Kawasaki ZX-7 User Manual

Kawasaki®ZX-7

Owner’s Manual with Assembly Instructions

Please read this manual and save it with your original sale’s receipt.

For Model 78410

Tools needed for assembly: Phillips Screwdriver, Slotted Screwdriver, Hammer, Safety Scissors.

Use only with Power Wheels

Type H Battery, Power Wheels®25 Amp Fuse and

Power Wheels®Type H 6 Volt Charger (all included).

CAUTION

ELECTRIC TOY: Not recommended for children under 11/2years of age.

As with all electric products, precautions should be observed during

handling and use to prevent electric shock.

WARNING

• Children can be harmed by small parts, sharp edges and sharp points in the vehicle’s unassembled state, or by electrical items. Care should be taken in unpacking and assembly of the vehicle. Children should not handle the battery or other parts, or help in assembly.

• Keep small parts and plastic bags out of children’s reach. Dispose of plastic bags properly.

• Adult supervision is required. Children do not have the judgement necessary to avoid many accidents. Be sure that children operating this vehicle can do so safely and that they are supervised at all times.

• Improper use of this vehicle could lead to a serious or fatal accident. Allow children to play with the Kawasaki

ZX-7 only when you have determined that they can do so safely. Follow

all instructions to help your child enjoy this vehicle as safely as possible.

• Never use on or dangerously close to steps, inclines greater than 10˚, roadways, bodies of water, low obstructions or in the dark.

• Always wear shoes or sneakers when operating this vehicle.

• Never allow more than one rider.

• The rider should sit on the seat when the vehicle is in motion.

• Observe the maximum weight limit of 50 lbs.

• Never alter this vehicle or its electrical system in any way. Alterations could cause a fire resulting in injury and could also ruin the electrical system.

• Use of the wrong type battery, fuse or charger could cause a fire or explosion, resulting in serious injury.

• Never add unauthorized parts to the vehicle or use substitute parts. Use only specified Power Wheels

replacement parts.

• The battery must be handled by adults only.

• Never lift or carry the battery by the wires or connector. This can damage the battery and possibly cause a fire. Lift and carry the battery by the case only.

• Never permit a child to handle the battery. The battery is heavy and contains sulfuric acid (electrolyte), and if dropped, could result in serious injury. Read the cautions on the back panel of the battery.

• Never allow children to charge the battery. Battery charging must be done by adults only. A child could be injured by the electricity involved in charging the battery.

• Examine the battery, charger and their connectors for excessive wear or damage each time you charge the battery. If damage or excessive wear is detected, do not use the vehicle until you have replaced the worn or damaged part.

Throughout this manual you will find important messages in the form of WARNINGS, CAUTIONS, and NOTES.

WARNING

WARNING – SIGNALS SOMETHING THAT

COULD HURT YOUR CHILD OR YOU.

The message explains the hazard and

how you can avoid it.

CAUTION

• Do not operate the vehicle for the first time until you have inserted the 25 amp fuse into the battery and charged the battery for at least 18 hours. Never charge the battery longer than 30 hours.

• After first-time use, recharge the battery for at least 18 hours after each use. Never charge the battery longer than 30 hours.

• Use the charger indoors only.

• Read and follow the Battery Care instructions on page 26. Failure to follow the Battery Care instructions may permanently damage your battery and will void your warranty.

• To avoid damaging the motor and gears, do not overload the vehicle.

- Never allow more than one child on the vehicle at one time.

- Do not exceed the maximum weight capacity of 50 lbs.

- Do not tow anything behind the Kawasaki

ZX-7. The extra weight may overload

the vehicle.

• Avoid operating the vehicle in wet or snowy conditions, and do not spray the vehicle with a hose. Do not wash the vehicle with soap and water. Water or moisture in the motor or electrical switches can cause them to corrode, and could cause switch failure.

• Avoid operating the vehicle on grass, sand, loose dirt or gravel. Sand, loose dirt and gravel in the electrical switches or motor can cause them to jam, and could cause switch failure. Use the Kawasaki

ZX-7 on asphalt, cement or other hard surfaces.

CAUTION

CAUTION – SIGNALS SOMETHING THAT

COULD DAMAGE THE VEHICLE.

The message explains the risk and

how you can avoid it.

NOTE – Is used to highlight useful information.

Table of Contents

A Message to Parents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

B Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

C Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

D Parts Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

E Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

F First-Time Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

G Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

H Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

I Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

J Battery Handling/Care/Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

K Rules for Safe Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

L How to Operate Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

M Questions and Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

N Problems and Solutions Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

O Statement of Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

P Authorized Service Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Message to Parents

Thank you for purchasing the Power Wheels

Kawasaki®ZX-7! For over 30 years, Power Wheels

has manufactured high-quality, battery-powered vehicles for children. Our goal is to provide your child with an enjoyable and safe driving experience. To help achieve this goal, it is extremely important that you read this entire manual and share the appropriate information with your child.

The Kawasaki

ZX-7 requires adult assembly. Please

set aside at least 30 minutes for assembly. Read the assembly instructions carefully and identify all parts before assembly. Refer to the Parts Section beginning on page 6 for parts identification. Save all packaging material until assembly is complete to ensure that no parts are discarded.

In the unlikely event that parts are missing or damaged or if you have any questions about your Power Wheels

vehicle, please call our Consumer Affairs toll-free service lines, open from 8 AM to 6 PM (EST) Monday through Friday.

Please call us at 1-800-348-0751.

Trained customer service representatives are available to take your call in English or French.

¿Habla Español? Si usted tiene alguna pregunta ó necesita asistencia llame gratis 1-800-348-0755 para los Estados Unidos. Tenemos representantes que hablan español para atender su llamada. Este manual tambien disponsible en Espanol.

We also have a nationwide Authorized Service Center network – with over 300 Authorized Service Centers. Our Authorized Service Centers will repair or replace parts under warranty at no charge. For vehicles beyond warranty, our Authorized Service Centers will perform repairs for a minimal charge. For the Authorized Service Center nearest you, please see the Authorized Service Center listing beginning on page 35.

Important Information

• Carefully read this manual for important safety information and operating instructions before using your vehicle.

• Please complete and return the enclosed Vehicle Registration Card, or call 1-800-348-0751 to register your vehicle by phone.

• The Kawasaki®ZX-7 is designed for use by children 11/2 - 4 years.

• Adult assembly is required.

• This vehicle uses a Power Wheels®Type H battery with a Power Wheels®25 amp fuse and a Power Wheels®Type H 6 volt charger (120 VAC 60 HZ 28W with an output of 6 VDC 1200 mA). Do not substitute any other battery, fuse or charger.

• Before first-time use, charge the battery for at

least 18 hours. Never charge the battery longer than 30 hours.

• After the first charge, charge the battery a minimum of 18 hours after each use. Never charge the battery longer than 30 hours.

• Do not run down the battery completely before charging.

• Leaving the battery in a discharged condition will ruin it.

• Charge the battery before storing your vehicle.

• Charge the battery at least once per month, even if the vehicle has not been used.

• Do not store the battery in temperatures above 75˚ F or below -10˚ F.

• Even with proper care, the battery will not last forever. The life of the battery depends on how well you follow the Battery Care instructions and the total number of hours the battery is used. Please refer to the Battery Handling/Care/Disposal instructions on page 26 for detailed information about battery care.

• To purchase a Power Wheels®Type H battery, Power Wheels®25 amp fuse or a Power Wheels®Type H 6 volt charger, please contact:

- the store where your vehicle was purchased.

- an Authorized Service Center (see Authorized

Service Center list beginning on page 35).

- Power Wheels®Consumer Affairs at 1-800-348-0751.

• While the battery is charging, the charger may become warm to the touch. This is normal, and does not indicate a problem.

• The Kawasaki®ZX-7 is suitable for use on asphalt, cement or other hard surfaces. To prevent damage to the motor and switches, do not operate the vehicle on loose dirt, gravel or sand.

• The Kawasaki®ZX-7 is not designed for use on grass or hills. For best traction, use only on asphalt, cement, or other flat, hard surfaces.

• To prevent damage to electrical components, store the Kawasaki®ZX-7 inside or under a protective cover during snowy or rainy weather. Do not leave the Kawasaki®ZX-7 out in the rain or let your child wash it with soap and water.

• The Kawasaki®ZX-7 has a special circuit-breaker in the wiring to protect the motor and electrical system. If the vehicle is put under extreme load (driving on rough surfaces, too much weight, climbing too steep of an incline), the circuit-breaker will shut the electrical system down for up to 20 seconds. If the system repeatedly shuts down, the driving conditions may be too demanding (ie: too steep or too much weight).

• Metal parts have been coated with a lubricant to protect them during shipment. Wipe all metal parts with a paper towel to remove any excess lubricant.

Parts

Not Shown:

Literature Bag

6-V

Small Parts Bag

Hubcap – 2

Battery Retainer

If you experience a problem with this product, or are missing a part, please call us at

1-800-348-0751, rather than return this product to the store.

Please save all packaging material until assembly is complete to ensure that no parts are discarded.

Dashboard

Microphone

Windshield

Shock Set – 1

Headlight Lens Set

Fender

Hand Grips – 2

6 Volt Charger

Wheel Bushing – 2

#6 x 3/8" Screw – 2

#8 x7/8" Screw

Cap Nut – 3*

#8 x 11/2" Screw – 4

25 Amp Fuse –2*

Radio Knob – 2

Fairing

Not Shown: Label Sheets

6 Volt Battery

Left Handlebar

Parts

Gas Cap

#8 x3/4" Screw – 4

All Screws Shown

Actual Size

Vehicle Body

Seat

Front Axle

Right Handlebar

Front Wheel

*For your convenience, an extra 25 amp fuse

and cap nut have been included.

Key Assembly

Handlebar Plug – 2

Parts Diagram

FOR MODEL 78410

6 VOLT

Kawasaki®ZX-7

CHARGER

ASSEMBLY A

MOTOR/GEARBOX ASSEMBLY

SEE ASSEMBLY A

Parts List

Item

No. Description Part No. Qty.

1 Battery 80008-0110 1 2 25 amp Fuse 80014-0070 1

3 Wheel Driver Screw 80006-0017 1 4 Foot Switch 80014-0022 1 5 Motor/Gearbox Assembly 74780-0640 1 6 Wiring Harness 80064-0083 1 7 Driver 80001-0247 1

8 Windshield 80063-0068 1 9 Lens Cover Set 80030-0074 1

10 .354 Retainer w/Body 80047-0104 2 11

/16" Washer 80061-0039 2

12 1

/2" Screw 80006-0175 5

13 Handgrip 80028-0016 2 14 Right Handlebar 80029-0020 1 15 Shock Set 80001-0435 1 16 Front Axle 80025-0027 1

17 .437 Retainer w/Body 80047-0106 4

18 Front Hubcap 80033-0077 2

19 Wheel Spacer 80009-0060 5

20 Front Wheel 80062-0036 1

21 Footboard Cover 80023-0033 1 22 Foot Pedal w/Spring Clip 80041-0004 1 23 Rear Wheel 80062-0047 2 24 Rear Hubcap 80033-0076 2 25 Motor Cover 80039-0052 1 26 Rear Axle 80046-0090 1 27 Axle Spacer Tube 80052-0012 1

28 Body 80005-0340 1

29 Trunk Lid 80001-0511 1

30 Battery Retainer 80047-0022 1

/8" Screw 80006-0173 1

32 Seat 80067-0064 1 33 Gas Cap 80001-0512 1

34 Pivot Pin 80006-0027 1

35 Left Handlebar 80029-0041 1 36 Key Housing 80001-0281 1 37 Fairing 80063-0122 1 38 Microphone 80038-0009 1

/8” Screw 80006-0171 2

40 Dash 80016-0047 1

41 Swivel Bracket 80007-0005 1 42

/4" Screw 80006-0172 4

43 Fender 80022-0065 1

44 Motor 80039-0043 1 45 Drive Gear Metal 80026-0098 1 46 Gearbox 80026-0056 1 47 Lock Fastener 80001-0622 1 48 Motor Bolt 80006-0052 2 49 Flex Plate 80001-0305 1 50 Rectangular Wheel Bushing 80009-0052 2 51 1" Screw 80006-0032 1

52 Radio Knobs 80045-0025 2

Parts Not Shown

#6 - 20 x 1" Screw for

Swivel Bracket 80006-0034 1

/4" Screw for Flex Plate 80006-0022 2

Handlebar Plugs 80047-0026 2

Literature Bag 80034-0772 1 Adhesive Harness Clip 80023-0088 1 Main Decal Sheet 80017-0458 1 Paper Decal Sheet 80017-0457 1 Headlight Decal Sheet 78410-0300 1

Note: The parts listed below are not all consumer assembled. Consumer assembled parts are shown on pages 6 and 7 and are highlighted in bold type below.

First-Time Battery Charging

WARNING

• The battery must be handled by adults only.

• Never allow children to charge the battery. Battery charging must be done by adults only. A child could be injured by the electricity involved in charging the battery.

• Use of the wrong type battery, fuse or charger could cause a fire or explosion, resulting in serious injury.

• Never lift or carry the battery by the wires or connector. This can damage the battery and possibly cause a fire. Lift and carry the battery by the case only.

• Examine the battery, charger and their connectors for excessive wear or damage each time you charge the battery. If damage or excessive wear is detected, do not use the charger or the vehicle until you have replaced the worn or damaged part.

• Never alter this vehicle or its electrical system in any way. Alterations could cause a fire resulting in injury and could also ruin the electrical system.

• Never add unauthorized parts to the vehicle or use substitute parts. Use only specified Power Wheels

replacement parts.

CAUTION

• Do not operate the vehicle for the first time until you have inserted a 25 amp fuse into the battery and charged the battery for at least 18 hours. Never charge the battery longer than 30 hours.

• Read and follow the Battery Care instructions on page 26. Failure to follow the Battery Care instructions may permanently damage your battery and may void your warranty.

• Use the charger indoors only.

We recommend that you begin charging your battery before beginning assembly of your vehicle. Your new battery must be charged for at least 18 hours before using your vehicle for

the first time.

• Squeeze the Lock-In

connector tabs on the charger connector and plug it into the battery connector.

• Plug the charger into a standard 120 volt wall outlet.

Note: If power flow to the wall outlet is controlled by a switch, make sure the switch is “ON”.

• Before first time use, charge the

battery for at least 18 hours. Never charge the battery longer than 30 hours.

Note: The battery must be upright while charging.

Battery Connector

Charger Connector

Lock-In

Connector Tabs

First-Time Battery Charging

• Insert the 25 amp fuse into the battery.

Fuse

Charger

Assembly

Do Not Omit Any Steps. Please set aside at least 30 minutes for assembly.

• Position a handlebar plug against the top end of a handlebar.

• Moisten a hand grip with warm water.

• Slide the hand grip onto the end of the handlebar.

• Repeat this procedure to attach the other handlebar plug and handgrip to the other handlebar.

• Stand the vehicle body on its rear wheels.

• Slide the left handlebar through the holes in the left side of the swivel bracket.

Please Note: The left handlebar is marked “L”; the right handlebar is marked “R”.

Handlebar Plug

WARNING

• Keep small parts and plastic bags out of children’s reach. Dispose of plastic bags properly.

Hand Grip

Swivel Bracket

Left Handlebar

+ 26 hidden pages