ZAP Dude 2010 Owner's And Operator's Manual

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2010

Owner and Operator’s Manual

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 specications 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.

501 Fourth Street, Santa Rosa, CA 95401 USA

www.zapworld.com

Stock Symbol: ZAAP

1(800)251-4555

2010

Owner and Operator’s Manual

100 % ELECTRIC RANCH-HAND ATV

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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Owner and Operator’s Manual

100 % ELECTRIC RANCH-HAND ATV

TABLE OF CONTENTS

Chapter 1 General Information

1. Overall dimensions............................................4

2. Table of performance, structure

and specication for entire truck..................5

3. Vehicle marking..................................................9

Chapter 2 Safety and Important Notes

1. Non-permissible to ret..................................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. Deated 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. Specication 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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Owner and Operator’s Manual

100 % ELECTRIC RANCH-HAND ATV

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

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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)

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Owner and Operator’s Manual

100 % ELECTRIC RANCH-HAND ATV

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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Owner and Operator’s Manual

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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 difcult 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 certied

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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Owner and Operator’s Manual

100 % ELECTRIC RANCH-HAND ATV

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

specied 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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Owner and Operator’s Manual

100 % ELECTRIC RANCH-HAND ATV

wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings.

• Always use the size and type tires specied in this manual. Always maintain

proper tire pressure as described in this manual. Never modify an ATV through improper installation or use of accessories.

• Never exceed the stated load capacity

for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo. Allow greater distance for braking.

• The combined weight of the rider and any

accessories or cargo must never exceed the vehicle’s load capacity of 285 lbs.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product

Safety Commission at 1-800-638-2772, SVIA

obtain, review, and follow all provincial and municipal government acts and regulations pertaining to owning and operating an offroad vehicle.

INSPECTION BEFORE RIDING

Failing to inspect the ATV before operating could be hazardous. Failing to perform proper maintenance could also be hazardous. Failing to inspect and maintain your ATV could increase the chances of an accident or equipment damage. Always inspect your ATV each time before riding, and make sure it is in a safe operating condition. Refer to the INSPECTION AND MAINTENANCE section in this manual.

ITEMS TO CHECK

Steering Smoothness; No restriction of movement; No play or looseness. Brakes Proper brake lever free play; enough brake force; Hand brake effectiveness. Proper tire air pressure; Enough tread depth; No cracks, rips, or other damages. Overloading could be

1-800-887-2877, or ZAP Safety Hotline at1-800-251-4555

Beginning and inexperienced operators

should complete the certied training course

offered by SVIA (www.svia.org). They should then regularly practice the skills learned in the course and the operating techniques described in the owner’s manual. For more information about the training course, contact an authorized ZAP ATV dealer or call SVIA at 1-800-887-2887.

Make sure that it is legal to ride in the area you selected. Review the local laws and make sure you are not trespassing. Call the police if you do not know where you can ride. Protect your riding areas. Do not destroy plants, trees or other vegetation. Do not litter and do not bother wildlife.

After you have found a good place to practice, review the control system on

your ATV before riding. Learn to nd these

controls without looking for them, because you will not have time to look for them when you are riding. Canadian residents must

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Owner and Operator’s Manual

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General Information

hazardous. Overloading could cause changes in vehicle handling and could lead to an accident.

Never exceed the stated load capacity for this ATV. Refer to the ACCESSORY USE AND VEHICLE LOADING section in this manual.

WARNING

Operating this ATV with improper

modications could be hazardous. Improper installation of accessories or

modications to this vehicle may cause

changes in handling. In some situations, this could lead to an accident.

Never modify this ATV through improper installation or use of accessories. Refer to the ACCESSORY USE AND LOADING section in this manual.

WARNING

Operating this ATV with improper tires,

or improper tire air pressure could be hazardous. If you use improper tires or

operate this ATV on any public street, road or highway. In many states is it actually illegal to operate ATVs on public streets, roads and highways.

We recommend that you do not drive this ATV at night.

Although the ZAP Dude is equipped with headlights, it is recommended you restrict

your use to daylight hours. Night is dened as

the period of time 30 minutes before sunset to 30 minutes after sunrise.

SAFETY GEAR

A DOT approved motorcycle helmet is the most important part of your safety gear. A DOT approved motorcycle helmet can help prevent a serious head injury. Choose

a helmet that ts snugly. Motorcycle dealers

can help in selecting a good quality

helmet which ts properly. You should wear

eye protection when you ride. If a rock or a branch hits your eyes, you could be severely injured. Wear goggles or a face shield. Wear proper clothing when you ride. Proper clothes can protect you from injury. Wear a

improper air pressure, you may lose control of the ATV. This will cause an accident.

Always use tires with the same size

and type specied in this user’s manual.

Always maintain proper tire air pressure as described in the INSPECTION AND MAINTENANCE section.

Make sure batteries are fully charged for the intended trip or planned usage;

Never carry a passenger. The long seat is to allow the operator to shift position as needed during operation. It is not for carrying passenger.

Carrying a passenger on this ATV.

Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passenger.

Operating this ATV on public streets, roads or highways is prohibited.

You may collide with another vehicle. Never

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Owner and Operator’s Manual

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good pair of gloves, strong boots that are over the ankle, long pants, and a long sleeve shirt.

Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident. Operating without protective clothing increases your chances of severe injury in the event of an accident.

Always wear an approved motorcycle helmet

that ts properly. You should also wear:

•eye protection (goggles or face shield)

•gloves

•boots

•long-sleeved shirt or jacket

•long pants

Operating this ATV after consuming alcohol or drugs.

•Could seriously affect your judgment.

•Could cause you to react more slowly.

WARNING

Removing hands from handlebars or

feet from the footrests during operation. Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV. If you remove a foot from the footrest, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident. Always keep both hands on the handlebars and both feet on the foot rests of your ATV during operation.

Use extra care when operating this ATV on unfamiliar terrain.

You can come upon hidden rocks, bumps, or holes without enough time to react. Could result in the ATV overturning or going out of control. Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.

•Could affect your balance and perception.

•Could result in an accident.

Never consume alcohol or drugs before or while driving this ATV.

Operating this ATV at excessive speeds.

Increases your chances of losing control of the ATV, which can result in an accident. Always go at a speed that is proper for the terrain, visibility and operating conditions, and your experience.

Attempting wheelies, jumps, and other stunts increases the chance of an accident, including an overturn.

Failure to inspect the ATV before operating.

Failure to properly maintain the ATV increases the possibility of an accident or equipment damage. Always inspect your ATV each time you us it to make sure the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the owner’s manual.

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Owner and Operator’s Manual

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inside wheel, allowing it to skid. This allows it to travel a shorter distance than the outside wheel. This happens even though both wheels are still turning at the same speed.

FOR HIGHER SPEEDS OR SHARPER TURNS

Use the same technique that you use when you move your body weight farther toward the inside of the turn to maintain your balance. Natural turning forces (which can push the vehicle to the outside of the turn) increase as the speed or the turn sharpness increases. This means you must lean your body farther into the turn as you go faster or turn more sharply. This prevents the vehicle from tipping over to the outside of the turn. If your ATV starts to tip while turning, lean your body farther into the turn while gradually reducing the throttle and making the turn wider, if possible.

To turn ATV, use the following technique:

• Move your body weight forward and to

the inside of the turn.

moving could be hazardous. The front wheels could lock causing a skid and an accident. Apply parking brake only after ATV has come to a complete stop.

WARNING

Turning improperly. ATV could go

out of control, causing a collision or overturn. Always follow proper procedures for turning as described in the owner’s manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed.

To turn the ATV, the rider must use the proper technique. Because this vehicle has a solid rear axle, both rear wheels always turn at the same speed. This means that if the rear wheels are getting equal traction, the vehicle will tend to move straight ahead. This is because the rear wheels will travel the same distance. For the vehicle to turn, the outside rear wheel must travel a longer distance that the inside rear wheel. To make this happen, the rider must create less traction for the

STARTING THE MOTOR

Before attempting to start the motor, make sure you are completely familiar with all operational aspects of this ATV.

Activating the throttle suddenly could be hazardous. The front wheels could leave the ground and cause loss of control of the ATV. Always open the throttle gradually when accelerating

Braking while turning the ATV could be hazardous. Use of the brake when turning could cause the ATV to slide or roll over. Use the brake to slow down before you begin to turn.

Braking hard on slippery surfaces could be hazardous.

The ATV could skid and go out of control if you brake too hard.

Apply the brakes lightly and carefully on slippery surfaces Operating the parking brake when the ATV is

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• Turn the handlebar while looking in the

direction of the turn.

FOR HIGHER SPEEDS OR SHARPER TURNS

Operating on Hills - Operating on excessively steep hills.

The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills. Never operate the ATV on hills too steep for the ATV or

for your abilities. Practice on smaller hills before attempting larger hills. Climbing hills improperly could cause loss of control or cause ATV to overturn. Always follow the proper procedures for climbing hills as described in this owner’s manual. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces.

Shift your weight forward. Never open the throttle suddenly or make sudden gear

changes. The ATV could ip over backwards.

Never go over the top of any hill at a high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.

To climb a hill with the ATV, follow these directions:

1. Speed up and maintain a steady speed before reaching the top of the hill. Remember that you must ride at a steady speed all the way to the top of the hill.

2. Shift your body forward by sliding forward on the seat. Lean slightly forward. For steep

hills, stand on thefootrests and lean forward.

3. Maintain a steady speed while climbing the hill.

4. Slow down gradually when you reach the top of the hill.

WARNING

Going down a hill improperly could

cause loss of control or cause ATV to overturn. Always follow proper procedures for going down hills as described in the owners manual.

NOTE:

A special technique is required when

braking as you go down a hill. Always 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.

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regain traction unexpectedly, which may cause the ATV to overturn. 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.

SKIDDING OR SLIDING

You may experience skidding or sliding when you are not braking. You may be able to overcome it by using the techniques listed below. If your front wheel skids, gain front wheel traction by reducing the throttle opening and leaning your body slightly forward.

If your rear wheel skids:

If space permits, steer in the direction of the skid. Shift your body away from the skid slightly. Avoid using the throttle or brakes until you regain directional control of the vehicle.

in a new area, check for obstacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described in the owner’s manual.

If you come to an obstacle that you cannot avoid, you may be able to cross over it by using the following procedure.

1. If the obstacle is in front of you, approach at walking speed.

2. Rise up slightly on the footrests.

3. Pull up on the handlebar and apply a little throttle as the front wheels reach the obstacle.

4. Lean forward and release the throttle after the front wheels are over the obstacle.

Remember that some obstacles are too high for your ATV or for your abilities. If you are not sure that you can safely cross over an obstacle, back up and ride around the obstacle.

Skidding or sliding improperly could results in loss of control of this ATV. You may also

To ride down a hill with the ATV, follow the instructions below.

1. Check the terrain carefully for any obstacles before you go down the hill.

2. Point the ATV straight down the hill.

3. Transfer your body to the rear by sliding back on the seat.

4. Ride down the hill slowly with the throttle released.

5. Apply the brake to control the speed.

6. Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side. Go straight down the hill if possible.

Improperly crossing hills or turning on hills could cause loss of control or cause ATV to overturn. Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the owner’s manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill.

Improperly operating over obstacles could cause loss of control or a collision. Could cause the ATV to overturn. Before operating

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RIDING THROUGH WATER

You can ride the ATV through shallow water. Make sure it is not more than 4 inches deep and is not moving fast. Choose a good place to cross before you ride through the water. Look for a spot where the banks are gently sloped on both sides and the bottom of the stream is hard. If you are unfamiliar with the area, park the ATV and inspect the stream

rst to nd a suitable spot for crossing. When

crossing, operate the ATV at a slow, steady speed. Be careful not to amage banks when crossing.

Operating the ATV in water, sand, or mud causes rapid brake wear. Excessive brake wear could cause the brakes to be less effective. After repeated operation of the ATV in these conditions, bring it to your authorized service center to have the brakes inspected and cleaned.

RIDING IN COLD WEATHER

Pre-ride Inspection

Check that the throttle and all control levers

move freely. Make sure that the footrests are free of ice or snow.

Move the ATV forward and backward to check that the wheels roll freely. If you cannot move the ATV, the tires may be frozen to the ground, or the brakes may be frozen to the wheels. If the tires are frozen to the ground, pour warm water around them to melt the ice. If the brakes are frozen, bring the ATV to a warmer area to thaw out the brakes. After the motor has been started, check the brakes. Do this inspection on level ground and do not exceed the walking speed. Be sure to check the operation of both front and rear brakes. If the brakes do not work adequately, stop riding the ATV. Bring the ATV to a warmer area to allow the brakes to thaw out. After the brakes thaw, dry them by applying them several times before riding. If the brakes do not regain full stopping power, ask your authorized service center to check them before you continue riding your ATV. Water that enters the brakes may freeze after you park your ATV. The frozen water can prevent wheels from turning or the brakes from working. After riding through

water, mud, snow or slush, it is important to dry the brakes before parking the ATV. To dry the brakes, apply them several times while riding slowly. Before your next ride, be sure to do a Pre-ride inspection as described earlier in this section.

WARNING

Operating the ATV without a properly functioning brake system could be hazardous. Wet or frozen brakes will increase stopping distance. This will increase your chance of having an accident. Be sure to inspect the brakes before riding the vehicle in cold weather as described above.

CAUTION

Using motor power to free up frozen

wheels could damage your ATV. Severe damage to the drive train may occur if you use motor power to free frozen wheels. Before riding, manually move the ATV forward and backward to make certain that all wheels roll freely.

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fall into the cold water. Check with local authorities to verify the thickness of the ice and areas to avoid.

WARNING

Failing to use extra care when operating

on slippery surfaces such as hard-packed snow and ice could be hazardous. Failing to use extra care could cause loss of traction or loss of vehicle control. This could result in an accident, including an overturn. Do not operate on slippery surfaces until you have learned and practiced the skills necessary to control the ATV on such terrain. Always use extra care on slippery surfaces. Avoid riding on snow or ice covered hills whenever possible.

Practice riding your ATV in an open snow or ice covered area, at slow speeds, before heading out on snow- or ice-covered trails. Learn how your ATV responds to steering and braking on the type of terrain you will encounter on your ride. Your eyes may be sensitive to

that if you do any cold-weather riding, that you familiarize yourself with the symptoms, treatment, and prevention of hypothermia. Information is available at libraries and through government agencies. Plan your winter rides with safety and comfort in mind. Dress for the worst conditions you might encounter. Be prepared for bad weather and ATV breakdowns. Wear warm, waterresistant clothing such as thermal underwear, snowmobile suits, lined gloves, lined boots, and wool socks.

Riding on snow-covered terrain, even with care, could be hazardous. Snow may cover rocks, holes, ice or other hazards that can cause loss of control. Severe injury or death could occur if you lose control of the ATV. Go slowly and be careful when riding on snow-covered terrain. Always be alert to changing terrain conditions.

WARNING

Riding on a frozen lake or river could be

hazardous. Serious injury or death could occur if the ice breaks and you could

Operating your ATV in cold weather without proper clothing could be hazardous. Continued exposure in the cold weather could lead to Hypothermia.

Hypothermia is a condition where your body’s inner temperature drops low enough to cause injury or death. Always dress for the worst weather conditions you might encounter. Be prepared for bad weather and ATV breakdowns

Riding in cold weather can be hazardous. At a temperature of 10°F, the wind chill created by going just 10 mph makes you as cold as if you were standing still at a temperature

of -9°F. At this temperature, exposed esh

will freeze in just a few minutes. Continued exposure in the cold weather could lead to hypothermia. Hypothermia occurs when your body’s inner temperature drops. Symptoms include numbness in the extremities (hands, feet, arms, and legs), and shivering. Damp clothing contributes to hypothermia because cold water on your skin will drain heat from your body’s core. We strongly recommend

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sunlight when you ride over snow or ice on a bright, sunny day. Snow and ice

reects more light into your eyes than

dirt or grass. Tinted eye protection will reduce the amount of light reaching your eyes.

Operating this ATV with improper

modications could be hazardous.

Improper installation of accessories or

modications of the vehicle may cause

changes in handling which could lead to an accident. Never modify the ATV with improper installation or use of improper accessories. All parts and accessories added to the ATV should be genuine parts or their equivalent designed for use on this ATV. Install and use them according to their instructions. If you have any questions, contact your dealer.

There are many types of accessories for sale. However, we cannot have direct control over their quality or suitability. We cannot test each accessory that is available. If you add

the wrong accessories or misuse the vehicle with some accessories installed, it can make the ATV unsafe to ride. Be cautious when choosing and installing accessories to your vehicle. Your dealer may be able to help you choose accessories and install them correctly. The guidelines below should help you to decide how to equip your ATV and how to use it correctly when you use accessories.

Accessory Use and Vehicle Loading Guidelines

1. The weight of the rider must never exceed the vehicle’s load capacity of 285 lbs.

2. Check accessory mounting brackets and other attachments to make sure they provide a rigid non-movable mount.

3. Accessories added to the handlebar of the ATV should be as light as possible. The extra weight would cause the vehicle to be harder to steer.

4. Do not add accessories or cargo which interferes with controls or other equipment.

5. Do not carry heavy or bulky cargo beyond the ATV’s rated capability.

6. Distribute cargo weight evenly between the front and rear racks of the ATV. Locate cargo weight as close to the center of each rack if possible.

7. Secure your load well. Shifting weight can affect your ability to handle the vehicle safely.

8. Ride at slow speeds and avoid hills when carrying cargo. Carrying loads would affect the stability and handling of your ATV.

9. Allow enough stopping distance. Stopping distance increases if you carry loads. Use motor braking as much as possible.

Improper maintenance or failing to perform recommended maintenance could be hazardous. If you perform improper maintenance or do not maintain your ATV you may have an accident. Keep your ATV in good condition. Ask your authorized

service center or a qualied mechanic

to do major maintenance work. You may perform maintenance items by referring to the instructions in this section if you have mechanical experience. If you are not sure how to do the maintenance ask your

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I=Inspect and clean, adjust, lubricate or replace, if necessary. C=Clean R=Replace T=Tighten

authorized service center or call ZAP.

If you use your ATV under severe conditions, it will need maintenance more often than shown in the chart. Operating your ATV under severe conditions causes more wear on your ATV. Severe conditions include operating under frequent full throttle, or in dusty, wet, sandy, or muddy areas. These conditions could cause the ATV to wear more quickly. Perform maintenance more often than shown in the chart. If you have any questions regarding maintenance intervals, consult your authorized service center or call ZAP.

It is very important to inspect and maintain your ATV regularly. Follow the guidelines in the chart. The intervals between periodic services in months are shown. At the end of each interval be sure to perform the maintenance listed.

Item Initial (See chart)

1 Month

20hrs

3 Months

50 hrs

6 Months

100 hrs

Brake Hose and Joints

Drive Chain

Brakes

Wheels

Wheel Bearings

Brake Caliper Linings

Front and Rear Suspension

Sterring System

Steering Shaft Lubrication (use Li Grease)

Fittings and Fasteners

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BATTERY REPLACEMENT

The following procedure can be dangerous and should be performed with the utmost care and attention. Wear protective eyewear, rubber gloves, and have water available should electrolyte come in contact with skin or eyes.

KEEP ALL CHILDREN AWAY FROM THE AREA WHILE THIS PROCEDURE IS BEING PERFORMED. POISON – CAUSES SEVERE BURNS

Contains sulfuric acid. Avoid contact with skin, eyes, or clothing To prevent accidents, rinse empty container with water.

ANTIDOTE:

External – ush with water

Internal – Call physician immediately. Drink large quantities of water or milk. Follow with milk of magnesia, beaten eggs or vegetable. Eyes – Flush with water for 15 minutes and get prompt medical attention.

KEEP OUT OF REACH OF

CHILDREN.

DO NOT open sealed caps to add water to battery.

• Always wear safety glasses and charge in a

ventilated area.

• If battery gets hot to the touch,

discontinue charging and allow battery to cool down.

• Do not use fast charging unless it is an

emergency.

• At the beginning or end of charging, turn off the charger rst, in

order to prevent electric spark and explosion.

• Charge in a well ventilated area.

• DO NOT smoke around batteries and keep away from open ame.

To avoid possibility of explosion, always connect battery cable in

the order specied: RED rst; BLACK last. An

exploding battery can cause serious injury or death.

• Batteries contain sulfuric acid.

• Always shield eyes with protective eye-

wear when working around

battery acid.

• Battery acid is poisonous and can cause

severe burns.

• DO NOT smoke around batteries and keep away from open ame.

Remove old battery(s). Mark which cable is connected to the positive terminal (+) and which cable is connected to the negative (-) terminal.

• Clean cable connectors with wire brush

or sandpaper to remove oxidation.

• After charging, install new battery. Put

dielectric grease on the battery terminals to avoid corrosion. Connect cables to the proper terminals. Positive (+) red cable to positive (+) terminal and negative (-) cable to negative (-) terminal .

• Positive (+) cable is red .Negative cable

is black. CONNECT NEGATIVE CABLE LAST.

Throttle lever adjustment

Operating the vehicle with an inadequate throttle lever free distance could be hazardous. Inadequate throttle lever free

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chain, solve the problem by repairing or replacing the chain. If necessary, consult your authorized service center. If it is determined the drive chain is damaged, check the sprocket also for damage. A worn chain can have an adverse affect on the front and rear sprockets. When inspecting the sprockets, look for the following:

DRIVE CHAIN CLEANING, OILING AND ADJUSTING

Clean and oil the chain according to the following:

1. Wash the chain with water.

2. Dry the chain, and then oil the links with Chain lube or equivalent.

Adjusting the Drive Chain

The drive chain should be adjusted making sure there is 20~30 mm (0.8~1.2 inches) of slack, as shown above.

WARNING

Failing to inspect the drive chain slack

before each use of the ATV could be hazardous. Too much chain slack could

chain can have an adverse affect on the front and rear sprockets. When inspecting the sprockets, look for the following:

If you nd any of these problems with your

sprocket, consult ZAP or your local service center.

WARNING

Failing to maintain the chain properly before each riding could be hazardous. Riding with the chain in poor condition could lead to an accident. Be sure to inspect and maintain the chain before riding, according to these guidelines.

Inspecting the Drive Chain

When inspecting the chain, look for the following:

• Loose pins

• Damaged rollers

• Dry or rusted links

• Kinked or binding links

• Excessive wear

If you nd anything wrong with the drive

distance could cause motor speed to rise suddenly when you turn the handlebars. This can lead the rider to lose control.

DRIVE CHAIN/SPROCKETS

The condition and adjustment of the drive chain should be checked before riding. Always follow the guidelines below for inspecting and servicing the chain.

Inspecting the Drive Chain

When inspecting the chain, look for the following:

• Loose pins

• Damaged rollers

• Dry or rusted links

• Kinked or binding links

• Excessive wear

If you nd anything wrong with the drive

chain, solve the problem by repairing or replacing the chain. If necessary, consult your authorized service center.

If it is determined the drive chain is damaged, check the sprocket also for damage. A worn

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cause the chain to come off the sprockets, resulting in an accident or serious damage to the ATV. Inspect the drive chain slack before each use.

Always use the size and type tires

specied. Always maintain proper

tireair pressure as described in this section.

Using worn tires could be hazardous. The traction of the vehicle will be decreased. This increases your risk of having an accident. Replace the front and rear tires when the depth on the tread is 4.0 mm (0.16 inches) or less.

The ATV is equipped with low pressure tubeless tires of the size and type listed below.

Tire Air Pressure

Check the air pressure in all tires before riding. Improper air pressure would effect handling, steering response, traction, tire life and rider comfort. Be sure that the tires are

inated to the pressures shown. Tire pressure

should only be measured or adjusted when the tires are cold.

WARNING

Operating this ATV with improper tires, or even improper tire air pressure could be hazardous. If you use improper tires or improper tire air pressure, you may lose control of the ATV. Always use the

size and type tires specied. Always

maintain proper tire air pressure as described in this section.

Front/Rear

Size AT23X7-10 AT22X10-10 Cold Tire Air Pressure Front 6.5 ± 0.5 psi (21 ± 3.5Kpa) Rear 6.5 ± 0.5 psi (21 ± 3.5Kpa)

Operating this ATV with improper

modications.

Improper installation of accessories or

modications to this vehicle may cause

changes in handling which in some situations could lead to an accident. Never modify this

ATV through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine ZAP. or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult a ZAP authorized ATV dealer.

Overloading this ATV or carrying or towing cargo improperly.

Could cause changes in vehicle handling which could lead to an accident. Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo. Allow greater distance for braking.

Always follow the instructions in your owner’s manual for carrying cargo.

Overlling the air to the tires could be

hazardous. If you put too much air into the tire, the tire may burst causing severe injury. Check the air pressure from time to time

while gradually inating the tire, until the

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or other extreme conditions can cause accelerated brake wear. This could lead to an accident. If you operate your vehicle under these conditions, the brake must be inspected more often than recommended in the MAINTENANCE SCHEDULE.

1. Inspect the front disk brake caliper for

leakage. If brake uid leaks, the safety of

riding could be affected.

2. Inspect the brake hose for cracks, and the joint for leakage.

3. Check the brake uid level in the brake uid reservoir, if level is low inspect brake

pads for wear and hydraulic system for leaks.

4. To add brake uid, unscrew the 2 screws on top of the brake uid container. Add DOT3 or DOT4 brake uid. Do not mix brake uid types.

Brake uid cap Brake uid reservoir

Brake hose Front disk brake caliper Brake disk

Brake uid level

Tubeless Tire Repair:

If a leak or at tire occurs due to a puncture,

the tire may be repaired using a plug type patch (if permissible by law). If the damage is from a cut, or if the puncture cannot be repaired using a plug, the tire should be replaced. When operating your ATV in areas here transportation or service facilities are not readily available, it is strongly recommended that you bring a plug type repair kit and a tire air pump with you.

Failing to inspect and maintain your ATV’s brake system properly could be hazardous. Improper maintenance of the brake increases your chance of having an accident. Be sure to inspect the brake before riding according to the INSPECTION BEFORE RIDING section.

Always maintain your brakes according to the MAINTENANCE SCHEDULE. WARNING

Operating the ATV in harsh conditions could be hazardous if you do not inspect brake wear often. Operating in mud, water, sand,

specied air pressure is obtained.

Using tires that have been installed incorrectly could be hazardous.The ATV may have unusual handling if the tires are installed incorrectly. The tires are intended to rotate

in a specic direction, as indicated by the

arrows on the sidewall of each tire. Install tires correctly so they rotate in the proper direction.

Tire Replacement:

Your ATV has low-pressure tubeless tires. Air is sealed by the contact surfaces of the inner wheel rim and the tire bead. If the inner wheel rim or tire bead is damaged, air may leak. Be extremely careful not to damage these sections when replacing tires.

It is important to use the proper tools when repairing or replacing tires in order to protect the tire bead or wheel rims. Have this work done by your authorized service

center or a qualied tire repair station. When

breaking the tire bead loose from the wheel, be extremely careful not to damage the inner wheel rim surface or the tire bead.

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FRONT BRAKE INSPECTION

Failing to maintain the brake shoes or pads could be hazardous. Riding with worn brake shoes, pads, or shoes that are seriously worn, will increase your chance of having an accident. If you need to replace brake shoe pads, have your authorized service center do the work. Inspecting and maintaining the brake shoe pads is recommended. Replace the shoe pads in sets.

1. Inspect the rear disk brake caliper for

leakage. If brake uid leaks, the safety of

riding could be affected.

2. Inspect the brake hose for cracks, and the joint for leakage.

3. Check the brake uid level in the brake uid reservoir, if level is low inspect brake

pads for wear and hydraulic system for leaks.

4. To add brake uid, remove top of the bake uid container. Add DOT3 or DOT4 brake uid. Do not mix brake uid types.

Min. Max Rear disk caliper

Brake hose

Rear brake uid

reservoir

Brake uid

reservoir cap

GENERAL LUBRICATION

Proper lubrication is important for safe, smooth operation and long life of your ATV. Be sure that all lubrication is performed during periodic maintenance on the vehicle. Increase intervals when you use your ATV in severe conditions. Your authorized service center may offer general lubrication services as shown in the MAINTENANCE CHART.

Failing to troubleshoot a problem correctly would damage your ATV. Improper repairs or adjustments may damage the vehicle. Such damage may not be covered under warranty. If you are not sure about the proper action, consult your authorized service center or ZAP. about the problem.

High pressure washers could damage your ATV. High pressure washers such as those

found at coin-operated car washes have enough pressure to damage the parts of your ATV. It may cause rust, corrosion and increase wear. Do not use high pressure washers to clean your ATV.

A thorough cleaning of your ATV is a necessary part of maintenance. It will help keep your ATV looking and performing best. Proper cleaning can also extend the life of your ATV. It is important to clean and inspect your ATV after every ride, especially if it is used in mud, brush, grass, water, salt water, or very dusty conditions The build-up of mud, brush, grass, etc. especially on the motor, controller and/or batteries could impact ATV operation, conceal damage, or increase wear of certain parts. It is important to remove all debris during cleaning.

PREPARATION FOR CLEANING

Wash the ATV before any mud dries on the ATV

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Owner and Operator’s Manual

100 % ELECTRIC RANCH-HAND ATV

Place the vehicle on level ground and wash the entire vehicle.

Tires

Inate tires to the normal pressure.

Batteries

Disconnect or tickle charge at least once monthly to a full charge when when not in use.

External

1. Spray all vinyl and rubber parts with rubber protection.

2. Spray unpainted surfaces with rust preventative.

3. Coat painted surfaces with car wax.

PROCEDURE FOR RETURNING TO SERVICE

1. Clean the entire vehicle.

2. Make sure that the vehicle is properly lubricated.

3. Perform the INSPECTION BEFORE RIDING as listed in this manual.

4. Start the vehicle as outlined in this

as much stopping power as dry brakes. This could lead to an accident. Test your brakes after washing the ATV, riding at a slow speed. If necessary, apply brake several times to let the friction dry out the linings.

Remove the rags or wrapping from the exhaust pipe. For extended life ofyour ATV, lubricate according to GENERAL LUBRICATION section. Follow the procedures in the INSPECTION BEFORE RIDING section to check your ATV for any problems that may have occurred during your last ride.

STORAGE PROCEDURE

If you do not use your ATV for an extended period, it will need special service requiring appropriate materials, equipment and skill. For this reason, we recommend that you trust this maintenance work to your authorized service center. If you wish to service the machine for storage yourself, follow the general guidelines below:

Vehicle

WASHING YOUR ATV

With some care, your ATV can be washed in a similar manner to washing an automobile.

Note: Avoid spraying or allowing water to

ow over the following places:

• Electrical controls

• Batteries

• Controller

• Motor assembly

Use a garden hose at low pressure to remove the majority of dirt or other debris. Hand wash your ATV with mild soap or detergent and water. Try to thoroughly remove all dirt and debris without excessive water pressure, even at remote areas such as on motor

cooling ns, linkages or mounting brackets.

Cloth rags, washing mitts or cleaning brushes can be used. Be careful with brushes as they may scratch plastic or painted surfaces. Rinse the ATV thoroughly with clean water. Dry all areas using a chamois or soft absorbent cloth.

Operating the ATV with wet brakes could be hazardous. Wet brakes may not provide

100 % ELECTRIC RANCH-HAND ATV

Cut, fold and staple or tape this card and mail back:

REGISTRATION CARD

(Not returning this card will not void the original 6-months limited warranty.)

1. Name & Address:

* Title Mr. Mrs. Ms. Miss

First NameInitialLast Name

Street Apt. No. City

State/Province Zip/Postal Code

E-mail Address

2. Your date of birth:

3. Marital status: Married Single

Month Year

4. Date of purchase:

5. VIN#

7. Did You: Purchase this product yourself? Receive this product as a gift?

Month Day Year

9. What other vehicles did you seriously consider before making this purchase?

11. Not including yourself, what is the GENDER and AGE (in years) of children and other adults living in your household?

12. Occupation: (check all that apply) You Spouse

Received as a gift Advertisement Brand name Friend's/relative's recommendation Green qualities Product brochure PriceReview in media/internet Salesperson's recommendationStore display

Leisure/fun travel Commuting to work Short errands Primary vehicle

No one else in household

1.Male Female Age (in yrs):

2.Male Female Age (in yrs):

3.Male Female Age (in yrs):

4.Male Female Age (in yrs):

Professional/Technical Upper Management/Executive Middle Management Sales/Marketing Clerical/Service Worker Tradesman/Machine Operator/Laborer

Features:

Color, design and style Economy

Size Speed

10. How do you plan to use your Dude?

6. Name of DUDE dealer where purchased:

8. What most inuenced your decision to purchase a DUDE?

Factors (check all that apply):

13. Are you or your spouse: You Spouse

14. Which group describes your annual family income?

15. Level of education: (check highest level completed)

16. For your primary residence, do you: Own Rent

17. How recently did you move into your current residence?

18. Please check all that apply to your household.

A Homemaker? Retired? A Student? Self Employed/Business Owner? Working from a Home Office? In the Military? A Veteran?

Under $15,000 $15,000-$19,999 $20,000-$29,999 $30,000-$39,999 $40,000-$49,999

High School College Graduate School

Within 30 days 7 to 12 months ago Within 1-3 months Have not moved in the last 12 months Within 4-6 months

Shop by Catalog/Mail Member of Frequent Flyer Program Own a Compact Disc Player Have a Cat Speak Spanish Own a CD-ROM Drive

$50,000-$59,999 $60,000-$74,999 $75,000-$99,999 $100,000-$124,999 $125,000-$149,999

$150,000-$174,999 $175,000-$199,999 $200,000-$249,999 $250,000 & over

Shop via the Internet Donate to Charitable Causes Have a Dog Own a Wireless/Cellular Phone Own an Apple/Macintosh Computer

19. To help us understand our customers' lifestyles, please check the interests and activities in which you or your spouse enjoy participating on a regular basis.

20. Using the numbers in the above list, please indicate your 3 most important activities: ____ _____ _____

01. Bicycling

02. Golf

03. Physical Fitness/Exercise

04. Running/Jogging

05. Snow Skiing

06. Tennis

07. Camping/Hiking

08. Fishing

09. Hunting/Shooting

10. Powerboating

11. Sailing

12. Grandchildren

13. Needlework/Knitting

14. Sewing

15. Flower Gardening

16. Vegetable Gardening

17. Crafts

18. Buy Prerecorded Videos

19. Automotive Work

20. Electronics

21. Home Workshop/Do-It-Yourself

22. Recreation Vehicles (RVs)

23. Listen to Records/Tapes/CDs

24. Avid Book Reading

25. Bible/Devotional Reading

26. Health/Natural Foods

27. Photography

28. Cultural/Arts Events

29. Fashion Clothing

30. Art/Antique Collecting

31. Foreign Travel

32. Cruise Ship Vacations

33. Travel in USA

34. Gourmet Cooking/Fine Foods

35. Wines

36. Stamp/Coin Collecting

37. Collectibles

38. Our Nation's Heritage

39. Real Estate Investments

40. Stocks/Bond Investments

41. Contests/Sweepstakes

42. Casino Gambling

43. Science Fiction

44. Wildlife/Environmental Issues

45. Dieting/Weight Control

46. Science/New Technology

47. Self-Improvement

48. Walking for Health

49. Watching Sports on TV

50. Home Video Recording

51. Moneymaking Opportunities

Thank you for filling in this registration card. Please tear off along the doted line and mail to the following address:

ZAP 501 Fourth Street, Santa Rosa, CA 95403 USA.

ZAP Dude 2010 Owner's And Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual