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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.
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,
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).
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
BRIDGE MOUNT INSTALLATION (see Fig. 3)
NOTE: The seat stay bridge of your bike is the short horizontal
tube between the seat stays.
Bicycle
down tube
Worm
drive clamp
Bicycle
seat tube
Motor/Controller
leads
Worm drive
clamp
Easy Installation Guide
Fig.1
Yellow
Throttle Switch
Fig.2
8
Worm
drive clamp
Fig.3