DANGER. THE INSTRUCTIONS OR WARNINGS THEY GIVE ARE NOT SUBSTITUTES FOR PROPER ACCIDENT PREVENTION MEASURES. 2.
SAFETY WARNINGS CONTINUED 9. Do not disassemble the charger. The charger is not serviceable; disassembly may result in a risk of electric shock or fire. 10. To reduce the risk of electric shock, unplug the charger from the outlet before attempting any cleaning of the charger. 11. Do not use charger outdoors in wet conditions. 12. Charge in a well-ventilated area away from sparks, flames and smoking areas. 13.
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 your first ride. Although your PowerBike ® or ElectriCruizer® has passed our Quality Assurance procedure, things can happen during shipping which may alter the adjustment of the system. ü 1.
Battery Care To ensure your new ZAP battery gives its best performance, these following suggestions must be followed. 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. 3) Keep the terminals clean and tight. 4) Handle it with care (don’t drop it).
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.
Torque Ratings CONVERSION INSTRUCTIONS Multiply By To Get Foot pounds Foot pounds Foot pounds Inch pounds Inch pounds Inch pounds Nm Nm Nm Kgf-cm Kgf-cm Kgf-cm 12 1.355 13.826 0.083 0.113 1.152 0.738 8.857 0.098 0.072 0.868 10.
ZAPWORLD.COM where transportation is going ©2001 ZAPWORLD.COM. All rights reserved. ZAP® 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.
ZAP BUYER’S CHECKLIST As members of a new transportation industry, our staff and management would like to thank you for purchasing your ZAP electric bicycle from us. As in many recreational activities, accidents can and do occasionally occur. It is for this reason that we specifically bring the following points to your attention. We ask that you read each point carefully and ask questions of our staff if you do not clearly understand any particular point addressed.
ZAP® warrants each new ZAP product for three (3) months according to the following terms. Batteries are also warrantied for three (3) months. ALL IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE THREE (3) MONTHS WARRANTY PERIOD OR thirty (30) DAYS FOR PRODUCTS USED FOR ANY COMMERCIAL PURPOSE. ACCORDINGLY, ANY SUCH IMPLIED WARRANTIES INCLUDING MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, OR OTHERWISE, ARE DISCLAIMED IN THEIR ENTIRETY AFTER THE EXPIRATION OF THE APPROPRIATE THIRTY DAY WARRANTY PERIOD.
