Zap DX User's Manual
Contents
1. Motors hang free Engagement cam in up position Engagement cam in down position K Motors remain in down position Drive roller remains in contact with tire Drive roller does not touch tire OPERATIONS AND FEATURES 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 The high speed is used for quick accel eration and higher speed cruising Throttle Switch For safety the Throttle Switch is a spring loaded two speed selector switch When released it will return to the off position When the switch is pushed away from the rider it activates the low speed When the switch is pulled toward the rider it acti vates the high speed It is recommended that the switch be mounted in such a way that it can be activated with the index fin ger of the left hand We have found this to be the most com fortable position Main Power Switch The main power switch is a black button located on the left side of the battery tray Power to the system can be turned either on or of2. errands or simply for fun Welcome to the world of ZAP electric Bikes Is clean non polluting and in AZ traffic faster than your car Costs only pennies in electricity For fresh air and fun ZAP puts you at the forefront of a worldwide move ment in transportation A ZAP Electric Bike is appro priate technology for many of the problems that face our society today and in the years to come 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 ZAP is an entirely new transportation option that combines the environmental friendliness of a bicycle and the conve nience of a gasoline vehicle without the pollution For just a few pennies of electricity your ZAP can replace you car for short trips trips that make up most 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 exercise fresh air and fun but you can feel good because you are doing something positive for the planet Imagine that all this in one small elegant ZAP bicycle system We have designed our electric bicycle system for simple easy installation and operation Keep in mind that improper i
3. 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 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 Finger tighten the remaining motor mount bolt through the Bridge Mount and into the Threaded Plate IF YOUR BIKE DOES HAVE THE WELDED PLATE START HERE Motor Mount Bolts Washers Hinge Bracket Threaded Plate Welded Plate Insert the motor mount bolts through two of the holes in the weld ed bridge plate and finger tighten into the two holes of the Threaded Plate see Fig 4 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 4 Adjusting Motor Unit With Cam Lever in the up disengaged position adjust the ZAP Motor Unit by sliding it up or down along the seat stays until the proper Critical Set Up Distance CSD is achieved The CSD is the distance between the motor and the Seat Stays when the roller is just touching the tire see Fig 5 Determine the CSD
4. Thoroughly inspect your ZAP Power System for loose or damaged parts before each use If there are any loose or damaged parts perform the needed adjust ments or repairs before starting your ZAP Power System GENERAL WARNINGS 1 Do not smoke while operating the ZAP Power System Keep ZAP Power System away from open flames such as pilot lights cigarettes etc 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 Ride your bicycle in such a manner that the electrical assistance is not necessary for maintaining control of the bicycle Always be prepared for the sudden loss of electrical assistance Also the rider must know and obey all local laws con cerning the operation of and equipment requirements of electrically assisted bicycles Make sure that your equipment and operation of your electrically assisted bicycle meets these standards Failure to obey these laws may result in severe injury or death 4 AVOID UNINTENTIONAL STARTING Do not leave the ZAP Power System with the master on off switch ON when not in use For greater safety disconnect Battery Power Connector 5 DO NOT disassemble the motor controller Return the ZAP Power System to your authorized service dealer for se
5. battery terminals or Battery Power Connector IT IS EXTREMELY IMPORTANT THAT YOU FOLLOW THE SAFETY GUIDELINES CONTAINED IN THIS MANU AL IN ORDER TO INSURE MAXIMUM SAFETY FAILURE TO COMPLY WITH THE STANDARDS OUTLINED IN THIS MANUAL COULD RESULT IN FIRE AND OR SERI OUS INJURY ZAP POWER SYSTEMS ZAP IS NOT IN ANY WAY RESPONSIBLE OR LIABLE FOR ANY DAM AGE OR INJURIES CAUSED BY UNSAFE OR FAULTY REPAIRS ANY REPAIRS MADE TO THIS PRODUCT BY UNAUTHORIZED SERVICE TECHNICIANS ARE THE SOLE RESPONSIBILITY OF THE OWNER 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 t is imperative that you review this checklist before your first ride Although your PowerBike ElectriCruizer has passed our Quality Assurance proce dure things can happen during ship ping which may alter the adjustment of the system vi 1 Check Tire Pressure The tires on your PowerBike should be at their maximum tire pres sure 65 PSl pounds per square inch and the tires on your ElectriCruizer should be at 40 PSI If you installed a kit on your own bike then check to see that the tire pressure is at the recommend ed value for the tires you have vi 2 Check Motor Alignment Make sure the roller is centered on the tire so that there isn t a possibility of one of the motors rubbing against the tire I
6. controller power connector black amp red Attach the Velcro on the battery bag flaps to Velcro on the battery tray and make it tight Run the battery strap underneath the battery tray and through the D ring on the other battery flap and pull tight Fasten the battery strap to itself with the velcro attached to it NOTE Initially tray is very tight around battery ZAP DEFLATES THE TIRES BEFORE PACKAGING THE BIKE TO PREVENT DAMAGE DURING SHIPPING INFLATE BOTH TIRES TO 55 PSI Engagement Lever Operation Lx 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 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 pedaling has initiated and when the engagement cam is moved to the down position the drive roller is already in contact with the tire when the motor is activat ed Pedaling over 11 mph in the low speed setting recharges the battery This recharging is called eration Fig 3 To learn more about regeneration refer to page 9 10 Engagement cam in up position
7. in Ibs Handlebar Binder Bolt 175 260 Ibs Hex Wrench 50 70 in Ibs Hub Axle Locknut 88 220 in Ibs Bottom Bracket Fixed Cassette Lockrings 300 440 in Ibs Cup amp Lockring Steel Front Axle Nuts Bottom Bracket 600 690 in lbs wheel mount 180 240 in lbs Alloy bottom bracket see manufacturer Rear Axle Nuts Chainwheel Bolts 70 95 in lbs wheel mount 240 300 in Ibs Crank Arm Bolt 350 in Ibs Quick Release Shift Lever Clamp Bolt To Tighten Not more than 45 lbs Screwdriver 22 26 in lbs pressure at 55mm Hex Wrench 44 52 in lbs from pivot Rear Derailleur To Release 12 25 lbs pressure Hanger Bolt 70 85 in Ibs Brake Arch Cable Bolt 45 60 in Ibs Attaching Bolt 70 85 in 105 Front Derailleur Shoe Bolt 43 60 in lbs Clamp Bolt 45 60 in lbs Cable Bolt 50 70 in lbs Cable Bolt 45 60 in lbs Toe Clip Bolts 22 in lbs TORQUE RATINGS CONVERSION INSTRUCTIONS Foot pounds Foot pounds Foot pounds Inch pounds Inch pounds Inch pounds Nm Nm Nm Kgf cm Kgf cm Kgf cm Inch pounds Nm Kgf cm Foot pounds Nm Kgf cm Foot pounds Inch pounds Kgf cm Foot pounds Inch pounds Nm ALWAYS WEAR A HELMET WHEN RIDING 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 com Stock Symbol ZAPP Z
8. system We recom mend a semi slick tire Tires should be inflated to their maximum inflation rating This is printed on the side of the tire Bicycle You will be adding weight to your bicycle when you install the ZAP Power System The condition of your bicycle is crit ical to your safety Wheels should be trued running straight Brakes are the most important safety component on your bicycle and should be carefully checked and adjusted A professional bike tune up is highly recommended Bicycle down tube Bicycle seat tube Motor Controller leads 1 Attaching the Battery Tray Position battery tray in bicycle frame so the rear part of the bat tery tray is parallel to the bicycle seat tube Fig 1 Secure the rear part of the battery tray to the bicycle seat tube and the front part of the battery tray to the bicycle down tube with the worm drive clamps provided Tighten clamps until battery 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 along the right 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 Yellow Th
9. when riding You re done Now you can look forward to great fun and becoming a pioneer riding on your ZAP Electric Bicycle IMPORTANT PLEASE READ CAREFULLY ALONG WITH YOUR BIKE 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 YOU MUST MAIL THE WARRANTY FORM IN WITHIN 10 DAYS OF RECEIVING YOUR ZAP POWER SYSTEM IN ORDER TO ACTIVATE THE WARRANTY 2001 ZAPWORLD COM Easy Installation Guide IMPORTANT PLEASE READ CAREFULLY 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 You must return the warranty form within 10 days of receiving your ZAP Power System in order to activate the warranty Before You Begin We strongly suggest that your ZAP Electric Bicycle be assembled and tuned by a professional bike mechanic Required Tools 4mm 5mm 6mm allen wrench crescent wrench 15 32mm head amp pedal wrench cutters axle wrench phillips head screwdriver flat head screwdriver amp tape measure NOTE Please refer to the Description of System on page 4 for a detailed list of your kit s key features Tires It is extremely important that you have the right tires on your bicycle before you begin this installation Not all tires will work properly with the Zap Power System Full knobby tires will not work properly and may damage the motor
10. AP is a Publicly Traded Company 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 occa sionally 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 clear ly understand any particular point addressed 1 have received the owner s manuals and agree to read them thoroughly especially the safety warnings before using the bicycle understand that all riders should wear a bicycle hel met whenever riding the electric bicycle Please initial 2 understand that this electric bicycle is subject to all the laws of the road and that many states and localities have addition al laws which specifically apply to electric bicycles Please initial 3 understand the use of brakes and gear shifting mecha nisms and in the use of all quick release mechanisms 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 am aware that riding an electric bicycle involves certain risks dangers and hazards which can result in serious per sonal injury or death As such hereby freely agree to assume and accept any and all unknown risks of injury w
11. ED TO EXPENSE OF RETURNING THE ZAP PRODUCT TO AN AUTHORIZED SERVICE DEALER AND EXPENSE OF DELIVERING IT BACK TO THE OWNER MECHANIC S TRAVEL TIME TELEPHONE OR TELEGRAPH CHARGES RENTAL OF A LIKE PRODUCT DURING THE TIME WARRANTY SERVICE IS BEING PER FORMED TRAVEL LOSS OR DAMAGE TO PERSONAL PROPERTY LOSS OF REVENUE LOSS OF USE OF THE PRODUCT LOSS OF TIME OR INCONVENIENCE SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU This warranty gives you specific legal rights and you may also have other rights which vary from state to state This warranty applies to all ZAP Products manufactured by ZAP and sold in the United States To locate a service dealer or to purchase an Extended Warranty Plan call 707 824 4150 MANUFACTURED BY ZAP PATENTS PENDING ONE ZAP DRIVE 117 MORRIS STREET SEBASTOPOL CALIFORNIA 95472 USA 2002 ZAP UY FOLD HERE FROM PLACE FIRST CLASS POSTAGE HERE ZAPWORLD COM One ZAP Drive 117 Morris Street Sebastopol California 95472 USA ATTN Warranty Department E RO A I R World Solar Bike Race P OLLU T I o
12. GAGEMENT LEVER OPERATION _ 10 OPERATION MANUAL 8 CHARGING GUIDE _ 11 SAFETY 5 Mte pua nid Rs ud UR 12 13 PRE RIDE aas 14 Abu HUMUM UM MIU ME MEMOREM 15 TROUBLESHOOTING GUIDE 5sssssssssseennnnnrnnnnnnnnnnnnnnen 16 17 WARRANTY FORM 17 18 Description of System NOTE The items referred to on this page are important when installing your ZAP Use this page as a reference guide 1 ZAP Motor Unit 11 4mm Allen Wrench 2 Battery Pack 12 Motor Mount Bolts 3 Throttle Switch Assembly 13 Bridge Mount 4 Battery Tray 14 Threaded Plate 5 Main Power Switch 15 Cam Ramp 6 Motor Controller Leads 16 Double Sided Tape 7 Controller Power Connector 17 Cam Lever 8 Auxiliary Power Alternate 18 Hinge Bracket Charging Jack 19 Spacer Tube 9 Worm Drive Clamps 20 Zip Ties 10 Battery Charger 21 Battery Power Connector not included in ZAP factory bikes with a welded bridge plate 4 Detail of PowerBike SEAT STAY SEAT SEAT BATTERY DOWN THROTTLE BRIDGE STAYS TUBE PACK T
13. The rear reflector should be perpen dicular with the ground Step 2 Attach the front reflector bracket to the hole in the front fork crown 1 Nut 2 3 amp 4 Beveled Washer only included in bikes that have the metal reflector bracket 5 Bolt 7 Ihe tront tork crown 15 located immediately above the wheel Inspect the front reflector and reflector bracket 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 printed on the tires It is normal for bicycle tires to lose a little tire pressure every week Since proper tire pressure is critical to the operation of your ZAP motor please check your tire pressure weekly 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 12 FINAL ZAP POWER SYSTEM INSPECTION Make sure your ZAP motor is positioned correctly on the bicy cle Refer to installation instructions in your ZAP Owner s Manual Charge the battery completely before riding It is very important to the life of your battery that you completely charge the battery immediately after every use ZAP DEFLATES THE TIRES BEFORE PACKAGING THE BIKE TO PREVENT DAM AGE DURING SHIPPING INFLATE BOTH TIRES TO 55 PSI BE SAFE Always wear a helmet
14. UBE SWITCH ZAP MOTOR CHAIN CRANK BATTERY UNIT STAYS TRAY MINIMUM FIT DIMENSIONS FOR ZAP POWER SYSTEM TRAY MODEL Do not use ZAP System on bikes without metal seat stays SEAT STAYS TOP TUBE DX DRIVE SYSTEMS N 5 SX DRIVE SYSTEMS REAR WHEEL IMPORTANT PLEASE NOTE The standard ZAP Power System will not fit on a monostay bike 5 RE ASSEMBLY INSTRUCTIONS FOR A PRE ASSEMBLED BOXED ZAP ELECTRICRUIZER 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 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 If you need assistance in working with a local bike dealer please ZAP 707 824 4150 In order to final assemble your elec tric bike you will need the following nine simple tools 4mm 5mm 6mm Metric Pliers Allen Wrenches XS NOS Head amp Pedal 6 amp 10 Phillips Standard 15 32mm Wrench Wrenc Screwdriver Ew 1 REMOVING PACKAGING Carefully remove all packing material from bicycle and inspect the bike for any damages which may have occurred during shipping If necessary please call both the shipper and ZAP immediately to report a
15. WORLD RECORD HOLDER Gum Ap World Solar Bike Race 2 00 2 REV 5 15 00 OWNERS MANUAL POWER SYSTEM MADE IN THE USA Patent 25 491 390 45 671 821 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 Rights Reserved ZAP is a registered trademark it Wh SAFE Always Wear a elme t when riding 8 ae STR Ee 6 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 BEFORE YOU 7AP 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 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 Introduction ongratulations on your purchase of a ZAP Electric Bike or Power System In the com ing years you will find many ways to use your ZAP commuting exercise
16. adhesive tape Do not attempt to destroy or dis assemble battery pack or remove any of its components Also never touch both terminals with metal objects and or body parts as short circuit may result Keep away Pb from children Failure to comply with these warnings RECYCLE could result in fire and or serious injury Vv E Temperature Effects on Battery Capacity 100 80 60 40 Battery Capacity 96 20 0 115 F 104 F TEE 32 F 46 C 40 C 25 C 0 C 15 C Temperature Remember Charge fully immediately after every each use 15 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 Problem Insufficient Range Drive Roller Slips Note Roller should never slip against tire Motor Does Not Start Motor Runs Only on High Motor Runs in Reverse Motor Shuts off During Use Possible Cause Low tire pressure Insufficient rider input Over engaged roller greater than 1 16 Poorly tuned bike Battery is not broken in Cold battery Battery not fully charged Heavy rider Damaged battery Wrong type of tire Improper critical setup distance or motor position Wet roads Tire pressure low Power switch is in off position Loose wire connections Battery is d
17. e Country Zip Purchased From Serial Number On Motor Serial Number On Bike Frame Age Sex Occupation Is this your first Electric Vehicle The type of bike ZAPPED was a use my ZAP for Commuting Recreation Work Fun Shopping Exercise Other My typical length of ride is miles Where did you hear about our product Friend Relative Associate Internet Show News Article Dealer Ad where Other Do you own a computer If so what kind Yes No PC Mac Other Do you use the internet Yes No If so what is your E mail address Favorite Magazines 1 2 3 Are you interested in accessories for your ZAP Yes No Are you interested in assisting us in check applicable EARN 50 FOR ARTICLES Call ZAP s PR Department for details Marketing Sales Public Relations Dealer Information Shareholder Information ZAP is publicly traded Stock Symbol ZAPP Comments WORLD RECORD HOLDER World Solar Bike Race See us at our Web Site ZAPWORLD COM Y ZAP warrants each new ZAP product for three 3 months according to the following terms Batteries are also warrantied for three 3 months This warranty extends to the original retail purchaser only and commences on the date of the original retail purchase Any part of the ZAP Product manufactured or supplied by ZAP and found in the reasonable judgment of ZAP t
18. e 13 Safety You are adding weight to your bicycle when you install a ZAP Power System This will change the riding and handling char acteristics of your bicycle The rider should always be capable of riding the bicycle with the system installed but not activated The brakes should be capable of stopping the bike even with the power on at any speed The rider must obey all local traffic laws SEE PAGE 10 11 FOR COMPLETE SAFETY INSTRUCTIONS CHARGING Charge the battery immediately after use in order to maximize battery life There are two ways to charge your battery The ZAP battery charger connects to the Battery Power Connector locat ed on top of the battery or the Auxiliary Power Jack located near the battery tray Using any other charger will damage the battery To Connect Charger CHARGE AFTER EVERY USE 1 First connect the charger power connector to either the Battery Power Connector or Auxiliary Power Jack 2 Then plug the ZAP charger into a standard 110 VAC wall Socket NOTE You can remove the battery and charge away from the bicycle 3 Please observe all safety warnings described on pages 10 11 To Disconnect Charger 1 First unplug the ZAP charger from the 110 wall Socket 2 Then disconnect the Charger Power Connector from the Battery Power Connector The 17 amp hr battery will take at most three hours to fully recharge The light will flash between YELLOW and GREEN When fully c
19. e lever is parallel to the seatpost Grip the seatpost with your fingers and use the palm of your hand to close the lever with as much strength as possi ble When closed the lever must be in the CLOSE position The side of the lever with the inscription CLOSE must be fac ing away from the seatpost 9 FRONT BRAKE CABLE HANGER If you are also installing ZAP PowerLight the lighl bracket should be installea beneath the headset top nut Remove the top nut from the fork While align ing the cable hangers tooth with the groove on the steerer tube slide the brake cable hanger onto the forks steerer tube Next re install the top nut securing it with the proper torque specifications After installing the front brake cable hanger inspect the adjustment for the headset bearings If the fork does not turn freely first loosen by turning counterclockwise the top nut and then loosen the cone then re secure the top nut If the fork is too loose then loosen the top nut tighten the cone then re secure the top nut Before you ride the bike make sure that the brakes are properly adjusted Cable Hanger Steerer Tube lock Ring one 6 INSTALLING THE HANDLEBAR ASSEMBLY Insert the stem into the bicycle head tube past the minimum insertion mark align with front wheel and tighten the stem binder bolt Position handlebars at desired angle and tight en handlebar binder bolt The handlebars should be center
20. ed at the stem Both binder bolts should be TEE with a 6mm allen wrench tight enough so that you cannot twist the stem and handlebars out of alignment Adjust the brake levers to desired angles and tighten to proper torque Rear Brake Lever Handlebar Binder I VUNNEUTING THE REAR BRAKE GABLE Brake Lever Lock Nut Step 1 At the rear brake assembly located at the back wheel unhook the rear brake cable barrel end This made easier by squeezing the cantilever brakes towards the rim to decrease the cable tension in order to unhook the rear brake cable barrel end from the brake unit Also make sure to screw by turning clockwise in the barrel adjuster all the way into the brake lever This will make the brake wire easier to work with by increasing the slack in the brake cable Step 2 On the rear brake lever line up the slots on the barrel adjuster and adjuster locknut with the slots on the brake lever Insert the brake cable into the brake lever Turn the barrel so that the slots are no longer aligned Step 3 Re attach the brake cable to the rear brake assembly Before you ride the bike make sure that the brakes are prop erly adjusted Screw pedals into crank arms and tighten with a 15mm open ended wrench to proper torque The right pedal tightens clockwise and the left pedal tightens counter clockwise Step 1 Inspect the rear reflector and reflector bracket to make sure that they are tight
21. f by pushing the button until it clicks 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 Circuit Breaker Your ZAP Power System is equipped with an automatically resetting circuit breaker If you are drawing more than 60 amps of current it will momentarily shut off The circuit breaker will reset in a few seconds The system will continue to shut down until the current draw is less than 60 amps If your system shuts off you should move the Throttle Switch to the low position The circuit breaker is necessary to protect your motors from damage Efficiency The ZAP Power System is an accessory to not a replacement for your human power The rider needs to always pedal to oper ate the ZAP Power System The efficiency of the system is greatly controlled by the rider When the rider pedals more the efficiency of the system is dramatically increased It takes four 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 needed It may be possible to pedal then start out in the high position but this will greatly reduce the range and may trip the circuit breaker see pag
22. f it needs adjustment simply loosen the motor mount bolts center the system and re tight en Wheels should be running straight amp true vi 3 Check Motor Engagement Make sure that the roller engages and 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 less than 1 16 Then re tighten the motor mount bolts vi 4 Check Brake Pad Alignment Make sure your front and rear brake pads are not rub bing the rim tire or spokes If they are we rec ommend having them adjusted by a professional bike mechanic at a bicycle store vi 5 Check Battery Tray Stability Make sure the battery is properly secured to the tray Attach the Velcro flaps to the sides of the Battery Tray Route the strap under the battery tray and With the battery secure check to see that the tray is properly fixed thread through the D ring to the bike by trying to move the battery and tray a bit Tighten the two worm drive clamps if they need tightening but be sure not to over tighten which may strip the clamps vi 6 Be sure all wire connections espe cially battery terminals are tight On the PowerBike check the Quick Release levers on both wheels Wear your ANSI or Snell approved helmet Use front and rear lights when riding at night and be sure all reflectors are properly af
23. fixed NOW YOU ARE READY SO HAWE A GOOD RIDE 14 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 5 Recharge your battery as soon as you can after riding The ZAP battery will take 4 10 cycles of riding and charging to bring the battery up to its full potential Greater depth of discharge on a continual basis will diminish the overall life of the battery see charts below BATTERY PACK REPLACEMENT Batteries must be recycled To preserve natural resources please recycle or dispose of 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 options REPLACING THE BATTERY When the battery needs to be replaced we recommend that you contact your nearest ZAP authorized dealer THIS PRODUCT CONTAINS A SEALED LEAD ACID BATTERY PREPARATION BATTERY IT MUST BE RECYCLED WARING QE OR DISPOSED OF PROPERLY Upon the removal of the battery cover the terminals with heavy duty
24. for your bike by referring to Fig 6 The recommended pressure for your tires is printed on the tires NOTE n some cases on Cruiser bikes in particular the Standoff silver member between the two motors will hit the tire when the Motor Unit is pulled in against the seat stays of the bike When this happens adhere the remain ing piece of Cam Ramp on the motor where it contacts the seat stay Then readjust the motor using the space between the Seat Stay and the piece of Cam Ramp as the new CSD Once the CSD is attained tighten the bolts using the 4mm Allen Wrench make sure the ZAP Motor Unit is centered around the tire and the roller is flat on the tire as opposed to being slanted Re check CSD and correct if needed Put the Cam Lever in the down engaged position and notice how far it forces the Roller into the tire Ideally the Cam will force Critical Setup Distance CSD for Different Tire Pressures 1 2 1 40 45 50 55 60 65 70 75 80 85 90 Tire Pressure psi Fig 6 the Roller about 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 Lever and check to see if the Cam forces the Roller into the tire the desired 1 16 without a Cam Ramp If the engagement is less than 1 16 take the spare Cam Ramp which is shorter and slotted and insert i
25. harged the GREEN indicator light is lit most of the time 6 seconds or more Regeneration The ZAP Power System 2 speed system offers a regeneration feature This allows you to recharge your battery by pedaling or coasting when wheel speed is greater than 11 mph with the throttle switch on in low The regeneration feature is most use ful when descending hills The regeneration feature will provide up to 40 amps of current to your battery depending on your speed In order to regenerate while riding follow the steps below 1 Place the cam lever in the down position Cam engaged 2 Keep the Throttle Switch to the low speed 3 Keep the wheel speed above 11 mph 11 SAFETY WARNINGS THE PURPOSE OF SAFETY SYMBOLS IS 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 DAN GER THE INSTRUCTIONS OR WARNINGS THEY GIVE ARE NOT SUBSTI TUTES FOR PROPER ACCIDENT PREVENTION MEASURES WARNING Failure to obey a safety warning can result in injury to yourself or others Always follow the safety precau tions to reduce the risk of fire electric shock and personal injury PRE OPERATIONAL SAFETY WARN INGS 1 Read and understand this owner s manual carefully before using this unit Be thoroughly familiar with the proper use of your ZAP Power System 2
26. he influence of drugs alcohol or medication 5 Some states require that all bicycle riders wear a safety helmet It is recommended that this precaution be followed at all times for maximum safety protection 6 Never ride at night without functioning rear and front lights and all safety reflectors on your bike 7 Be sure all wire connections especially all battery connections are tight 8 Follow all federal state and local laws 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 are not described in this manual Call 707 824 4150 for your near est dealer 2 Use only original equipment manufacturer s replacement parts when servicing this ZAP Power System These parts are available from your authorized service dealer The use of non standard parts or other accessories or attachments not designed for this ZAP Power System could result in serious injury to the user and or damage to the ZAP Power System 3 STORE UNIT INDOORS When not in use the ZAP Power System should be stored In a cool dry place out of reach of children 4 IMPORTANT Before storing or ship ping your ZAP Power System be sure to disconnect your Battery Power Connector Remove your battery from the bicycle and store it in a FULLY CHARGED CONDITION and away from any objects that may short the
27. hile using the electric bicycle Please initial 5 understand that regular maintenance is required to keep this electric bicycle operating properly and that failure to main tain may void the manufacturer s warranty and may make the electric bicycle unsafe Regular maintenance includes fre quent inspection of all quick release mechanisms and wheel retention devices also understand that maintaining appropri ate tire pressure at all times is essential for the safe use of this electric bicycle The recommended tire pressure is marked on the tire Please initial 6 By initialing each item on the above checklist have indi cated my complete understanding of these points and acknowledge my responsibilities regarding the contents also agree to explain the points on this checklist to anyone besides myself who will be using the electric bicycle now and in the future X Buyer s Signature Date X Buyer s Name Print If buyer is under 18 years of age the buyer s guardian must sign UJ FOLD HERE TO ACTIVATE WARRANTY PLEASE INITIAL AND SIGN THE BUYER S CHECKLIST ABOVE AND RETURN WITHIN 10 DAYS OF PURCHASE WARRANTY CARD Please complete both sides and return within 10 days of purchase Please take a couple of minutes to fill out your registration card This informal survey will aid us in providing our customers with the best possible product Name Address City State Phone H W Purchase Dat
28. ion The wire size is large enough for the AC ampere rating of the charger as specified below RECOMMENDED WIRE SIZE AWG FOR GIVEN WIRE LENGTH FEET 25 50 100 AWG 14 12 10 7 DO OPERATE CHARGER WITH A DAMAGED CORD OR PLUG If the cord or plug is damaged replace the charger 8 Do not operate the charger if it has received a sharp blow been dropped or damaged in any way If the charger case is damaged replace the charger 12 A A SAFETY WARNINGS CONTINUED A A 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 For optimum performance your ZAP Power System should be charged in a location where the temperature is more than 50 10 C but less than 100 F 37 C See Battery Care on page 14 OPERATIONAL SAFETY WARNINGS 1 Keep hands face feet and long hair away from all moving parts 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 Donotoperate your ZAP Power System while under t
29. nstallation and opera tion of the ZAP can reduce your performance and your overall enjoyment so before you start we strongly rec ommend the following Familiarize yourself with your owner s manual Carefully follow each step in the installation to assure a proper fit and installation Just a little extra time reading your manual now can help you avoid frustration in the future Our Customer Service department is available between 9 00 a m and 4 30 p m PST Monday through Friday at 707 824 4150 to help you with any problems that may occur You can also e mail your customer service questions 24 hours a day seven days a week to zap zapworld com Once again thank you for purchasing a ZAP Our hope is that you will like it so much it will become your favorite mode of transportation Table of Contents BEFORE YOU BEGIN olo e o bleed d s b ale mbi e en 1 INTRODUCTION oon irk vet aden need De ados i be neta rere s or tb e d 2 TABLE OF CONTENTS eio tian c care ad Reda DE ard rcm n aed caes 3 DESCRIPTION OF SYSTEM o oo ccc cece cecscsecececsesecsssesesecscsesesessesesessssesasassesesassesesesacaesesassusesesaeeeeecaeees 4 DETAIL OF ZAP POWERBIKE 5 RE ASSEMBLY INSTRUCTIONS FOR PRE ASSEMBLED ELECTRICRUIZERS 6 7 EASY INSTALLATION GUIDE o oo cece ccescsecseseseecsesssessssesesessesessssssesecassesesessesesesassecacseseeneass 8 9 EN
30. ny damage 2 OWNER S MANUALS Before you begin assembly thoroughly read through the ZAP Owner s Manual ZAP Owner s Manual Supplemental and this assembly sheet Review page four of the ZAP Owner s Manual Supplemental Please refer to the Torque Ratings Guide when tightening or securing bicycle parts All bicycle parts referred to during assembly will have a number corresponding to the dia gram appearing on this page 3 FRONT WHEEL Attach the front wheel to the forks with a 15mm wrench or an adjustable wrench Tighten each side partially center and balance wheel then tighten completely Insert seatpost into the bracket on the underside of the seat Be sure that the top of the seat is level Securely fasten the seat to the seatpost using an adjustable wrench Insert seat you have the standard binder bolt using an allen wrench securely tighten the seatpost enough so that you cannot twist the saddle out of alignment B If you have the optional quick release lever tighten the quick release nut enough so that you cannot twist the saddle out of alignment after the quick release is engaged 4h HOW TO FASTEN THE SEAT QUICK RELEASE Open and close the quick release lever with your right hand while gradually tightening the adjusting nut located on the opposite side of the seatpost with your left hand in the clock wise direction Continue tightening the nut until you feel resis tance with your hand at the point when th
31. o be defective in material or workmanship will be repaired or replaced by an authorized ZAP service dealer without charge for parts and labor The ZAP Product including any defective part must be returned to an authorized service dealer within the warranty period The expense of delivering the ZAP Product to the factory or authorized service dealer for war ranty work and the expense of returning it back to the owner after repair or replacement will be paid for by the owner All dealer returns are subject to a 1596 restocking fee ZAP s responsibility in respect to claims is limited to mak ing the required repairs or replacements and no claim of breach of warranty shall be cause for cancellation or rescission of the contract of sale of any ZAP product Proof of date of purchase will be required by the dealer to substanti ate any warranty claim An authorized ZAP service dealer must perform all warranty work This warranty is limited to thirty 30 days from the date of the original purchase for any ZAP Product that is used for rental demonstration or commercial pur poses or any other income producing purpose This warranty does not cover any ZAP Product that has been subject to mis use neglect negligence or accident or that has been operated in any way con trary to the operating instructions as specified in the 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 an
32. rained Electrical fault in wiring Only one motor connected Motor controller leads reversed Circuit breaker has tripped Motor speed setting too high for hill incline Inadequate rider input pedaling for 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 tune your bike correctly bring your bike to a local bike mechanic Charge use charge 4 10 times before optimum range Keep them warm or indoors when stored and charging Keep battery in fully charged condition Order dual battery upgrade Replace battery Use only semi slick tire Readjust motor position see page 7 Engage cam lever Add air to maximum tire rating Push switch on the left side of the battery tray to ON position Push button until it clicks Check tighten all connections Charge battery immediately Check all wiring connections battery terminals motor leads etc Plug in second motor Switch leads Release throttle wait 10 seconds Use low speed setting Pedal more TIGHTENING SPECIFICATIONS Pedals 350 in lbs Cantilever Brake Seat Post Bolt Clamp 75 100 in Ibs Frame Bolt 43 60 in lbs Seat Clamp Shoe Bolt 50 75 in lbs Single Bolt 120 145 in lbs Cable Carrier Nut 50 70 in lbs Double Bolt 72 96 in lbs Brake Lever Clamp Headset Topnut 300 in Ibs Screwdriver 22 30
33. rottle Switch 2 Attaching the Throttle Switch Loosen the front brake lever and front shifter lever and slide it away from the grip Attach throttle switch between the grip and the front brake lever with the yellow toggle switch pointing away from the center of the handlebar Fig 2 Once the throttle switch has been secured slide the brake lever back until it is snug against the throttle switch Adjust brake lever and front shifter lever to the correct position and tighten it back down Secure the throttle switch wire to the front shifter lever cable housing with the small zip ties provided For cruisers attach throt tle switch wire to front brake cable housing Secure remaining throttle switch wire to the bicycle down tube with two of the large zip ties provided Carefully stuff any excess throttle switch wire back into the bat tery tray 3 Mounting Motor Unit NOTE f 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 Motor Mount Bolts Bridge Mount Hinge Threaded Plate Seat Stay Bridge 4 mm Allen Wrench BRIDGE MOUNT INSTALLATION see Fig 3 side of the bicycle down tube NOTE The Auxiliary Power NOTE The seat stay bridge of your bike is the short horizontal Alternate Charging Jack is identified by the black rubber cover tube between the seat stays Take the
34. rvice or repair BATTERY WARNINGS 1 To reduce the risk of injury use only ZAP batteries Other batteries may explode causing personal injury and damage 2 DO NOT PLACE THE BATTERY NEAR FIRE OR HEAT IT COULD EXPLODE 3 Batteries can emit explosive gases while being charged Do not obstruct 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 instructions and cautionary markings in this manual on the battery charger and the ZAP Power System using the battery charger 2 USE ONLY THE CHARGER PROVIDED WITH YOUR ZAP Power System Do not substitute any other charger Use of any other charger could cause the battery to explode causing serious injury w Do not expose charger to moisture and water A To reduce the risk of damage to the charger and cord pull the charger by the plug rather the cord when disconnecting the charger 5 Make sure the cord is located so that it will not be stepped on tripped over or otherwise subject to damage or stress 6 An extension cord should not be used unless absolutely necessary Use of improper extension cords could result in risk of fire and electric shock If an extension cord must be used make sure a The pins on the plug of the extension cord are the same number b The extension cord is properly wired and in good electrical condit
35. t where the original Cam Ramp was removed Check the engage ment once again If the Roller engagement into the tire is greater than 1 16 then snap off the end of the shorter Cam Ramp using a flathead screwdriver or pliers and check the engagement One of these sizes of Cam Ramp will give you approximately 1 16 of engagement When the correct Cam Ramp size and position is found cut a piece of the Double Sided Tape to match the inside of the Cam Ramp Peel off one side of the tape and adhere it to the inside of the Cam Ramp without touching the tacky sur face see Fig 7 Peel off the other side of the tape and care fully adhere the Cam Ramp to the motor under the Cam butted up against the sil ver Spacer Tube Now recheck all critical dimensions Critical Setup Distance Roller engagement into the tire when the Cam Lever is in the down position 1 16 NOTE f you have a bike with a welded bridge plate you may have to use different holes in the welded bridge plate higher or lower to achieve proper set up Double Sided Tape 7 5 Connecting the Motor to the Controller Attach the motor controller lead with the white dot to the motor lead with the white dot Plug the other motor controller lead into the remaining motor lead the lead without the white dot 6 Connecting Battery Pack Push the battery pack assembly into the battery tray Connect battery power connector to
36. y 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 This war ranty does not extend to repairs made necessary by normal wear or by the use of parts or accessories which are either incompatible with the ZAP Product or adversely affect its operation performance or durability In addition this warranty does not cover items that experience normal wear and tear ZAP reserves the right to change or improve the design of any ZAP Product without assuming any obligation to modify any product previously manufac tured 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 ZAP S OBLIGATION UNDER THIS WARRANTY IS STRICTLY AND EXCLUSIVELY LIMITED TO THE REPAIR OR REPLACE MENT OF DEFECTIVE PARTS AND ZAP DOES NOT ASSUME OR AUTHO RIZE ANYONE TO ASSUME FOR THEM ANY OTHER OBLIGATION SOME STATES DO NOT ALLOW ANY LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LAST SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU ZAP ASSUMES NO RESPONSIBILITY FOR INCIDENTAL CONSEQUENTIAL OR OTHER DAMAGES INCLUDING BUT NOT LIMIT
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