Zap Zapino User manual

Operation and Maintenance Instructions
OWNER’S
MANUAL
We strongly recommend that you
read this entire manual before
using your vehicle for the first time
www.zapworld.com
ZAP © 2008 - All Rights Reserved

Read before riding Page 2
Delivery Inspection Page 3
Point Inspection Page 4
Installing the mirrors Page 4
Technical Specifications Page 5
Wiring Diagram Page 6
Ignition Key Positions Page 7
Handle Bar Controls Page 8
Accelerating & Braking Page 9
Battery & Charging Page 10
Performance Page 11
Maintenance Page 12
Maintenance Schedule Page 13
Frequently Asked Questions Page 14 -16
Troubleshooting Page 17
Diagnostic Warning Signal Lights Page 18
Warranty Page 19 - 21
Wiring Display Page 22
Equipment Location Page 23 - 24
Contents Page

2
1) To ensure the vehicle is functioning correctly, do a quick check of th vehicle's tires
and check that the brakes are working. (For more detailed maintenance instructions
see the Maintenance Schedule). Your vehicle has been thoroughly checked by our
engineers before delivery but on the spot checks are equally important.
2) When the key is inserted and turned to the "ON" position, the power indicator will
illuminate. If current drain is over 60A, the power will be automatically cut off to avoid
over-heating. Wait for one minute and then press the red button (see pg.7) to restart
the vehicle.
3) To avoid unplanned acceleration, always turn the key to the “OFF”position before
dismounting or leaving the bike unattended.
4)
5) This vehicle may be ridden in wet conditions, but be sure to avoid soaking it during
cleaning to avoid damaging any of the electric components.
6) The vehicle should not be left in strong, direct sunlight for long periods as some of
the electric components may overheat.
7) Motorcyclists and moped users must abide by the same traffic rules and
regulations as other motorists. Before taking your motorcycle/moped on a public
road, be familiar with DMV traffic rules and regulations and any special
requirements for motorcycles/mopeds.
8) Alcohol slows reflexes and greatly limits your ability to
operate a . Even a very small amount of alcohol will reduce your
ability to operate a safely.
9)
SAFETY NOTICE: Be sure that you are seated on the bike and kick stands
are clear of the floor before touching the throttle handle. If you twist the
throttle before you are ready to go or while you are mounting the bike it may
run away from you and could lead to an accident.
Note:
Never drink and ride.
Some states may classify ZAPINO as
a moped, others a motorcycle.
motorcycle/moped
motorcycle/moped
ALWAYS wear an approved safety helmet!
WARNING! Read Before Riding
If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you
should immediately inform the National Highway Traffic safety Administration (NHTSA) in addition to
notifying ZAP.
If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists
in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become
involved in individual problems between you, your dealer, or ZAP.
To contact NHTSA, you may call the Vehicle Safety Hotline toll-free at 1-888-327-4236 (TTY: 1-800-424-
9153); go to http://www.safercar.gov ; or write to: Administrator, NHTSA, 400 Seventh Street, SW.,
Washington DC 20590. You can also obtain other information about motor vehicle safety from
http://www.safercar.gov.

3
The following checks/operations are necessary before riding and
delivering.
1) Always Charge the batteries (observing battery guidelines) before
using and after every use.
2) Check the action of the front and rear-wheel suspension.
3) Check the functionality of all controls.
4) Check the screws, nuts and fastening parts; check the engine
fixing, main and side kick stands, suspension strut, yoke and
steering-head bearing.
5) Check the lights/headlight.
6) Check all main screws.
7) Check the tire pressure.
8) Check the function of the front and rear brakes
9) Perform a final inspection of the following elements: steering,
brakes, instuments, indicator lights, lights and signal system, as well
as the tires and wheels.
10) Explain the terms and conditions of the warranty to the customer,
and have them return the registration card.
ALWAYS:
Pre-Delivery Inspection

Important Notes
1. Regularly perform a routine maintenance check. Doing so will
help protect yourself and your vehicle.
2. If any parts are damaged, whether normal or abnormal, please
check with the dealer before riding.
1. Mirrors need to be attached to the handle bars between the grips
and the brake handle.
2. Screw in the mirror clockwise. The mirror that goes on the left side
is curved to the left and the mirror that goes on the right side curves to
the right.
3. Secure mirrors by tightening the bolts.
4. Clean and adjust both mirrors before you ride. Adjust each mirror
so you can see the lane behind you and as far as possible the lane
next to you. When the mirror is properly adjusted you can see the
edge of your arm and shoulder.
Point Inspection before every use
Item Action
Front Brake Squeeze right hand brake and push the vehicle to
see whether it rolls easily. If it does, then the brake
must be tightened. Tighten the bolt until the vehicle
will no longer move with the brakes applied.
Rear Power/Disc Brake Listen for any noticeable grinding or squealing from
the tires while the brake is applied. If so, contact
the dealer to adjust.
Brake Fluid Check fluid gauge on the left handlebar to ensure
that the brake fluid is above the indicated level. If
not, top it up with a good brand of brake fluid.
Electric Switch Handle Turn THrottle counter clockwise then release; the
Throttle should spring back to stop position. If not,
contact your supplier.
Tires Check the tire pressure is 36 PSI
Controller/ Motor Check the usage and condition
Battery Check the power level by looking at the gauge or
with a voltage meter.
Signal Check to make sure your lights are working.
Nuts and Bolts Check to make sure that all nuts and bolts are
tightened and secured.
Speed Switch Normal Moped operation is DOWN
Installing the mirrors
4

5
OPTIONS
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Solar Panel
Fast Charger
Extended Range
Luggage Boxes
220V Charger
Battery
Technical Specifications
Motor Power 3000W Brushless Hub Motor
Battery DC 60V, 38AH with the green saver ( silicone power) batteries
Charger 5A,110V~250V/50 Hz ~60Hz
Charging Time 6~10 Hours
Life of Battery 400 Deep Cycles
Wheelbase 10 Inches
Torque 103Nm (76 ft-lb)
Top Moped Speed 30 mph (50km/H) for 3000W motor
Single Charge 30Mile (50km) based on 38AH battery
Climbing Capacity 1:4 Gradient for a 155 lb. (70kg) Rider
Maximum Weight Capacity 282 lbs (128kg)
Tire Front:3.50-10.00 Inch 8PR Rear:3.5-10.00 Inch 8PR, tubeless
Gross Weight (135kgs) with 38AH60V battery
Net Weight (81kgs) (not include battery)
Battery Weight 128lbs (58kgs)
Product Size L 70”x W 27”x H47”
Brake System Front and Rear Disc brake
297 lbs
178 lbs

Wiring Diagram
CONTROLLER
POWER
MOTOR
ACCELEROTOR
UNDER-PRESSURE
SIGNAL
HALL SIGNAL
BRAKE
Red (0.75mm )
Red (2.5mm )
Black (2.5mm )
2
2
2
Blue (2.5mm )
Green (2.5mm )
Yellow (2.5mm )
2
2
2
Red (0.3mm )
Black (0.3mm )
Green (0.3mm )
2
2
2
Red (0.3mm )
Brown (0.3mm )
Yellow (0.3mm )
Red (0.3mm )
2
2
2
2
Green (0.3mm )
Blue (0.3mm )
Black (0.3mm )
2
2
2
White (0.3mm )
2
Brushless
Motor
Controller
DC to DC 60 V. Battery
Key Lock
+12V
Horn
Tail Light
Relay
6
Lights
Lights
Lights
Lights

Ignition Key Positions
Key Position Description
On
Off
Lock Handlebar
Opening the seat
Key cannot be taken out when power is on
Key can be taken out when power is off
To prevent theft, turn the Handle Bar to the far
left and turn the key into the lock position. The
key can be taken out when handle bar is in the
lock position.
Turn the key in the slot to release the locking
mechanism of the seat, and to access Charge
port.
7

Handle Bar Controls
Headlight Switch
When Brake Handle is compressed the rear wheel will slow
to a stop and power will be cut off. Power will flow once lever
has been released.
Horn Push red button on the left.
High Beam Push switch up
Low Beam Push switch down
LEFT HANDLE BAR
Horizontal Switch
Horn Button
Rear Brake Lever
Left Turn Signal Slide switch to the left
Right Turn Signal Slide switch to the right
Turning off Signal Press central release button
Turn Signals
Horn
High/Low Beam
Rear Brake
1
2
4
3
1
2
3
4
Speed Switch
The dashboard lights, headlight, and taillight will turn on
when the switch is in the middle position.
Turn throttle counter clockwise to increase speed.
Economical speed switch can ensure longer range and high
speed switch provides bigger AMP for accelerating, climbing
and higher speed.
RIGHT HANDLE BAR
Front Brake Lever
Parking Lights
Throttle
When brake handle is compressed the front wheel will slow
to a stop and power will be cut off. Power will flow once lever
has been released. To start, turn the throttle counter
clockwise.
The dashboard lights, headlight, and taillight will turn on
when the switch is in the left position.
Head Light
Lights -On/Off
Throttle
SpeedHigh/Low
1
2
3
1
2
3
8

9
THROTTLE TIPS
BRAKING TIPS
If running under
top speed, don't always full throttle. Frequently releasing the
throttle and running with inertia will longer increase range too.
This motor has good torque and the inertia momentum is
enough to run an automatic distance without electric power.
1. Turn the key to the 'ON' position, and turn the Throttle gradually to
accelerate.
2. To prevent losing control of the vehicle, please turn the Throttle
slowly until the speed increases.
3. Do not turn the Throttle until you are in the position to drive.
4. To stop, release the throttle and apply the front and rear brake
simultaneously.
5. To move, release the brakes and turn the Throttle gradually.
6. The Brushless motor makes a small electromagnetic noise when
turning the Throttle to start. This is normal.
7. Please, for your safety and security, take the key out when you are
not riding.
1. For safety, this vehicle has a circuit cut-out brake system. When
the front and rear brake is applied, the controller will disable the
circuit; to run, release the throttle back to the start position then
accelerate again.
2. Less sudden braking will increase range entirely.
Accelerating and Braking

10
CHARGING
BATTERY LONGEVITY
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The battery for this vehicle is a sealed, maintenance free D/C
battery. The owner must use the factory-supplied charger with an
110V (or 240V) outlet.
Turn off all switches while charging the battery. Plug one side to an
110V (or 240V) outlet and the other to charging plug on the vehicle
(located under the seat).
The average charging time is 8 hours (90%). To fully charge
battery, charging time will be 4 to 10 hours.
After charging, turn the ignition to the 'On' position and unplug the
charger from both sides.
To keep the battery in good condition, charge it after each use.
Please charge the battery fully once a month, even when the vehicle
has not been ridden.
The range with standard battery is 30miles.
The driver should ALWAYS charge the scooter after every trip as this
will help the battery's life. The life of the Green saver battery is 400
deep cycles (100% discharged), but if you charge the battery every
time or when its capacity falls below 50%, the battery life will be
greatly increased. Therefore we advise the rider to charge the bike
as often as possible.
Battery Gauge and
Charging Instructions
Color
When power is low (around 50%) the battery gauge will turn
to yellow.
This light indicates that the battery is 75% of full charge
Green
Yellow
Green (2nd)
While riding, when the battery is fully charged the gauge light
will be green.
When the battery is discharged the motor will be
automatically cut off. This means that there is less than 25%
charge remaining. Switch to “Economical speed”and find
the nearest charging point asap.
Red
Description

11
1. A range of up to 55M (90km) has been recorded, yet the distance
and speed depend upon various elements of the rider's style and the
road conditions. A 20mph constant speed will ensure the longest
range but our figures include going flat out too. Other factors include
weather, vehicle condition, and battery charge. Drivers must be
cautious when driving on rough roads, in poor weather, or when the
battery charge is low.
2. This vehicle has a power- circuit brake system to protect the
vehicle when the brake is applied;
3. After each trip, the driver should turn off the vehicle, take out the
key and charge the battery. This battery does not have memory (i.e.
you do not have to run it down completely to achieve a good charge.
On the contrary, regular charging will lengthen the life of the battery)
and can be charged at any time in the cycle of the battery.
4. Always check the battery gauge while you are riding and be sure
that it does not get too low too often.
cut
Performance

12
This electric motor bike represents a new generation of
environmentally friendly two-wheeled transportation. Therefore,
good maintenance will play a major role in keeping your vehicle in
good working condition and prolonging the life of the batteries.
Please follow these suggestions:
To prevent rust always keep your vehicle dry and clean.
Regularly check the front and rear tires, suspension and body
frame and all fasteners.
When riding in rain do not go through deep puddles or muddy
areas; excessive water may harm the motor and other electrical
components.
To prevent rust from forming on the vehicle, avoid parking your
vehicle in high humidity and corrosive areas.
To avoid damage to the electrical parts of this vehicle, especially
the controller, do not store the vehicle in direct sunlight or in heavy
rain.
Customers should NEVER attempt to take out any of the parts, or
attempt major maintenance without consulting the supplier/dealer
(this will invalidate the warranty).
Never overload and ride the vehicle for an extended period of time,
prolonged use with excessive weight could cause damage to the
electronic and mechanical parts.
Always check your vehicle and perform necessary maintenance -
tires, brakes, nuts and bolts.
For your safety, perform routine maintenance on your vehicle. This
will lower the potential for damage.
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Maintenance

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Maintenance Schedule
A: Adjust C: Check T: Tighten
Mileage 400 1000 2000 3000 4000 5000 6000 Maintenance
Battery C C
Charger C C
Tire
Pressure C C C C C C C A
Tire
Wear C
Brake
System C C C C A
Brake
Pad A
Nuts
and
Bolts T T T
Mileage 7000 8000 9000 10,000 11,000 12,000 Maintenance
Battery C C
Charger C C
Tire
Pressure C C C C C C A
Tire
Wear C C
Brake
System C C C A
Brake
Pad A A
Nuts
and
Bolts T T

14
1. Fully charged, what is the range of the electric vehicle?
2. Is riding an electric vehicle a comfortable riding experience?
3. Do you have to warm-up the electric vehicle before riding it?
4. What about maintenance?
5. What about parts, is it a problem getting parts for the Zapino?
I. The Range is affected by the weight of rider, the type of terrain
and the speed at which the vehicle is driven. Under optimal
conditions (push red button and keep a steady 20mph rate
speed), a range of (50 miles) has been recorded on a single
charge.
II. See the specification sheet for the full range and speed of the
models.
I. Riding an electric vehicle is indescribably more comfortable
than riding a gasoline motor vehicle. The silence and the
smoothness of a direct drive electric-motor-powered vehicle are
incomparable.
II. Quick accelerating---speed from 0 to 30 mph (50km/H) takes
only 4 seconds.
I. When the driver turns the ignition key, three beeps will
immediately follow telling the driver that the vehicle is ready to
drive. There is absolutely no warm-up time needed. Just turn the
key and you are ready to go.
I. This motor bike is designed for minimum maintenance.
Considering the fact that this vehicle has no combustion engine,
no transmission, no belts, no chains, no gasoline, no lubricants,
no ignition plugs, no carburetor, etc. The unique design of the
direct drive system and the total absence of belts or chains make
this vehicle much easier to maintain than other electric scooters.
Practically any scooter dealer can do most of the maintenance
that may be required. The motor is brushless so there is never a
need to change brushes.
I. ALL parts can be purchased directly from the dealer including
batteries, tires, bulbs, body shells, seats etc.
II. We supply a 6 month warranty for all parts (subject to normal
care from the driver) excluding batteries, tires and other normal
wear parts. (See warranty)
Frequently Asked Questions

15
Frequently Asked Questions
6. Can the electric vehicle be cleaned or washed with water
without any concern?
7. Do you need to wear a helmet to drive the ZAPINO?
8. Is it easy to recharge the batteries?
9. How long will the batteries last, what is the batteries life
cycle?
10. How can I know the batteries condition and energy level?
I. One should be careful not to pour water directly into the
charger outlet, the controller and the internal battery set when
washing or cleaning.
I. For safety reasons we always advise the use of a helmet.
ALWAYS follow local laws.
I. Yes. The user just needs to insert the input plug of the Battery
Charger into any regular wall outlet of AC110V (or AC220V) and
the output plug into the inlet on the right rear side of the vehicle,
which is clearly marked. This will start to recharge the batteries.
Daily charge of the battery will lengthen its life cycle, up to 1000
deep charges from 400 occasional charges.
I. The battery's life cycle will be reduced or damaged if an
insufficient charge level is retained for a long period of time.
Depending on the user's operation, between 400 and 1000
cycles. Normally the batteries should last between one and three
years if the user charges it regularly.
I. The display panel includes a row of LED lights, which clearly
indicate the power level of the batteries in your vehicle.FULL:
First green light is on.
75% FULL: Second green light is on.
50% LEFT: Yellow light is on and you also hear a Warning Beep
(At this level, charging is highly recommended).
Low 25% LEFT : Red light is on (Immediate charging is
necessary).
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Frequently Asked Questions
11. If one of the batteries has a problem do I need to change all
the four batteries?
12. Why is this product UNIQUE?
I. Not necessarily. Simply check the condition of all batteries and
only replace the battery which shows lack of charge.
It has a Brushless wheel motor. We emphasize "brushless" not
just because this is the latest technology, but because these
permanent magnet motors are extremely efficient! These motors
produce high torque at low speeds, keeping an acceptable
balance of torque and energy across the whole speed range. In
addition to not wasting energy at idle, the motors offer the
advantage of using the permanent magnet motor's energy
recovery capability during deceleration (regenerative braking),
so the batteries recharge during deceleration. Often other types
of electric vehicles on the market today will still use sealed brush-
type motors that are dependant upon brush life that build up
brush dust (residue) and susceptible to wear over time which
may affect maximum speed and electrical noise or become
problematic in other ways.

17
Troubleshooting
spring position. Contact the
Problem Condition Check Solution
When I turn
my vehicle
on nothing
happens.
1. Power
indicator light is
off while riding.
1. Check power
connection and battery
level.
1. Fasten connections.
2. Indicating
light on motor is
not illuminated.
2. Check battery and
motor connection.
2. Recharge battery.
3. Assess the weather for
humidity.
3. Loosen connection and
wipe down with a damp rag
and dry and fasten again.
Contact the supplier.
4. Check regulator. 4. If there is any corrosion
replace. Contact the supplier.
5. Battery level is low. 5. Change or replace
damaged part. Contact the
supplier.
The Throttle
does not
work or
switch on,
the vehicle
moves
without
acceleration.
The Throttle
does not return
to stop position.
1. Check the grip for
damage
1. Use a flat head
screwdriver to adjust the gap
between the rubber handle
and the cover.
2. Check the Throttle
spring.
2. Readjust the Throttle
supplier.
3. The Throttle handle is
loose.
3. Lubricate the Throttle
spring. Contact the supplier.
The
batteries do
not take a
charge.
Charger light is
off
1. Check the charger plug
position.
1. Check by unplugging
charger and plugging in
again.
2. Check the fuse in the
charger box.
2. Unplug the charger and
replace the fuse. Contact the
supplier to order a new
charger fuse/charger.
3. Charger has blown a
fuse.
3. Replace the charger fuse.
The fuse box is located on
the floorboard, unscrew the
two screws and open the
fuse case, and replace
scooter. Contact the supplier
to order a new fuse.
4. A bad connection
exists between the
charger and the battery.
4. Unplug and plug in again.
Otherwise contact the
supplier.
Horn No Noise 1. Check Connection. 1. Fasten Connection.
2. Adjustment Screw. 2. Turn for desired sound.

18
If the ZAPINO is not working, check the diagnostic light (break down
lights) above the speedometer, the signals are as follows:
First flash 3 and after a pause flash 3 times again:
Flash 1 time and after a pause then 1 time again:
First flash 1 time and after a pause then 2 times again:
First flash 1 and after a pause 4 times again:
First flash 1 and after a pause 5 times again:
First flash 3 times and after a pause 1 time again:
First flash 0 and after a pause 3 times again:
First flash 0 and after a pause 2 times again:
First flash 0 and after a pause 10 times again:
First flash 2 and after a pause 3 times again:
First flash 3 and after a pause 2 times again:
First flash 2 and after a pause 1 time again:
First flash 2 times:
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problem with throttle spring, it didn't come back to normal position.
problem with brake, check brake level for kick stand released or not.
problem with connection of throttle, broken wire is loosened.
problem with voltage, battery too low (charge).
battery too high voltage.
problem with motor, overloaded.
problem with motor, overloaded.
the battery overload can't release enough current to motor.
motor thermal sensor problem.
overheat protection, leave to cool.
problem on controller current sensor. Restart the key or repair
controller.
Motor rotated hold back. Release the motor.
Brake light on, brake stuck on, or broken circuit.
Diagnostic Warning Signal Lights

1. WARRANTY COVERAGE PERIOD
ZAP (ZAP) warrants from the date of delivery to the first consumer, that each
Electric Vehicle sold as “NEW”and “UNUSED”in 200 and pre-
delivered by an authorized ZAP dealer, and a copy of the bill of sale and
registration-warranty card has been presented to ZAP will be free from any
defect in material and/or workmanship for a period of:
SIX (6) MONTHS WARRANTY
NINETY (90) DAYS, for rental use owners
PRORATED WARRANTY on the batteries
All-Inclusive Coverage
ZAP will repair or replace, as its option, all genuine ZAP parts found faulty in
material and/or workmanship, under normal use, maintenance and service, with
genuine ZAP parts without charge for parts and labor, at any authorized ZAPINO
dealer during warranty coverage period.
All genuine ZAP accessories are warranted with respect to parts and labor
against defects in materials and workmanship for a period of 90 days from the
date of purchase to original retail purchaser. Except as otherwise provided
herein:
#Normal wear and tear items such as the charger plug and receptacle, seats,
windshield wiper blades, trim pieces, fuses, decals (except safety decals), brake
pads, brushes, bushings, light bulbs, mats and pads, cosmetic deterioration, and
items which deteriorate or fail due to exposure;
#Damage caused by failure to provide proper service, maintenance and/or
storage, as described in the ZAP Owner's Manual.
#Damages resulting from improper repairs, modifications or use of non-
approved parts or repairs done by a non-authorized ZAP dealer;
#Damage resulting from continued use of the vehicle after a defect is or should
have been discovered.
#Damage resulting from accident, fire, explosion, theft, vandalism, riot or any
act of God.
#Damages to batteries resulting from lack of maintenance, too deep of
discharge, or from freezing condition.
#Misusing the ZAP vehicle, such as driving over curbs, overloading or racing.
#Tampering with the ZAP vehicle.
#Altering or modifying the ZAP vehicle, including the body, chassis, mechanical
or electrical.
#Customer applied chemicals or accidental spills.
#Using contaminated or improper fluids.
#Non - ZAP parts installed after the vehicle leaves the ZAP factory or control.
#Transportation expenses for warranty services (covered under the On-Site
Program).
#Damages related to plastic and finish on plastic, including but not limited to
scratches, cracks, and discoloration.
#Driving through water deep enough to cause electrical system damage.
#This warranty does not cover such tires that have failed as a result from
ZAPINO 8
2. WHAT IS NOT COVERED
19
Warranty June 1, 2007