Zap DX - Manual (Page 8)

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:
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.
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
adjustable wrench. Insert seat-
post into the seat tube of bicycle
so that the minimum insertion
mark is no longer visible. A) If
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.
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
Insert the stem into the
bicycle head tube past the
minimum insertion mark,
align with front wheel, and
tighten the stem binder
bolt. Position handlebars
at desired angle and tight-
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.
Seat Post
Hub of front wheel (9)
RE-ASSEMBLY INSTRUCTIONS FOR A PRE-ASSEMBLED, BOXED ZAP ELECTRICRUIZER
®
Stem
Rear Brake
Lever
Stem Binder Bolt
Handlebar
Binder
Bolt
6