2010
Owner and Operator’s Manual
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100 % ELECTRIC RANCH-HAND ATV
IMPORTANT!
BEFORE YOU OPERATE YOUR DUDETM 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 specications 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
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We know you want to start riding right away, but it is critically important to….
ATV Start-Up Procedure
Step 1: 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 or R 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.
READ THESE IMPORTANT FIRST STEPS
BEFORE EVEN THINKING OF RIDING!
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TABLE OF CONTENTS
Chapter 1
General Information
1. Overall dimensions............................................4
2. Table of performance, structure
and specication for entire truck..................5
3. Vehicle marking..................................................9
Chapter 2
Safety and Important Notes
1. Non-permissible to ret..................................9
2. Inspection of new vehicle................................9
3. Vehicle maintenance..........................................9
4. Vehicle load......................................................10
5. Inspection of tire and tire pressure............10
6. Usage of lubricants and uid for
vehicle................................................................10
7. Proper usage of safety belt...........................10
Chapter 3
Introduction of Devices
and Control Mechanism
1. Position of switches and
control levers in the cabin.............................11
2. Keys, doors and windows..............................17
3. Seats...................................................................18
4. Back gate and side gates of truck bed ........18
5. Safety belts........................................................19
6. Other Devices.................................................21
Chapter 4
Driving Suggestions
1. Driving operation...................................................24
2. Normal driving suggestions .................................24
3. Economical driving suggestions ..........................25
4. Suggestion on slippery road driving...................25
5. Suggestion on parking brake................................25
Chapter 5
Emergency Conditions
1. Vehicle refuses to start..........................................26
2. Vehicle stops running.............................................26
3. Braking trouble.......................................................26
4. Steering trouble......................................................26
5. Light changing..........................................................26
6. Deated tires..........................................................27
7. Emergency towing..................................................29
8. Anchoring.................................................................29
Chapter 6
Service and Maintenance
1. Cleaning and maintenance....................................30
2. Routine maintenance.............................................31
3. Regular maintenance..............................................31
4. Requirement for regular maintenance..............34
Chapter 7
Solutions for Malfunctions
1. Rear axle malfunction..............................................38
2. Steering, suspension, wheel and tire....................39
3. Braking malfunctions...............................................44
4. Malfunctions of power system..............................46
5. Malfunctions of on-board charger........................46
6. Malfunctions of electric controlling system.......47
7.Malfunctions of lights, instruments,
switches and indicating lights.................................48
Chapter 8
Oil Fluid for Vehicle
And Electric Theory Fig
of Complete Vehicle
1. Specication and capacity of lubricant,
lubricant grease and braking uid.........................54
2. Electric Theory Fig of Complete Vehicle............54
ZAP Registration Card...................................55
TBD
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General Information
1. Overall Dimensions
Fig 1: ATV Controls
1. Lights
2. Horn
3. Drive
4. Power
5. Reverse
6. State of Charge
7. Key
8. Throttle
9. Cut-Out Power Button
8
5
4
6
2
1
7
3
9
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Fig 2: ATV Controls Cont.
1. 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)
1
4
5
6
2
3
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GETTING TO KNOW YOUR NEW ATV
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.
Should you experience a problem with your
vehicle, please call ZAP customer service line
800- 251-4555 between the 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 OF THE SALES RECEIPT IS REQUIRED.
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 contained in this owner’s manual and the labels
on your vehicle. Failure to follow these warning can result in SEVERE INJURY OR DEATH.
Keep the owner’s manual with your vehicle at
all times.
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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 difcult 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
alcohol or drugs can be hazardous.
Alcohol and drugs could seriously affect
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
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
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.
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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
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
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 certied
instructor. Contact an authorized ZAP ATV
dealer or call SVIA at 1-800-887-2887 to nd
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
ts properly. You should also wear eye
protection (goggles or face shield), gloves,
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conditions when operating the ATV.
• Never operate on excessively rough,
slippery or loose terrain until you have
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
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 owing
water or in water deeper than that
specied in this manual. Remember that
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
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
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