$2.00
REV 5/15/00
OWNER’S MANUAL
DX
ZAP POWER SYSTEM
MADE IN THE USA
Patent #5,491,390 #5,671,821 • Other Patents Pending
ZAPWORLD.COM
where transportation is going
One ZAP Drive •117 Morris Street • Sebastopol California 95472 U.S.A.
tel (707) 824-4150 • fax (707) 824-4159
e-mail: zap@zapworld.com • Stock Symbol:ZAPP
©2001 ZAPWORLD.COM. All Rights Reserved. ZAP®is a registered trademark.
YOUR INSURANCE POLICIES
MAY NOT PROVIDE COVERAGE
FOR ACCIDENTS INVOLVING
THE USE OF THIS BICYCLE.
TO DETERMINE IF COVERAGE
IS PROVIDED, YOU SHOULD
CONTACT YOUR INSURANCE
COMPANY OR AGENT.
STOP
YOU ZAP
SINCE YOUR EXISTING INSURANCE POLICY MAY NOT PROVIDE COVERAGE FOR ELECTRIC
BICYCLES, YOU SHOULD CONTACT YOUR INSURANCE COMPANY OR INSURANCE AGENT TO
-
FILL OUT THE FORM ON THE
BACK. YOU MUST MAIL THE WARRANTY FORM WITHIN 10 DAYS OF RECEIVING YOUR ZAP
STOP
BEFORE
YOUR BIKE!
IMPORTANT! PLEASE READ CAREFULLY:
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
POWER SYSTEM IN ORDER TO ACTIVATE THE WARRANTY.
1
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
We have designed our electric bicycle system for
Keep in mind that improper installation 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
Our Customer Service department is available
between 9:00 a.m. and 4:30 p.m. PST, Monday
to help you with any
problems that may occur. You can also e-mail your
customer service questions 24 hours a day, seven
Once again, thank you for purchasing a ZAP. Our
hope is that you will like it so much, it will become your
Introduction
ongratulations on your purchase of a ZAP
Electric Bike or Power System. In the coming years you will find many ways to use
your ZAP — commuting, exercise, errands,
C
Welcome to the world of ZAP electric Bikes!
ment in transportation. A ZAP Electric Bike is appropriate technology for many of the problems that face
our society today and in the years to come. Since virtually all of the world’s one billion bicycles are upgradable with a ZAP, it is truly an invention that can change
or simply for fun!
- Is clean, non-polluting and in
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-
this in one small, elegant ZAP bicycle system.
simple, easy installation and operation.
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 convenience 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.
you avoid frustration in the future.
through Friday at (707) 824-4150
days a week to: zap@zapworld.com.
favorite mode of transportation.
2
Table of Contents
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...................................................6-7
....................................................................................................................8-9
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BEFORE YOU BEGIN
INTRODUCTION
TABLE OF CONTENTS
DESCRIPTION OF SYSTEM
DETAIL OF ZAP POWERBIKE
RE-ASSEMBLY INSTRUCTIONS (FOR PRE-ASSEMBLED ELECTRICRUIZERS®)
EASY INSTALLATION GUIDE
ENGAGEMENT LEVER OPERATION
OPERATION MANUAL & CHARGING GUIDE
SAFETY WARNINGS
PRE-RIDE CHECKLIST
BATTERY CARE
TROUBLESHOOTING GUIDE
TORQUE RATINGS
WARRANTY FORM
3
Description of System
NOTE: The items referred to on this page are important when installing your ZAP.
Use this page as a reference guide.
10
2
21
11
12
13
7
8
6
20
14
18
19
15
16
5
17
3
4
9
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
1
11) 4mm Allen Wrench*
12) Motor Mount Bolts
13) Bridge Mount*
14) Threaded Plate
15) Cam Ramp
16) Double-Sided Tape
17) Cam Lever
18) Hinge Bracket
19) Spacer Tube
9) Worm Drive Clamps
10) Battery Charger
*not included in ZAP factory bikes with a welded bridge plate
4
20) Zip Ties
21) Battery Power Connector
Detail of ZAP PowerBike
The standard ZAP Power System
®
SEAT STAY
BRIDGE
SEAT
STAYS
SEAT
TUBE
BATTERY
PACK
DOWN
TUBE
THROTTLE
SWITCH
ZAP MOTOR
UNIT
MINIMUM FIT DIMENSIONS FOR ZAP POWER SYSTEM (TRAY MODEL)
Do not use ZAP System on bikes without metal seat stays!!!
TOP TUBE
13”
CHAIN
STAYS
5” -- DX DRIVE SYSTEMS
CRANK BATTERY
(4.5” - SX DRIVE SYSTEMS)
TRAY
“MONOSTAY”
SEAT STAYS
REAR WHEEL
IMPORTANT! PLEASE NOTE
will not fit on a monostay bike.
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