Zap DX manual

Patent #5,491,390 #5,671,821 • Other Patents Pending ZAPWORLD.COM where transportation is going One ZAP Drive •117 Morris Street • Sebastopol California 95472 U.S.A. tel (707) 824-4150 • fax (707) 824-4159 e-mail: zap@zapworld.com • Stock Symbol:ZAPP ©2001 ZAPWORLD.COM. A ll Rights Reserved. ZAP ® is a registered trademark. OWNER’S MA[...]

YOUR INSURANCE POLICIES MAY NOT PROVIDE COVERAGE FOR ACCIDENTS INVOLVING THE USE OF THIS BICYCLE. TO DETERMINE IF COVERAGE IS PROVIDED, YOU SHOULD CONTACT YOUR INSURANCE COMPANY OR AGENT.[...]

STOP STOP BEFORE YOU ZAP YOUR BIKE! IMPORTANT! PLEASE READ CAREFUL LY: SINCE YOUR EXISTING INSURANCE POLICY M AY NOT PROVIDE COVERAGE FOR ELECTRIC BICYCLES, YOU SHOULD CON TACT YOUR INSURANCE COM PANY 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. [...]

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, errands, or simply for fun! Welcome to the world of ZAP electric Bikes! - Is clean, non-polluting and in traffic, faster than your car. - Costs only pennies in electricit y. For fresh air an[...]

3 Table of Contents BEFORE YOU BEGIN ..................................................................................................................................1 INTRODUCTION .......................................................................................................................................2 TABLE OF CONTENTS .............[...]

1 2 3 4 5 6 7 8 10 18 13 11 12 1) ZAP Motor Unit 2) Battery Pack 3) Throttle Switch Assembly 4) Battery Tray 5) Main Power Switch 6) Motor / Controller Leads 7) Controller Power Connector 8) Auxiliary Power / Alternate Charging Jack 9) Worm Drive Clamps 10) Battery Charger 11) 4mm Allen Wrench* 12) Motor Mount Bolts 13) Bridge Mount* 14) Threaded P[...]

SEAT STAYS DOWN TUBE CRANK BATTERY TRAY CHAIN STAYS TOP TUBE SEAT TUBE BATTERY PACK THROTTLE SWITCH Detail of ZAP PowerBike ® MINIMUM FIT DIMENSIONS FOR ZAP POWER SYSTEM (TRAY MODEL) Do not use ZAP System on bikes without metal seat stays!!! 13” 5” -- DX DRIVE SYSTEMS (4.5” - SX DRIVE SYSTEMS) IMPOR TANT! PLEASE NOTE The standard ZAP Power S[...]

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 [...]

7) CONNECTING THE REAR BRAKE CABLE 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 clockw[...]

IMPORTANT! PLEASE READ CAREFUL LY: 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 sugges[...]

• T ake the Bridge Mount and position it on the seat stay bridge, centered and aligned with the seat stays. • Insert one of the motor mount bolts through the bottom hole of the Bridge Mount and finger-tighten it into the bottom hole of the Threaded Plate. MOUNTING MOTOR UNIT • Slide the slot of the Hinge Bracket (attached to the ZAP Motor Uni[...]

Engagement Lever Operation Rider Power Only The engagement cam is in the “up” position, and the motors are off and hang free, just clearing the tire. This mode is for riding when power is not needed and allows the rider to pedal without any drag from the motor. Fig.1 Motor-Assisted After pedaling has initiated, activation of the throttle switch[...]

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 spe[...]

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. 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 re[...]

9. Do not disassemble the charger. The charger is not serviceable; disassembly may result in a risk of electric shock or fire. 10. To reduce the risk of electric shock, unplug the charger from the outlet before attempting any cleaning of the charger. 11. Do not use charger outdoors in wet conditions. 12. Charge in a well-ventilated area away from s[...]

It is a good idea to periodically go through this checklist to make sure that your ZAP Power System and your bike are in proper adjustment for safety and optimal performance. It is imperative that you review this checklist before your first ride. Although your PowerBike ® or ElectriCruizer ® has passed our Quality Assurance proce - dure, things c[...]

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 temperat[...]

16 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. Possible Cause Low tire pressure Insufficient rider input Over-eng[...]

ALW AYS WEAR A HELMET WHEN RIDING Pedals 350 in. lbs. Seat Post Bolt Clamp 75-100 in. lbs. Seat Clamp Single Bolt 120-145 in. lbs. Double Bolt 72-96 in. lbs. Headset Topnut 300 in. lbs. Handlebar Binder Bolt 175-260 in. lbs. Hub Axle Locknut 88-220 in. lbs. Cassette Lockrings 300-440 in. lbs. Front Axle Nuts (wheel mount) 180-240 in. lbs. Rear Axle[...]

ZAPWORLD.COM • One ZAP Drive 117 Morris Street, Sebastopol CA 95472 USA tel (707) 824-4150 fax (707) 824-4159 e-mail: zap@zapworld.com • Stock Symbol:ZAPP ZAP is a Publicly Traded Company ZAPWORLD.COM where transportation is going ©2001 ZAPWORLD.COM. All rights reserved. ZAP ® is a registered trademark.[...]

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 y[...]

FROM : ZAPWORLD.COM One ZAP Drive 117 Morris Street Sebastopol California 95472 USA ATTN: Warranty Department ZERO AIR POLLUTIO N ® PLACE FIRST CLASS POSTAGE HERE ò FOLD HERE ò 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 th[...]