Zap DX owner manual Easy Installation Guide, Attaching the Throttle Switch, Mounting Motor Unit

Easy Installation Guide

IMPORTANT! PLEASE READ CAREFULLY:

Along with your kit, we’ve included an invoice, owner’s manual,

and a warranty form. Please read the warranty carefully and fill out the form on the back. You must return the warranty form within 10 days of receiving your ZAP Power System in order to activate the warranty.

Before You Begin: We strongly suggest that your ZAP Electric Bicycle be assembled and tuned by a professional bike mechanic.

Required Tools

4mm, 5mm, 6mm allen wrench, crescent wrench, 15/32mm head

&pedal wrench, cutters, axle wrench, phillips head screwdriver, flat-head screwdriver, & tape measure.

NOTE: Please refer to the “Description of System” on page 4 for a detailed list of your kit’s key features

•Tires: It is extremely important that you have the right tires on your bicycle before you begin this installation. Not all tires will work properly with the Zap Power System. Full knobby tires will not work properly and may damage the motor system. We recom- mend a semi-slick tire. Tires should be inflated to their maximum inflation rating. This is printed on the side of the tire.

•Bicycle: You will be adding weight to your bicycle when you install the ZAP Power System. The condition of your bicycle is crit- ical to your safety. Wheels should be trued (running straight). Brakes are the most important safety component on your bicycle and should be carefully checked and adjusted. A professional bike tune-up is highly recommended.

Bicycle

down tube

Bicycle

seat tube

Motor/Controller

leads

			Worm
Worm		drive clamp
	drive
				Fig.1
clamp

which should be removed once the tray is installed.

•Route the Motor / Controller lead marked with a white dot along the right side of the bicycle seat tube and the other Motor / Controller lead along the left side of the bicycle seat tube. (Right and left are relative to a person sitting on the bicycle).

Yellow

Throttle Switch

Fig.2

2) Attaching the Throttle Switch

•Loosen the front brake lever and front shifter lever and slide it away from the grip.

•Attach throttle switch between the grip and the front brake lever with the yellow toggle switch pointing away from the center of the handlebar. (Fig. 2).

•Once the throttle switch has been secured, slide the brake lever back until it is snug against the throttle switch.

•Adjust brake lever and front shifter lever to the correct position and tighten it back down.

•Secure the throttle switch wire to the front shifter lever cable housing with the small zip-ties provided. For cruisers, attach throt- tle switch wire to front brake cable housing.

•Secure remaining throttle switch wire to the bicycle down tube with two of the large zip-ties provided.

•Carefully stuff any excess throttle switch wire back into the bat- tery tray.

3) Mounting Motor Unit

NOTE: If you buy a bike directly from ZAP, your bike may have a welded bridge plate instead of a seat stay bridge.

IF YOUR BIKE DOES NOT HAVE THE WELDED PLATE, START HERE

1) Attaching the Battery Tray

•Position battery tray in bicycle frame so the rear part of the bat- tery tray is parallel to the bicycle seat tube, (Fig. 1).

•Secure the rear part of the battery tray to the bicycle seat tube and the front part of the battery tray to the bicycle down tube with the worm drive clamps provided. Tighten clamps until battery tray is held firmly in place. Be sure not to clamp any cables to the frame.

•Route throttle switch wire along the left side of the bicycle down tube and Auxiliary Power / Alternate Charging Jack along the right side of the bicycle down tube. NOTE: The Auxiliary Power / Alternate Charging Jack is identified by the black rubber cover,

Fig.3

BRIDGE MOUNT INSTALLATION (see Fig. 3)

NOTE: The seat stay bridge of your bike is the short horizontal tube between the seat stays.

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