Zap DX owner manual If Your Bike Does Have The Welded Plate, Start Here, Adjusting Motor Unit

Double

Sided Tape

•Take the Bridge Mount and position it on the seat stay bridge, centered and aligned with the seat stays.

•Insert one of the motor mount bolts through the bottom hole of the Bridge Mount and finger-tighten it into the bottom hole of the Threaded Plate.

MOUNTING MOTOR UNIT

•Slide the slot of the Hinge Bracket (attached to the ZAP Motor Unit) around the Motor Mount Bolt, between the inside of the seat stays and the Threaded Plate. Deflating the tire may be necessary to get the motor in place.

•Finger tighten the remaining motor mount bolt through the Bridge Mount, and into the Threaded Plate.

IF YOUR BIKE DOES HAVE THE WELDED PLATE, START HERE

Fig.4

•Insert the motor mount bolts through two of the holes in the weld- ed bridge plate and finger tighten into the two holes of the Threaded Plate. (see Fig. 4)

•Slide the slot of the Hinge Bracket (attached to the ZAP Motor Unit) around the Motor Mount Bolt, between the inside of the seat stays and the Threaded Plate. Deflating the tire may be necessary to get the motor in place.

4) Adjusting Motor Unit

•With Cam Lever in the up (disengaged) position, adjust the ZAP Motor Unit by sliding it up or down along the seat stays until the proper Critical Set-Up Distance (CSD) is achieved. The CSD is the distance between the motor and the Seat Stays when the roller is just touching the tire. (see Fig. 5). Determine the CSD for your bike by referring to Fig. 6. The recommended pressure for your tires is printed on the tires.

NOTE: In some cases (on Cruiser bikes in particular), the Standoff (silver member between the two motors) will hit the tire when the Motor Unit is pulled in against the seat stays of the bike. When

this happens,

adhere the remain-

ing piece of CamFig.5 Ramp on the motor

where it contacts the seat stay. Then, readjust the motor, using the space between the Seat Stay and the piece of Cam Ramp as the new CSD.

•Once the CSD is attained, tighten the bolts using the 4mm Allen Wrench (make sure the ZAP Motor Unit is centered around the tire and the roller is flat on the tire as opposed to being slanted). Re- check CSD and correct if needed.

•Put the Cam Lever in the down (engaged) position and notice how far it forces the Roller into the tire. Ideally, the Cam will force

Critical Setup Distance (CSD) for

Different Tire Pressures

3/4”

11/16”

5/8”

9/16”

1/2”

40	45	50	55	60	65	70	75	80	85	90
											Fig.6
				Tire Pressure (psi)

the Roller about 1/16” into the tire.

•If the Cam forces the roller into the tire more than 1/16”, remove the Cam Ramp which is adhered to the motor under the Cam using a flat-head screwdriver or pliers. Engage the Cam Lever, and check to see if the Cam forces the Roller into the tire the desired 1/16” without a Cam Ramp. If the engagement is less than 1/16”, take the spare Cam Ramp, which is shorter and slotted, and insert it where the original Cam Ramp was removed. Check the engage- ment once again. If the Roller engagement into the tire is greater than 1/16”, then snap off the end of the shorter Cam Ramp using a flathead screwdriver or pliers and check the engagement. One of these sizes of Cam Ramp will give you approximately 1/16” of engagement.

•When the correct Cam Ramp size and position is found, cut a piece of the Double-Sided Tape to match the inside of the Cam Ramp.

•Peel off one

side of the tape	Fig.7
and adhere it to

the inside of the Cam Ramp, without touching the tacky sur- face (see Fig. 7).

• Peel off the other side of the tape and care- fully adhere the

Cam Ramp to the motor, under the Cam butted up against the sil- ver Spacer Tube.

•Now recheck all critical dimensions: -Critical Setup Distance

-Roller engagement into the tire when the Cam Lever is in the down position (1/16”)

NOTE: If you have a bike with a welded bridge plate, you may have to use different holes in the welded bridge plate (higher or lower) to achieve proper set-up.

5) Connecting the Motor to the Controller

•Attach the motor / controller lead with the white dot to the motor lead with the white dot. Plug the other motor / controller lead into the remaining motor lead (the lead without the white dot.)

6) Connecting Battery Pack

•Push the battery pack assembly into the battery tray.

•Connect battery power connector to controller power connector (black & red).

•Attach the Velcro on the battery bag flaps to Velcro on the battery tray and make it tight.

•Run the battery strap underneath the battery tray and through the “D” ring on the other battery flap and pull tight.

•Fasten the battery strap to itself with the velcro attached to it. NOTE: Initially, tray is very tight around battery.

ZAP DEFLATES THE TIRES BEFORE PACKAGING THE BIKE TO PREVENT DAMAGE DURING SHIPPING. INFLATE BOTH TIRES TO 55 PSI.

9