- ZapWorld
Contents
1. 9 3 Vehicle maintenance tenens 9 A Vehicle load srne n 10 5 Inspection of tire and tire pressure 10 6 Usage of lubricants and fluid for ye hieleras 10 7 Proper usage of safety belt 10 Chapter 3 Introduction of Devices and Control Mechanism Position of switches and control levers in the 11 2 Keys doors and windows 17 Be C ICI TE 18 4 Back gate and side gates of truck bed 18 5 Safety Belts esee etis lieto I9 6 Other Devices isses 21 Chapter 4 Driving Suggestions LA Driving 2 Normal driving suggestions 3 Economical driving suggestions 25 4 Suggestion on slippery road driving 25 5 Suggestion on parking 25 Chapter 5 5 Light changlhg cinere riti teen 26 6 Deflated tik Scenen nae 27 F Emergency 29 M M 29 Chapter 6 Service and Maintenance Cleaning and maintenance 2 Routine maintenance 3 Regular maintenance eee 4 Requirement for regular maintenance 34 Owner and Operator s Manual Chapter 7 Solutions for Malfunctions Rear axle malfunctlon uiii esce arr inis 38 2 Steering suspension wheel and tire2. UDR Turn the handlebar while looking in the direction of the turn FOR HIGHER SPEEDS OR SHARPER TURNS Use the same technique that you use when you move your body weight farther toward the inside of the turn to maintain your balance Natural turning forces which can push the vehicle to the outside of the turn increase as the speed or the turn sharpness increases This means you must lean your body farther into the turn as you go faster or turn more sharply This prevents the vehicle from tipping over to the outside of the turn If your ATV starts to tip while turning lean your body farther into the turn while gradually reducing the throttle and making the turn wider if possible Operating on Hills Operating on excessively steep hills The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills Climbing hills improperly could cause loss of control or cause ATV to overturn Always follow the proper procedures for climbing hills as described in this owner s manual Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes The ATV could flip over backwards Never go over t
3. 7 Malfunctions of lights instruments switches and indicating lights 48 Chapter 8 Oil Fluid for Vehicle And Electric Theory Fig of Complete Vehicle Specification and capacity of lubricant lubricant grease and braking fluid 54 2 Electric Theory Fig of Complete Vehicle 54 ZAP Registration 55 Ww D lt Owner Operator s Manual General Information 1 Overall Dimensions Fig ATV Controls Lights 2 Horn 3 Drive 4 Power 5 Reverse 6 State of Charge 7 Key 8 Throttle 9 Cut Out Power Button W D lt Owner Operator s Manual Fig 2 ATV Controls Cont Trailer Hitch 2 High Beam Controls 3 Headlight Controls 4 Direction Controls 5 Removable Mirror 6 Parking Brake to engage hold handle bar in and lock into position ze UD GETTING TO KNOW YOUR NEW ATV ray This user s manual contains important safety and maintenance information Read it care fully before riding Failing to follow the warn ings contained in this manual could result in INJURY or DEATH It is important that this manual remain with the vehicle when you transfer it to another user or owner Should you experience a problem with your vehicle please call ZAP customer service line 800 251 4555 between t
4. CHILDREN DO NOT open sealed caps to add water to battery Always wear safety glasses and charge in a ventilated area If battery gets hot to the touch discontinue charging and allow battery to cool down Do not use fast charging unless it is an emergency At the beginning or end of charging turn off the charger first in order to prevent electric spark and explosion Charge in a well ventilated area DO NOT smoke around batteries and keep away from open flame To avoid possibility of explosion always connect battery cable in the order specified RED first BLACK last An exploding battery can cause serious injury or death Batteries contain sulfuric acid Always shield eyes with protective eye wear when working around 20 Owner and Operator s Manual battery acid Battery acid is poisonous and can cause severe burns DO NOT smoke around batteries and keep away from open flame Remove old battery s Mark which cable is connected to the positive terminal and which cable is connected to the negative terminal Clean cable connectors with wire brush or sandpaper to remove oxidation After charging install new battery Put dielectric grease on the battery terminals to avoid corrosion Connect cables to the proper terminals Positive red cable to positive terminal and negative cable to negative terminal Positive cable is red Negative cable is black CONNECT NE
5. ray Owner and Operator s Manual M z IMPORTANT BEFORE YOU OPERATE YOUR DUDE PLEASE READ THE ENTIRE MANUAL CAREFULLY Congratulations on your purchase of the ZAP Dude ATV It is warranted to be free of manufacturing defects in material and workmanship for a period of 90 days from the date of purchase During the warranty period ZAP will at its option repair provide replacement parts or replace your Zap Dude through a ZAP dealer at no charge This warranty does not cover normal wear items or damage caused by neglect or misuse of the ATV All information illustrations photographs and specifications contained in this manual are based on the latest product information available at the time of publication Due to improvements or other changes there may be some discrepancies in this manual We reserve the right to make product changes at any time without notice and without incurring any obligation to make the same or similar changes to the vehicle previously built or sold This user s manual contains important safety and maintenance information Read it carefully before riding Failing to follow the warnings contained in this manual could result in INJURY or DEATH It is important that this manual remain with the vehicle when you transfer it to another user or owner ZAP 2010 All Rights Reserved 501 Fourth Street Santa Rosa CA 95401 USA www zapworld com Stock Symbol ZAAP 1 800 251 4555
6. Could affect your balance and perception Could result in an accident Never consume alcohol or drugs before or while driving this ATV Operating this ATV at excessive speeds Increases your chances of losing control of the ATV which can result in an accident Always go at a speed that is proper for the terrain visibility and operating conditions and your experience Attempting wheelies jumps and other stunts increases the chance of an accident including an overturn Failure to inspect the ATV before operating Failure to properly maintain the ATV increases the possibility of an accident or equipment damage Always inspect your ATV each time you us it to make sure the ATV is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the owner s manual 12 Owner and Operator s Manual WARNING Removing hands from handlebars or feet from the footrests during operation Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV If you remove a foot from the footrest your foot or leg may come into contact with the rear wheels which could injure you or cause an accident Always keep both hands on the handlebars and both feet on the foot rests of your ATV during operation Use extra care when operating this ATV on unfamiliar terrain You can come upon hidden rocks bum
7. W D y Owner and Operator s Manual We know you want to start riding right away but it is critically important to READ THESE IMPORTANT FIRST STEPS BEFORE EVEN THINKING OF RIDING Step Plug in vehicle and charge fully Charge at least once a month for full charge even when not in use Failure to do so will greatly shorten the life of the batteries Step 2 Verify that the charger is unplugged Step 3 Place key in key slot located in the center gauge pod Step 4 Verify the gear selector is in the N position Step 5 Verify the Red Cut Out Button is pulled to the OUT position Step 6 Turn the key clockwise to the ON position the center orange power light will light up This indicates power is active The State of Charge meter will also activate showing the battery charge level Step 7 Choose the drive selector D for Drive or N for Neutral or R for Reverse When D are selected the D or R light will light up in the center dash pod Step 8 Verify the front park brake and side mounted hand brakes are released Step 9 Drive ATV Start Up Procedure ray ee UD TABLE OF CONTENTS Chapter General Information Overall dimensions es 4 2 Table of performance structure and specification for entire truck 3 Vehicle Marking ecnin Chapter 2 Safety and Important Notes 1 Non permissible to refit 9 2 Inspection of new
8. streg pd vy LI Color design and style Size LI Economy LI Speed State Province Zip Postal Code 9 What other vehicles did you seriously consider before making this purchase E mail Address 10 How do you plan to use your Dude Leisure fun travel LI Commuting to work L Short errands LI Primary vehicle 2 Your date of birth month Year 11 Not including yourself what is the GENDER and in years of children 3 Marital status Married J Single and other adults living in your household No one else in household 4 Date of purchase month Day Year 1 1 Female Age in yrs 2 Male Female Age in yrs E 5 VIN 3 Male Female Age in yrs 5 4 Female Age in yrs 6 Name of DUDE dealer where purchased 12 Occupation check all that apply You Spouse 2 Professional Technical LI LI 5 Upper Management Executive O O H Middle Management LI LI 2 7 Did You Sales Marketing 0 2 Purchase this product yourself Clerical Service Worker O d Receive this product as a gift Tradesman Machine Operator Laborer 26 13 Are you or your spouse A Homemaker Retired A Student Self Employed Business Owner Working from a Home Office In the Military A Veteran Spouse 0000000 14 Which group describes your annual family income Under 15 000 LI 15 000 19 999 L 20 000 29 999 L 30 000 39 999 L 40 000 4
9. The frozen water can prevent wheels from turning or the brakes from working After riding through 16 Owner and Operator s Manual water mud snow or slush it is important to dry the brakes before parking the ATV To dry the brakes apply them several times while riding slowly Before your next ride be sure to do a Pre ride inspection as described earlier in this section WARNING Operating the ATV without a properly functioning brake system could be hazardous Wet or frozen brakes will increase stopping distance This will increase your chance of having an accident Be sure to inspect the brakes before riding the vehicle in cold weather as described above CAUTION Using motor power to free up frozen wheels could damage your ATV Severe damage to the drive train may occur if you use motor power to free frozen wheels Before riding manually move the ATV forward and backward to make certain that all wheels roll freely ray M z Operating your ATV in cold weather without proper clothing could be hazardous Continued exposure in the cold weather could lead to Hypothermia Hypothermia is a condition where your body s inner temperature drops low enough to cause injury or death Always dress for the worst weather conditions you might encounter Be prepared for bad weather and ATV breakdowns Riding in cold weather can be hazardous At a temperature of 10 F the wind chill created by g
10. brake fluid reservoir Brake fluid reservoir cap GENERAL LUBRICATION Proper lubrication is important for safe smooth operation and long life of your ATV Be sure that all lubrication is performed during periodic maintenance on the vehicle Increase intervals when you use your ATV in severe conditions Your authorized service center may offer general lubrication services as shown in the MAINTENANCE CHART Failing to troubleshoot a problem correctly would damage your ATV Improper repairs or adjustments may damage the vehicle Such damage may not be covered under warranty If you are not sure about the proper action consult your authorized service center or ZAP about the problem High pressure washers could damage your ATV High pressure washers such as those 24 Owner and Operator s Manual found at coin operated car washes have enough pressure to damage the parts of your It may cause rust corrosion and increase wear Do not use high pressure washers to clean your ATV A thorough cleaning of your ATV is a necessary part of maintenance It will help keep your ATV looking and performing best Proper cleaning can also extend the life of your It is important to clean and inspect your ATV after every ride especially if it is used in mud brush grass water salt water or very dusty conditions The build up of mud brush grass etc especially on the motor controller and or batteries could impact ATV op
11. learned and practiced the skills necessary to control the ATV on such terrain Always be especially cautious on these types of terrain Always follow proper procedures for turning as described in this manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds Never operate that ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as described in this manual Check the terrain carefully before you start up any hill Never climb hills with excessively slipper or loose surfaces Shift you weight forward Never open the throttle suddenly or make sudden gear changes Never go over the top of any hill at high speed Always follow proper procedures for going down hills and for braking on hills as described in this manual Check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side Go straight down the hill where possible Always follow proper procedures for crossing the side of a hill as described in this manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV Never attempt to turn the ATV around on any hill until you have mastered the turning
12. operate the ATV at a slow steady speed Be careful not to amage banks when crossing Operating the ATV in water sand or mud causes rapid brake wear Excessive brake wear could cause the brakes to be less effective After repeated operation of the ATV in these conditions bring it to your authorized service center to have the brakes inspected and cleaned RIDING IN COLD WEATHER Pre ride Inspection Check that the throttle and all control levers move freely Make sure that the footrests are free of ice or snow Move the ATV forward and backward to check that the wheels roll freely If you cannot move the ATV the tires may be frozen to the ground or the brakes may be frozen to the wheels If the tires are frozen to the ground pour warm water around them to melt the ice If the brakes are frozen bring the ATV to a warmer area to thaw out the brakes After the motor has been started check the brakes Do this inspection on level ground and do not exceed the walking speed Be sure to check the operation of both front and rear brakes If the brakes do not work adequately stop riding the ATV Bring the ATV to a warmer area to allow the brakes to thaw out After the brakes thaw dry them by applying them several times before riding If the brakes do not regain full stopping power ask your authorized service center to check them before you continue riding your ATV Water that enters the brakes may freeze after you park your ATV
13. seat 4 Ride down the hill slowly with the throttle released 5 Apply the brake to control the speed 6 Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side Go straight down the hill if possible Improperly crossing hills or turning on hills could cause loss of control or cause ATV to overturn Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the owner s manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill Improperly operating over obstacles could cause loss of control or a collision Could cause the ATV to overturn Before operating in a new area check for obstacles Never attempt to ride over large obstacles such as large rocks or fallen trees When you go over obstacles always follow proper procedures as described in the owner s manual If you come to an obstacle that you cannot avoid you may be able to cross over it by using the following procedure If the obstacle is in front of you approach at walking speed 2 Rise up slightly on the footrests 3 Pull up on the handlebar and apply a little throttle as the front wheels reach the obstacle 4 Lean forward and release the throttle after the front wheels are over the obstacle Remember that some obstacles are too high for your ATV or for your abilities If you are not sure that you can safely cross over an
14. technique described in this manual on level ground Avoid crossing the side of a steep hill if possible Always use proper procedures if you stall or roll backwards when climbing a hill To 9 Owner and Operator s Manual avoid stalling use proper gear and maintain a steady speed when climbing a hill If you stall or roll backwards follow the special procedure for braking described in this manual Dismount on the uphill side or to a side if pointed straight uphill Turn the ATV around and remount following the procedure described in this manual Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as large rocks or fallen trees Always follow proper procedures when operating over obstacles as described in this manual Always be careful when skidding or sliding Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control Never operate an ATV in fast flowing water or in water deeper than that specified in this manual Remember that zi UDR wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always use the size and type tires specified in this
15. 9 999 O 50 000 59 999 LI 60 000 74 999 LI 75 000 99 999 LI 100 000 124 999 C 125 000 149 999 LI 150 000 174 999 LI 175 000 199 999 LJ 200 000 249 999 LJ 250 000 amp over 15 Level of education check highest level completed High School College Graduate School 16 For your primary residence do you Own Rent 17 How recently did you move into your current residence C Within 30 days LI Within 1 3 months LI Within 4 6 months 17 to 12 months ago Have not moved in the last 12 months 18 Please check all that apply to your household Shop by Catalog Mail LI Member of Frequent Flyer Program L Own a Compact Disc Player L Have a Cat LI Speak Spanish L Own a CD ROM Drive Ll Shop via the Internet LI Donate to Charitable Causes L Have a Dog L Own a Wireless Cellular Phone J Own an Apple Macintosh Computer 19 To help us understand our customers lifestyles please check the interests and activities in which you or your spouse enjoy participating on a regular basis 01 Bicycling 26 Health Natural Foods 02 Golf 27 Photography L 03 Physical Fitness Exercise 128 Cultural Arts Events LJ 04 Running J ogg
16. GATIVE CABLE LAST Throttle lever adjustment Operating the vehicle with an inadequate throttle lever free distance could be hazardous Inadequate throttle lever free UDR distance could cause motor speed to rise suddenly when you turn the handlebars This can lead the rider to lose control DRIVE CHAIN SPROCKETS The condition and adjustment of the drive chain should be checked before riding Always follow the guidelines below for inspecting and servicing the chain Inspecting the Drive Chain When inspecting the chain look for the following Loose pins Damaged rollers Dry or rusted links Kinked or binding links Excessive wear If you find anything wrong with the drive chain solve the problem by repairing or replacing the chain If necessary consult your authorized service center If it is determined the drive chain is damaged check the sprocket also for damage A worn chain can have an adverse affect on the front and rear sprockets When inspecting the sprockets look for the following If you find any of these problems with your sprocket consult ZAP or your local service center WARNING Failing to maintain the chain properly before each riding could be hazardous Riding with the chain in poor condition could lead to an accident Be sure to inspect and maintain the chain before riding according to these guidelines Inspecting the Drive Chain When insp
17. alcohol or drugs can be hazardous Alcohol and drugs could seriously affect your judgment and cause you to react more slowly They can also affect your balance and perception Operating this ATV after consuming alcohol or drugs can result in an accident Never consume alcohol or drugs before or while riding this ATV WARNING This manual should be considered a permanent part of the vehicle and should remain with the vehicle when resold or otherwise transferred to a new user or operator The manual contains important safety information and instructions which should be read carefully before operating the vehicle Please read this manual and follow all instructions carefully To emphasize the special information the symbol and the words WARNING or CAUTION have some special meanings Pay attention to the messages Owner and Operator s Manual NOTICE TO PARENTS This ATV is built for use by children age 16 and older but the users manual is written for adults who will be supervising the children we strongly recommend therefore that you review this entire manual with your child and carefully explain the instructions requirements and warnings it contains so that your child can understand them Children differ in skills physical abilities and judgement Some children may not be able to operate an ATV safely Parents should supervise their child s use of the ATV at all times Parents should permit continued use
18. and accessories added to the ATV should be genuine parts or their equivalent designed for use on this ATV Install and use them according to their instructions If you have any questions contact your dealer There are many types of accessories for sale However we cannot have direct control over their quality or suitability We cannot test each accessory that is available If you add the wrong accessories or misuse the vehicle with some accessories installed it can make the ATV unsafe to ride Be cautious when choosing and installing accessories to your vehicle Your dealer may be able to help you choose accessories and install them correctly The guidelines below should help you to decide how to equip your ATV and how to use it correctly when you use accessories Accessory Use and Vehicle Loading Guidelines I The weight of the rider must never exceed the vehicle s load capacity of 285 Ibs 2 Check accessory mounting brackets and other attachments to make sure they provide a rigid non movable mount 3 Accessories added to the handlebar of the ATV should be as light as possible The extra weight would cause the vehicle to be harder to steer 4 Do not add accessories or cargo which interferes with controls or other equipment 5 Do not carry heavy or bulky cargo beyond the rated capability 18 Owner and Operator s Manual 6 Distribute cargo weight evenly between the front and rear racks of the ATV Loc
19. ate cargo weight as close to the center of each rack if possible 7 Secure your load well Shifting weight can affect your ability to handle the vehicle safely 8 Ride at slow speeds and avoid hills when carrying cargo Carrying loads would affect the stability and handling of your ATV 9 Allow enough stopping distance Stopping distance increases if you carry loads Use motor braking as much as possible Improper maintenance or failing to perform recommended maintenance could be hazardous If you perform improper maintenance or do not maintain your ATV you may have an accident Keep your ATV in good condition Ask your authorized service center or a qualified mechanic to do major maintenance work You may perform maintenance items by referring to the instructions in this section if you have mechanical experience If you are not sure how to do the maintenance ask your authorized service center or call ZAP If you use your ATV under severe conditions it will need maintenance more often than shown in the chart Operating your ATV under severe conditions causes more wear on your ATV Severe conditions include operating under frequent full throttle or in dusty wet sandy or muddy areas These conditions could cause the ATV to wear more quickly Perform maintenance more often than shown in the chart If you have any questions regarding maintenance intervals consult your authorized service center o
20. dures in the INSPECTION BEFORE RIDING section to check your ATV for any problems that may have occurred during your last ride STORAGE PROCEDURE If you do not use your ATV for an extended period it will need special service requiring appropriate materials equipment and skill For this reason we recommend that you trust this maintenance work to your authorized service center If you wish to service the machine for storage yourself follow the general guidelines below Vehicle 25 Owner and Operator s Manual A I Spray all vinyl and rubber parts with rubber protection 2 Spray unpainted surfaces with rust preventative 3 Coat painted surfaces with car wax PROCEDURE FOR RETURNING TO SERVICE Clean the entire vehicle 2 Make sure that the vehicle is properly lubricated 3 Perform the INSPECTION BEFORE RIDING as listed in this manual 4 Start the vehicle as outlined in this ZWD REGI STRATI ON CARD Not returning this card will not void the original 6 months limited warranty 1 Name amp Address 8 What most influenced your decision to purchase a DUDE Title Mr MrsL Ms wisst Factors check all that apply LI Received as a gift L Advertisement LI Brand name LI Friend s relative s recommendation First Name Initial Last Name LI Green qualities LI Product brochure LI Price LI Review in media internet LI Salesperson s recommendation LI Store display Features treet Apt No it
21. e questions consult a ZAP authorized ATV dealer Overloading this ATV or carrying or towing cargo improperly Could cause changes in vehicle handling which could lead to an accident Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo Allow greater distance for braking Always follow the instructions in your owner s manual for carrying cargo Overfilling the air to the tires could be hazardous If you put too much air into the tire the tire may burst causing severe injury Check the air pressure from time to time while gradually inflating the tire until the zi UDR specified air pressure is obtained Using tires that have been installed incorrectly could be hazardous The ATV may have unusual handling if the tires are installed incorrectly The tires are intended to rotate in a specific direction as indicated by the arrows on the sidewall of each tire Install tires correctly so they rotate in the proper direction Tire Replacement Your ATV has low pressure tubeless tires Air is sealed by the contact surfaces of the inner wheel rim and the tire bead If the inner wheel rim or tire bead is damaged air may leak Be extremely careful not to damage these sections when replacing tires It is important to use the proper tools when repairing or replacing tires in order to protect the tire bead or w
22. e the front and rear tires when the depth on the tread is 4 0 mm 0 16 inches or less The ATV is equipped with low pressure tubeless tires of the size and type listed below Tire Air Pressure Check the air pressure in all tires before riding Improper air pressure would effect handling steering response traction tire life and rider comfort Be sure that the tires are inflated to the pressures shown Tire pressure should only be measured or adjusted when the tires are cold WARNING Operating this ATV with improper tires or even improper tire air pressure could be hazardous If you use improper tires or improper tire air pressure you may lose control of the ATV Always use the size and type tires specified Always maintain proper tire air pressure as described in this section Front Rear Size AT23X7 10 AT22X10 10 Cold Tire Air Pressure Front 6 5 0 5 psi 21 3 5Kpa Rear 6 5 0 5 psi 21 3 5Kpa Operating this ATV with improper modifications Improper installation of accessories or modifications to this vehicle may cause changes in handling which in some situations could lead to an accident Never modify this 22 Owner and Operator s Manual ATV through improper installation or use of accessories All parts and accessories added to this vehicle should be genuine ZAP or equivalent components designed for use on this ATV and should be installed and used according to instructions If you hav
23. ecting the chain look for the following Loose pins Damaged rollers Dry or rusted links Kinked or binding links Excessive wear If you find anything wrong with the drive 21 Owner and Operator s Manual chain solve the problem by repairing or replacing the chain If necessary consult your authorized service center If it is determined the drive chain is damaged check the sprocket also for damage A worn chain can have an adverse affect on the front and rear sprockets When inspecting the sprockets look for the following DRIVE CHAIN CLEANING OILING AND ADJUSTING Clean and oil the chain according to the following I Wash the chain with water 2 Dry the chain and then oil the links with Chain lube or equivalent Adjusting the Drive Chain The drive chain should be adjusted making sure there is 20 30 mm 0 8 1 2 inches of slack as shown above WARNING Failing to inspect the drive chain slack before each use of the ATV could be hazardous Too much chain slack could UDR cause the chain to come off the sprockets resulting in an accident or serious damage to the ATV Inspect the drive chain slack before each use Always use the size and type tires specified Always maintain proper tireair pressure as described in this section Using worn tires could be hazardous The traction of the vehicle will be decreased This increases your risk of having an accident Replac
24. eration conceal damage or increase wear of certain parts It is important to remove all debris during cleaning PREPARATION FOR CLEANING Wash the ATV before any mud dries on the ATV UDR WASHING YOUR ATV With some care your ATV can be washed in a similar manner to washing an automobile Note Avoid spraying or allowing water to flow over the following places Electrical controls Batteries Controller Motor assembly Use a garden hose at low pressure to remove the majority of dirt or other debris Hand wash your ATV with mild soap or detergent and water Try to thoroughly remove all dirt and debris without excessive water pressure even at remote areas such as on motor cooling fins linkages or mounting brackets Cloth rags washing mitts or cleaning brushes can be used Be careful with brushes as they may scratch plastic or painted surfaces Rinse the ATV thoroughly with clean water Dry all areas using a chamois or soft absorbent cloth Operating the ATV with wet brakes could be hazardous Wet brakes may not provide as much stopping power as dry brakes This could lead to an accident Test your brakes after washing the ATV riding at a slow speed If necessary apply brake several times to let the friction dry out the linings Remove the rags or wrapping from the exhaust pipe For extended life ofyour ATV lubricate according to GENERAL LUBRICATION section Follow the proce
25. he hours of 8am and 5pm Monday through Friday PST or PDT during the daylight saving time You will be instructed how to proceed A COPY OFTHE SALES RECEIPT IS RE QUIRED YOUR ATV CAN BE HAZARDOUS TO OPERATE A collision or rollover can occur quickly even during routine maneuvers such as turning and driving on hills or over obstacles if you fail to take proper precautions For your safety understand and follow all the warnings con tained in this owner s manual and the labels on your vehicle Failure to follow these warn ing can result in SEVERE INJURY OR DEATH Keep the owner s manual with your vehicle at all times IMPROPER USE OF THIS ATV CAN RESULT IN A SEVERE INJURY OR DEATH NEVER OPERATE A without proper training or instruction Ay at speeds that may risk proper handling of the vehicle due to skills or overall conditions on public roads a collision may occur A with a passenger carrying passengers affect the balance and steering and increase the risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns while turning and riding on hills and rough terrain avoid paved surfaces pavement may seriously affect handling and control Owner and Operator s Manual IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL AND THUS RESULT IN A SEVERE INJURY OR DEATH OPERATING TIRE PRESSURE set with tires cold Front 55 kPa 0 56 kgf cm 8
26. he top of any hill at a high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill To climb a hill with the ATV follow these directions Speed up and maintain a steady speed before reaching the top of the hill Remember that you must ride at a steady speed all the way to the top of the hill 2 Shift your body forward by sliding forward on the seat Lean slightly forward For steep 14 Owner Operator s Manual hills stand on thefootrests and lean forward 3 Maintain a steady speed while climbing the hill 4 Slow down gradually when you reach the top of the hill WARNING Going down a hill improperly could cause loss of control or cause ATV to overturn Always follow proper procedures for going down hills as described in the owners manual NOTE A special technique is required when braking as you go down a hill Always check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side Go straight down the hill where possible To ride down hill with the ATV follow the instructions below 1 Check the terrain carefully for any obstacles before you go down the hill 2 Point the ATV straight down the hill 3 Transfer your body to the rear by sliding back on the
27. heel rims Have this work done by your authorized service center or a qualified tire repair station When breaking the tire bead loose from the wheel be extremely careful not to damage the inner wheel rim surface or the tire bead Tubeless Tire Repair If a leak or flat tire occurs due to a puncture the tire may be repaired using a plug type patch if permissible by law If the damage is from a cut or if the puncture cannot be repaired using a plug the tire should be replaced When operating your ATV in areas here transportation or service facilities are not readily available it is strongly recommended that you bring a plug type repair kit and a tire air pump with you Failing to inspect and maintain your ATV s brake system properly could be hazardous Improper maintenance of the brake increases your chance of having an accident Be sure to inspect the brake before riding according to the INSPECTION BEFORE RIDING section Always maintain your brakes according to the MAINTENANCE SCHEDULE WARNING Operating the ATV in harsh conditions could be hazardous if you do not inspect brake wear often Operating in mud water sand 23 Owner and Operator s Manual or other extreme conditions can cause accelerated brake wear This could lead to an accident If you operate your vehicle under these conditions the brake must be inspected more often than recommended in the MAINTENANCE SCHEDULE Inspect the front disk bra
28. ht is defined as the period of time 30 minutes before sunset to 30 minutes after sunrise SAFETY GEAR A DOT approved motorcycle helmet is the most important part of your safety gear A DOT approved motorcycle helmet can help prevent a serious head injury Choose a helmet that fits snugly Motorcycle dealers can help in selecting a good quality helmet which fits properly You should wear eye protection when you ride If a rock or a branch hits your eyes you could be severely injured Wear goggles or a face shield Wear proper clothing when you ride Proper clothes can protect you from injury Wear a ray ee UID good pair of gloves strong boots that are over the ankle long pants and a long sleeve shirt Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident Operating without protective clothing increases your chances of severe injury in the event of an accident Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket long pants Operating this ATV after consuming alcohol or drugs Could seriously affect your judgment Could cause you to react more slowly
29. ing 29 Fashion Clothing 05 Snow Skiing 30 Art Antique Collecting 06 Tennis 31 Foreign Travel 07 Camping Hiking 32 Cruise Ship Vacations 08 Fishing 33 Travel in USA 09 Hunting Shooting 1 134 Gourmet Cooking Fine Foods r 10 Powerboating L35 Wines 11 Sailing LJ36 Stamp Coin Collecting 12 Grandchildren 37 Collectibles 13 Needlework Knitting 38 Our Nation s Heritage 14 Sewing 39 Real Estate Investments L 15 Flower Gardening 140 Stocks Bond Investments 16 Vegetable Gardening 41 Contests Sweepstakes 17 Crafts 42 Casino Gambling 18 Buy Prerecorded Videos 43 Science Fiction L 19 Automotive Work 44 Wildlife Environmental Issues LJ 20 Electronics 45 Dieting Weight Control 21 Home Workshop Do It Yourself 46 Science New Technology 22 Recreation Vehicles RVs 47 Self Improvement 23 Listen to Records Tapes CDs 48 Walking for Health C 24 Avid Book Reading 49 Watching Sports on TV _ 25 Bible Devotional Reading 50 Home Video Recording 51 Moneymaking Opportunities 20 Using the numbers in the above list please indicate your 3 most important activities ZAP 501 Fourth Street Santa Rosa CA 95403 USA Thank you for filling in this registration card Please tear off along the doted line and mail to the following address 27
30. ke caliper for leakage If brake fluid leaks the safety of riding could be affected 2 Inspect the brake hose for cracks and the joint for leakage 3 Check the brake fluid level in the brake fluid reservoir if level is low inspect brake pads for wear and hydraulic system for leaks 4 To add brake fluid unscrew the 2 screws on top of the brake fluid container Add DOT3 or DOT4 brake fluid Do not mix brake fluid types Brake fluid cap Brake fluid reservoir Brake hose Front disk brake caliper Brake disk Brake fluid level UDR FRONT BRAKE INSPECTION Failing to maintain the brake shoes or pads could be hazardous Riding with worn brake shoes pads or shoes that are seriously worn will increase your chance of having an accident If you need to replace brake shoe pads have your authorized service center do the work Inspecting and maintaining the brake shoe pads is recommended Replace the shoe pads in sets Inspect the rear disk brake caliper for leakage If brake fluid leaks the safety of riding could be affected 2 Inspect the brake hose for cracks and the joint for leakage 3 Check the brake fluid level in the brake fluid reservoir if level is low inspect brake pads for wear and hydraulic system for leaks 4 To add brake fluid remove top of the bake fluid container Add DOT3 or DOT4 brake fluid Do not mix brake fluid types Min Max Rear disk caliper Brake hose Rear
31. ld Owner and Operator s Manual fall into the cold water Check with local authorities to verify the thickness of the ice and areas to avoid WARNING Failing to use extra care when operating on slippery surfaces such as hard packed snow and ice could be hazardous Failing to use extra care could cause loss of traction or loss of vehicle control This could result in an accident including an overturn Do not operate on slippery surfaces until you have learned and practiced the skills necessary to control the ATV on such terrain Always use extra care on slippery surfaces Avoid riding on snow or ice covered hills whenever possible Practice riding your ATV in an open snow or ice covered area at slow speeds before heading out on snow or ice covered trails Learn how your ATV responds to steering and braking on the type of terrain you will encounter on your ride Your eyes may be sensitive to ray M z sunlight when you ride over snow or ice on a bright sunny day Snow and ice reflects more light into your eyes than dirt or grass Tinted eye protection will reduce the amount of light reaching your eyes Operating this ATV with improper modifications could be hazardous Improper installation of accessories or modifications of the vehicle may cause changes in handling which could lead to an accident Never modify the ATV with improper installation or use of improper accessories All parts
32. manual Always maintain proper tire pressure as described in this manual Never modify an ATV through improper installation or use of accessories Never exceed the stated load capacity for an ATV Cargo should be properly distributed and securely attached Reduce speed and follow instructions in this manual for carrying cargo Allow greater distance for braking The combined weight of the rider and any accessories or cargo must never exceed the vehicle s load capacity of 285 Ibs FOR MORE INFORMATION ABOUT ATV SAFET Y call the Consumer Product Safety Commission at 800 638 2772 SVIA 1 800 887 2877 or ZAP Safety Hotline atl 800 25 1 4555 Beginning and inexperienced operators should complete the certified training course offered by SVIA www svia org They should then regularly practice the skills learned in the course and the operating techniques described in the owner s manual For more information about the training course contact an authorized ZAP ATV dealer or call SVIA at 1 800 887 2887 Make sure that it is legal to ride in the area you selected Review the local laws and make sure you are not trespassing Call the police if you do not know where you can ride Protect your riding areas Do not destroy plants trees or other vegetation Do not litter and do not bother wildlife After you have found a good place to practice review the control system on your ATV before riding Learn to find these controls with
33. o turn the ATV the rider must use the proper technique Because this vehicle has a solid rear axle both rear wheels always turn at the same speed This means that if the rear wheels are getting equal traction the vehicle will tend to move straight ahead This is because the rear wheels will travel the same distance For the vehicle to turn the outside rear wheel must travel a longer distance that the inside rear wheel To make this happen the rider must create less traction for the 13 Owner and Operator s Manual inside wheel allowing it to skid This allows it to travel a shorter distance than the outside wheel This happens even though both wheels are still turning at the same speed FOR HIGHER SPEEDS OR SHARPER TURNS Use the same technique that you use when you move your body weight farther toward the inside of the turn to maintain your balance Natural turning forces which can push the vehicle to the outside of the turn increase as the speed or the turn sharpness increases This means you must lean your body farther into the turn as you go faster or turn more sharply This prevents the vehicle from tipping over to the outside of the turn If your ATV starts to tip while turning lean your body farther into the turn while gradually reducing the throttle and making the turn wider if possible To turn ATV use the following technique Move your body weight forward and to the inside of the turn
34. obstacle back up and ride around the obstacle Skidding or sliding improperly could results in loss of control of this ATV You may also 15 Owner and Operator s Manual regain traction unexpectedly which may cause the ATV to overturn Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control SKIDDING OR SLIDING You may experience skidding or sliding when you are not braking You may be able to overcome it by using the techniques listed below If your front wheel skids gain front wheel traction by reducing the throttle opening and leaning your body slightly forward If your rear wheel skids If space permits steer in the direction of the skid Shift your body away from the skid slightly Avoid using the throttle or brakes until you regain directional control of the vehicle UDR RIDING THROUGH WATER You can ride the ATV through shallow water Make sure it is not more than 4 inches deep and is not moving fast Choose a good place to cross before you ride through the water Look for a spot where the banks are gently sloped on both sides and the bottom of the stream is hard If you are unfamiliar with the area park the ATV and inspect the stream first to find a suitable spot for crossing When crossing
35. oing just 10 mph makes you as cold as if you were standing still at a temperature of 9 E At this temperature exposed flesh will freeze in just a few minutes Continued exposure in the cold weather could lead to hypothermia Hypothermia occurs when your body s inner temperature drops Symptoms include numbness in the extremities hands feet arms and legs and shivering Damp clothing contributes to hypothermia because cold water on your skin will drain heat from your body s core We strongly recommend that if you do any cold weather riding that you familiarize yourself with the symptoms treatment and prevention of hypothermia Information is available at libraries and through government agencies Plan your winter rides with safety and comfort in mind Dress for the worst conditions you might encounter Be prepared for bad weather and ATV breakdowns VVear warm water resistant clothing such as thermal underwear snowmobile suits lined gloves lined boots and wool socks Riding on snow covered terrain even with care could be hazardous Snow may cover rocks holes ice or other hazards that can cause loss of control Severe injury or death could occur if you lose control of the ATV Go slowly and be careful when riding on snow covered terrain Always be alert to changing terrain conditions WARNING Riding on a frozen lake or river could be hazardous Serious injury or death could occur if the ice breaks and you cou
36. only if they determine that the child has the ability to operate the ATV safely It is very important that every child who rides the ATV should complete a training course THIS ATV IS NOT A TOY AND COULD BE HAZARDOUS TO OPERATE An ATV handles differently from other vehicles including motorcycles and cars A ray ee UID collision or rollover can occur quickly even during routine maneuvers such as turning and driving on hills or over obstacles if you fail to take proper precautions Motor Warranty 90 days Battery Controller Warranty 90 days Warranty is void if Frame is bent or broken due to abuse Wheels are bent or broken Fender bent or broken due to abuse Any sign of impact accident jumping spin outs or roll over ZAP is not liable for any damage claim or liability claim person or otherwise resulting from the operation of this product in any way SAFETY We believe in conservation and protection of the earth s natural resources We encourage every vehicle owner and operator to do the same by obeying posted signs and riding only in areas designated and approved for off road recreational use SEVERE INJURY OR DEATH can result if you do not follow these instructions Read this manual and all labels carefully and follow the operating procedures described Never operate an ATV without proper instruction Take a training course Beginner should receive training from a certified ins
37. out looking for them because you will not have time to look for them when you are riding Canadian residents must 10 Owner and Operator s Manual obtain review and follow all provincial and municipal government acts and regulations pertaining to owning and operating an off road vehicle INSPECTION BEFORE RIDING Failing to inspect the ATV before operating could be hazardous Failing to perform proper maintenance could also be hazardous Failing to inspect and maintain your ATV could increase the chances of an accident or equipment damage Always inspect your ATV each time before riding and make sure it is in a safe operating condition Refer to the INSPECTION AND MAINTENANCE section in this manual ITEMSTO CHECK Steering Smoothness No restriction of movement No play or looseness Brakes Proper brake lever free play enough brake force Hand brake effectiveness Proper tire air pressure Enough tread depth No cracks rips or other damages Overloading could be pr General Information hazardous Overloading could cause changes in vehicle handling and could lead to an accident Never exceed the stated load capacity for this ATV Refer to the ACCESSORY USE AND VEHICLE LOADING section in this manual WARNING Operating this ATV with improper modifications could be hazardous Improper installation of accessories or modifications to this vehicle may cause changes in handling In some situation
38. ps or holes without enough time to react Could result in the ATV overturning or going out of control Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV UDR STARTING THE MOTOR Before attempting to start the motor make sure you are completely familiar with all operational aspects of this ATV Activating the throttle suddenly could be hazardous The front wheels could leave the ground and cause loss of control of the ATV Always open the throttle gradually when accelerating Braking while turning the ATV could be hazardous Use of the brake when turning could cause the ATV to slide or roll over Use the brake to slow down before you begin to turn Braking hard on slippery surfaces could be hazardous The ATV could skid and go out of control if you brake too hard Apply the brakes lightly and carefully on slippery surfaces Operating the parking brake when the ATV is moving could be hazardous The front wheels could lock causing a skid and an accident Apply parking brake only after ATV has come to a complete stop WARNING Turning improperly ATV could go out of control causing a collision or overturn Always follow proper procedures for turning as described in the owner s manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speed T
39. psi Rear 55 kPa 0 56 kgf cm 8psi CE Front 41 4 kPa 0 42 kgficm 6psi Rear 41 4 kPa 0 42 kgf cm 6psi NEVER SET TIRE PRESSURE BELOW MINIMUM This could cause the tire to dislodge from the rim LOADING TRAILER TOWING Cargo or a trailer can affect stability and handling Please read owner s manual before loading or towing When riding with cargo or towing a trailer Reduce speed and allow more room to stop Avoid steep hills and rough terrain Maximum Vehicle Load 364 Ibs 165 kg Includes weight of operator cargo and accessories and if applicable trailer tongue weight NEVER OPERATE THIS ATV IF YOU ARE UNDER 14 Operating this vehicle if you are under the age of 14 increases your chances of suffering a severe INJURY or DEATH pr M READ ALL WARNING LABELS Read and follow all of the warnings labels on your ATV Make sure you understand all the labels Keep the labels on the ATV Do not remove them for any reason If a label comes off or becomes difficult to read you should get a replacement by contacting ZAP WARNING Operation of this ATV by children under age 16 can be hazardous Use by children under age 16 can lead to their severe injury or death Children under age 16 may not have the size strength skills or judgment needed to operate this ATV safely Do not allow any child under age 16 to ride this ATV WARNING Operating this ATV after consuming
40. r call ZAP It is very important to inspect and maintain your ATV regularly Follow the guidelines in the chart The intervals between periodic services in months are shown At the end of each interval be sure to perform the maintenance listed Item Initial See chart Month 20hrs Brake Hose and Joints Drive Chain Brakes Wheels Wheel Bearings Brake Caliper Linings Front and Rear Suspension Sterring System Steering Shaft Lubrication use Li Grease Fittings and Fasteners I Inspect and clean adjust lubricate or replace if necessary C Clean R Replace T Tighten Owner and Operator s Manual 3 Months 50 hrs 6 Months UDR BATTERY REPLACEMENT The following procedure can be dangerous and should be performed with the utmost care and attention Wear protective eyewear rubber gloves and have water available should electrolyte come in contact with skin or eyes KEEP ALL CHILDREN AWAY FROM THE AREA WHILE THIS PROCEDURE IS BEING PERFORMED POISON CAUSES SEVERE BURNS Contains sulfuric acid Avoid contact with skin eyes or clothing To prevent accidents rinse empty container with water ANTIDOTE External flush with water Internal Call physician immediately Drink large quantities of water or milk Follow with milk of magnesia beaten eggs or vegetable Eyes Flush with water for 15 minutes and get prompt medical attention KEEP OUT OF REACH OF
41. s this could lead to an accident Never modify this ATV through improper installation or use of accessories Refer to the ACCESSORY USE AND LOADING section in this manual WARNING Operating this ATV with improper tires or improper tire air pressure could be hazardous If you use improper tires or improper air pressure you may lose control of the ATV This will cause an accident Always use tires with the same size and type specified in this user s manual Always maintain proper tire air pressure as described in the INSPECTION AND MAINTENANCE section Make sure batteries are fully charged for the intended trip or planned usage Never carry a passenger The long seat is to allow the operator to shift position as needed during operation It is not for carrying passenger Carrying a passenger on this ATV Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passenger Operating this ATV on public streets roads or highways is prohibited You may collide with another vehicle Never Owner and Operator s Manual operate this ATV on any public street road or highway In many states is it actually illegal to operate ATVs on public streets roads and highways We recommend that you do not drive this ATV at night Although the ZAP Dude is equipped with headlights it is recommended you restrict your use to daylight hours Nig
42. tructor Contact an authorized ZAP ATV dealer or call SVIA at 1 800 887 2887 to find out about the training courses nearest you Always follow these age recommendations Never operate an ATV on any paved surfaces including sidewalks driveways parking lots and streets Never operate an ATV on any public street road or highway even a dirt or gravel one Never operate an ATV without wearing an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves 8 Owner and Operator s Manual boots long sleeved shirt or jacket and long pants Never consume alcohol or drugs before or while operating this ATV Never operate this ATV at excessive speeds Always go at a speed that is proper for the terrain visibility and operating conditions and your experience Never attempt wheelies jumps or other stunts Always inspect your ATV each time you use it to make sure it is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in this manual Always keep both hands on the handlebars and both feet on the footrests ofthe ATV during operation Always go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain pr M conditions when operating the ATV Never operate on excessively rough slippery or loose terrain until you have
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