Zap DX owner manual Introduction

RE-ASSEMBLY INSTRUCTIONS FOR A PRE-ASSEMBLED, BOXED ZAP ELECTRICRUIZER®

INTRODUCTION

Welcome electric bicycle owner! Thank you for pur- chasing your ZAP Electric Bicycle - we are confident that you will love it. The innovative ZAP Power System you have pur- chased will bring you many hours of fun and enjoyment. However, before you start enjoying your bike, some assembly is required. We strongly suggest that your ZAP Electric Bike be assembled and tuned by a professional bike mechanic. If you need assistance in working with a local bike dealer, please call ZAP @707-824-4150. In order to final assemble your elec- tric bike, you will need the following nine simple tools:

you have the standard binder bolt, using an allen wrench, securely tighten the seatpost enough so that you cannot twist the saddle out of alignment. B) If you have the optional quick release lever, tighten the quick-release nut enough so that you cannot twist the saddle out of alignment after the quick release is engaged.

4b) HOW TO FASTEN THE SEAT QUICK RELEASE

Open and close the quick release lever with your right hand while gradually tightening the adjusting nut (located on the opposite side of the seatpost) with your left hand in the clock- wise direction. Continue tightening the nut until you feel resis- tance with your hand at the point when the lever is parallel to the seatpost. Grip the seatpost with your fingers and use the palm of your hand to close the lever with as much strength as possi- ble. When closed, the lever must be in the “CLOSE” position. The side of the lever with the inscription “CLOSE” must be fac- ing away from the seatpost.

1) REMOVING PACKAGING

Carefully remove all packing material from bicycle and inspect the bike for any damages which may have occurred during shipping. If necessary, please call both the shipper and ZAP immediately to report any damage.

2) OWNER’S MANUALS

Before you begin assembly, thoroughly read through the ZAP Owner’s Manual, ZAP Owner’s Manual Supplemental, and this assembly sheet. Review page four of the ZAP Owner’s Manual Supplemental. Please refer to the Torque Ratings Guide when tightening or securing bicycle parts. All bicycle parts referred to during assembly will have a number corresponding to the dia- gram appearing on this page.

3) FRONT WHEEL

Attach the front wheel to the forks with a 15mm wrench or an adjustable wrench. Tighten each side partially, center and balance wheel, then tighten completely.

Hub of front wheel (9)

4a) SEAT & SEATPOST

Insert seatpost into the bracket on the underside of the seat. Be sure that the top of the seat is level. Securely fasten the seat to the seatpost using an

Seat Post adjustable wrench. Insert seat- post into the seat tube of bicycle so that the minimum insertion mark is no longer visible. A) If

5) FRONT BRAKE CABLE HANGER

(If you are also installing a ZAP PowerLight, the light bracket should be installed beneath the headset top- nut.) Remove the top nut from the fork. While align- ing the cable hanger’s tooth with the groove on the steerer tube, slide the brake cable hanger onto the forks’ steerer tube. Next, re-install the top nut, securing it with the proper torque specifications. After

installing the front brake cable hanger, inspect the adjustment for the headset bearings. If the fork does not turn freely, first loosen by turning counterclockwise the top nut and then loosen the cone, then re-secure the top nut. If the fork is too loose, then loosen the top nut, tighten the cone, then re-secure the top nut. (Before you ride the bike, make sure that the brakes are properly adjusted).

6) INSTALLING THE HANDLEBAR ASSEMBLY

Rear Brake			Insert the stem into the
			bicycle head tube past the
	Lever	Handlebar	minimum	insertion		mark,
		Binder	align with front wheel, and
		Bolt
			tighten the stem			binder
Stem Binder Bolt			bolt. Position		handlebars
			at desired angle and tight-
Stem			en handlebar binder bolt
			The handlebars should be
			centered	at	the	stem.
			Both binder bolts should

be tightened with a 6mm allen wrench tight enough so that you cannot twist the stem and handlebars out of alignment. Adjust the brake levers to desired angles and tighten to proper torque.

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