Zapata Racing Flyboard Installation and operating manual

FlyBoard User and Safety Guide
Revised 9/25/12
Operators must read the FlyBoard User and Safety Manual before
taking the Video Operational Training Course.
Warning
Do Not let anyone Operate the FlyBoard from the PWC or operate the
FlyBoard, using the EMK, without being Certified by FlyBoard, Inc.,
the Video Operational Training Course or a Certified FlyBoard Inc.
Instructor. A person may seriously injure or cause death to
themselves, or someone else, without proper training.
When the FlyBoard Operator is using the Electronic Management Kit,
they must have a certified operator on the PWC.
Coming Soon
The Video Operational Training Course is available for
FREE Online
At FlyBoard.com
INSIDE THIS MANUAL
1. Description
2. Safety and General Information
a. Age
b. Weight
c. Wind Speed and Waves
d. Training
e. Use of FlyBoard
f. FlyBoard Operations
!g. Electronic Management Kit (EMK) Use
3. Type of PWC
4. Connection to the PWC
FlyBoard Use and Safety Guide © 2012 FlyBoard Inc. All Rights Reserved.

5. Where to Practice FlyBoard
6. Maintenance
7. Composition and assembly of the FlyBoard
DESCRIPTION
The FlyBoard!® is an accessory that attaches to any PWC (Personal Watercraft). The
PWC propels the FlyBoard through air and water. The FlyBoard propels 90% of the
water through the primary nozzle, with the remainder routing through the hand nozzles
which ensure stabilization. Despite its seemingly intuitive use, the FlyBoard is
extreme sport equipment. Operators should practice with great vigilance.
SAFETY AND GENERAL INFORMATION
Age and Weight
1.Persons MUST be 18 years of age or older to use the FlyBoard.
2. No Operator can weigh over 375 lbs.
Instructor Training
To become a Certified Instructor a person must take a 7 hour hands on Instructor
course at FlyBoard, Inc Instructor School, in Fruitland Park, Florida. Also, the person
must obtain and provide the following:
- First Aid and CPR Certifications (can be done online)
-Boat Safety Course (for your country and/or state law) (can be done online)
-Time Log – 20 hours minimum on the FlyBoard.
-Insurance
Equipment Required
(Operators must wear this equipment at all times while using
the FlyBoard)
1.Coast Guard approved Buoyancy Vest
2.Wakeboard (or comparable) helmet / FlyBoard Certified Helmet
3.Isothermal Pants – The penetration of water through the orifices of the body during a
fall may cause serious injuries. Wearing a simple bathing suit is not adequate
protection against the power of water penetration into the lower orifices of the body.
FlyBoard Manual © 2012 FlyBoard Inc. All Rights Reserved.

4.Ear Plugs (unless you have a Wakeboard Helmet that covers the ears) Putty style ear
plugs are recommended as they are not small enough to get forced into the ear canal.
Use of FlyBoard
1.The operator of the FlyBoard must have a fellow certified operator on the PWC at all
times with or without the Electronic Management Kit. This ensures that if any safety
concerns should arise, a qualified person is always present to assist.
2.The FlyBoard user and PWC driver must be able to swim efficiently.
3.The FlyBoard must be used only by one person. It is strictly forbidden to have two or
more persons on the FlyBoard at the same time.
DO NOT USE the FlyBoard when:
1. Winds exceed 35 mph and/or waves exceeding 3 ft in height.
2. Under the influence of alcohol, narcotics or drugs that affect alertness.
3. Pregnant.
4. Dealing with any pre-existing conditions and/or injuries; please consult your doctor
before use of the FlyBoard.
5. You are phobic of water.
6. Tired or fatigued.
7. Using compressed air or scuba equipment. This could cause an embolism and death.
8. Wearing contacts lenses or eye glasses.
Operators MUST:
1. Follow the navigational laws in force in the country where using the FlyBoard.
2. Find an area away from any other watercraft such as: boats, PWCs, and other
FlyBoard operators. Also, stay clear of swimmers, divers, and other people in the
water.
3. Operate the!FlyBoard!in a minimum depth of 8 feet of water, unless diving in and out
of the water, in which case maintain a depth of 12 feet or greater. Also, be aware of
any obstacles beneath the water and only dive in water with 100% visibility to
previously specified depths.
4. Be aware that water depth can change significantly over short periods of time due to
tides, currents, and manmade events. You must adjust your depth accordingly to
meet the minimum depth requirement set forth above.
DO NOT:
1. Direct the jet propulsion towards a person.
FlyBoard Use and Safety Guide © 2012 FlyBoard Inc. All Rights Reserved.

2. Dive into murky water. Most water injuries are caused by diving into the water.
You could cause neck and/or spinal injuries. Know your water area. If you are
going to dive into the water, it is best to dive into clear water.
3. Take off and/or land, on land, or use the FlyBoard near any surface such as rocks,
docks, beaches, boats, banks, etc., as the risk of injury near these surfaces is high.
4. Attempt to swim while attached to and/or using the FlyBoard. The FlyBoard will float
and while wearing the correct CE Certified vest, you will float.
5. Exceed your physical limits. Also, avoid aggressive maneuvers to reduce the risk of
losing control. The FlyBoard is a high performance machine, not a toy.
6. Reproduce stunts, tricks, and risky behaviors as seen on television, the internet, or in
person (example: back flips). These are made by professionals and if attempted by a
non-professional, could risk serious injury, put your life in danger, and damage the
equipment.
7. Operate the FlyBoard near sand. Sand will get into bearings. Time is needed to
break in the FlyBoard bearings and seals.
FlyBoard Operations
Warning: Make sure that the 45 foot hose is all the way extended before you
throttle the power of the Jet Ski to raise the FlyBoard user out of the water.
Powering the throttle before the hose is fully extended could seriously cause
injury to the FlyBoard user.
When turning, you must have a minimum turning radius of 30 feet. An aggressive turn
against the PWC may cause:
A. The FlyBoard user to fall
B. The PWC driver to fall
C. Malfunction of the FlyBoard
D. Destruction of FlyBoard in whole or in part
Do not turn 360 º loops in front of the watercraft as this may damage the hose and
electric cable.
You can go 45 feet high and we recommend not going deeper than 8 feet deep. If you
go deeper than 8 feet and you do not pressurize your ears, you can rupture your ear
drums.
It is advisable that the FlyBoard user falls forward as much as possible so that the
nozzles of the propulsion are directed downward, which greatly helps to cushion the fall
and aids in not sinking under water.
Never take a path towards the PWC either forward or backward.
FlyBoard Manual © 2012 FlyBoard Inc. All Rights Reserved.

The FlyBoard user and PWC driver must make sure that the FlyBoard user has
sufficient stability without falling (forwards or backwards) before attempting higher
elevations.
If, when submerged the operator becomes disoriented, the operator should release the
throttle or shut off the engine to the PWC in order to float back to the surface.
In water where strong currents are possible, you must have the PWC’s power on to be
able to escape the current from pulling the person on the FlyBoard under. If the
FlyBoard operator needs to turn the power off, quickly turn the power back on to aid in
escaping the water current.
For a novice FlyBoard user
The driver of the watercraft must not exceed 4500 RPMs (Revolutions per Minute) when
trying to lift the FlyBoard user out of the water, unless the FlyBoard user weighs 225 lbs
or more, then the watercraft must not exceed 5000 RPMs. If the FlyBoard user fails to
take off, it means that their feet are not positioned correctly. It is important not to
accelerate more than the RPMs stated because the user may be propelled in the air
and rise out of the water higher than is allowable.
When the FlyBoard is operated from a person from the PWC (without the electronic kit),
the driver of the watercraft must not exceed 6000 RPMs. It is recommended for PWCs
over 250 hp, to use their key to limit the amount of horse power used (please see your
PWC manual).
The FlyBoard user"must
1. Enter the water face forward.
1. Maintain a minimum distance of 15 feet from the PWC at all times.
2. Always be absolutely positioned to move forward and never backward to limit falls on
their back. You want to fall on your front side and fall away from the PWC, this will
help you avoid coming in contact with the PWC and Hose.
3. Constantly control their position relative to the PWC and be even more vigilant when
they rise to heights greater than 15 feet.
4. Also be aware of, and avoid, the presence of any objects, reefs, buoys, shallow land,
etc.
5. Be aware that the water depth can change significantly over short periods of time due
to tides, currents, and man made events, such as releasing water from reservoirs.
You must adjust your depth accordingly to meet the minimum depth requirement of 8
feet.
FlyBoard Use and Safety Guide © 2012 FlyBoard Inc. All Rights Reserved.

If and when the FlyBoard user
1. Gets closer than 15 feet, release the throttle. This will help the FlyBoard user to
remember to stay away from the PWC.If the FlyBoard user is higher than 10 ft,
release the throttle gradually.
2. Gets closer than about 8 feet, do not release the throttle, by doing so the operator of
the FlyBoard could hit the PWC. Instead, slowly let up on the throttle.
3. Falls into the water, the FlyBoard user must be aware of the distance between
themselves and the watercraft which the FlyBoard is connect to due to the inertia that
may push the PWC towards the FlyBoard user. You want to avoid the PWC from
hitting your head.
4. Falls on their back or goes underwater (from a fall, dip, etc.) the driver of the
watercraft must immediately release the throttle and turn off the engine to stop the
person from going to the bottom of the lake or body of water.
5. Falls, especially on their back, the user may go underwater to a depth of about 6 feet
and must anticipate an apnea of about 10 seconds during the fall and during
immersion.
Electronic Management Kit (EMK) Use
The electronic system must be installed by a professional.
The Electronic Management Kit or EMK has 4 LED lights indicating the amount of
propulsion used. 1 LED light is the minimum and 4 LED lights is the maximum.
The FlyBoard user must begin learning with step 1 (1 LED light) for a minimum of 20
minutes of use. More time may be necessary depending on user capabilities.
Each step (LED lights) must be performed for a minimum of 20 minutes before moving
on to the next step.
Step 4 (4th LED light), must not be used until the user has spent a minimum of 10 hours
in position 3 (3rd LED light) for PWCs in excess of 150 hp. Step 4 has the potential of
lifting the FlyBoard user 45 feet into the air. Step 4 should only be used by advanced
FlyBoard users.
If you have the EMK installed, you must lubricate the stainless bearing in the 180
degree Elbow after each use or when storing. Before you use the FlyBoard make sure
that stainless steel bearing rotates freely, if the bearing does rotate freely, it will damage
the EMK cable. This is not covered under Your warranty.
TYPE OF PWC
FlyBoard Manual © 2012 FlyBoard Inc. All Rights Reserved.

PWC - Any type of watercraft provided that is approved and certified by the authorities
of the country of use.
Power requirement: 100 hp
Maximum power allowable: 300 hp
It is extremely dangerous and not recommended to remove the buoyancy elements of
the PWC or FlyBoard.
Adapters are available from our distributors depending on the brand and model of each
watercraft.
Never trailer or launch the Jet Ski with the 180 degree elbow on back of the PWC.
WHERE TO PRACTICE THE FlyBoard?
The FlyBoard can be used in both closed water (ex. lakes) and in open water (ex.
ocean) provided that the minimum water depth of 8 feet is respected. 12 feet when
diving.
Warning: It is the responsibility of the user to ensure that there is sufficient depth of
water in the place chosen to use the FlyBoard.
If you are setting up, breaking down, or just docking the FlyBoard near a dock, where
there are waves, make sure to bring all parts of the FlyBoard (especially the hose) out
of the water because it may drift and get caught on rocks or get wrapped around the
dock.
MAINTENANCE
To ensure adequate security, we recommend:
a. Do not bend black arm hose more than 30 degrees, this will shorten the life of the
hose and void your warranty. When you do bend the hose, bend the hose back to it
original shape with a channel lock pliers. This will stop the wires from sticking out and
causing the hose to leak. Also, the hose is made extra long so that you can cut off the
hose where it leaks.
b. Spray the Bearing of the EMK on the 180 degree pipe with lubricant daily. Spray with
lubricant before and after being stored for a long period of time. Also, make sure that
the Bearing rotates freely before each use, if the Bearing does rotate freely, it will
damage the EMK Cable. This is not covered under Your warranty.
FlyBoard Use and Safety Guide © 2012 FlyBoard Inc. All Rights Reserved.

c. After two hours of operation of the FlyBoard, check and make sure the allen head
bolts that hold the hose housing in back of the PWC are tightened.
d. Each day you use the FlyBoard make sure the boots screws are tightened.!
e. Change the hose every 2 years
f. Changing the plastic ball pivot systems and rotation of the FlyBoard every 2 years
g. Change the pipes connecting the thrust system to the hands every 2 years
h. Change the hose protection carabineer regularly due to wear
i. The FlyBoard should be rinsed with clean water after each use
j. Do not pull the hose on the floor when full of water
k. The hose should be rinsed, dried, and rolled up after use and before each storage
l. Do not over tighten the 180 degree elbow to the PWC this will cause your allen
wrench to break. Have spare 6mm round allen wrench in your PWC compartment at
all times.!
m. Get a floating device for your allen wrench.
n. The FlyBoard must be stored in a dark, dry place.
CONNECTION TO THE PWC
To connect the FlyBoard to the watercraft
1. Remove the rear jet nozzle and braking system (your PWC may not have a braking
system).
2. Connect the adapter (part # 001) for the appropriate make and model to your PWC.
3. Attach the large 180º Elbow (part # A01) to the adapter (part # 001) that is attached to
your PWC.
The screws on the large 180º elbow (part # A01) must be tightened counter-clockwise
and should not be over tighten with the allen wrench, as over-tightening could break the
key or screw. Tighten screws with one hand. This will prevent over tightening.
With the large 180º elbow coming out of the PWC and going to the left (facing back of
PWC),you need to tighten the screw in the top right first as this is the screw that holds
theelbow in place.
FlyBoard Manual © 2012 FlyBoard Inc. All Rights Reserved.

To make sure that you have connected the top right screw properly, gently wiggle the
elbow back and forth the ensure that you have tightened the screw correctly so that the
elbow doesn’t slide around.
4. No longer is the back strap needed.
5. Connect the front strap (part # 006) to the coupling hook in front of the PWC as
shown in the picture below
The FlyBoard ® is licensed for all recreational and leisure rental, lucrative shows and
Demonstrations are exclusively reserved to ZAPATA RACING.
The FlyBoard ® is protected by USA and International patents.
All rights reserved. Any reproduction, even partial, of the product by any means
whatsoever is prohibited under penalty of law.
To have the 1 YEAR LIMITED GUARANTEE OF THE FlyBoard, you must register on
the site: www.zapata-racing.com, section “FlyBoard - Service” within 15 days after
purchase.
Zapata Racing does not guarantee the FlyBoard if not used as described in this manual.
The warranty is limited and covers only defective parts.
The warranty does not cover wear and tear on parts.
The FlyBoard should be used in its original configuration. It is strictly forbidden and
dangerous to modify, remove, or add parts other than those provided by Zapata Racing.
Breakage of equipment caused by falls associated with extreme use will not be
guaranteed.
This manual is not fully comprehensive and you must use sound judgment and
FlyBoard Use and Safety Guide © 2012 FlyBoard Inc. All Rights Reserved.

proceed with caution.
It is your responsibility to frequently check for the latest release of this manual.
The most current manual is available online at:
http://FlyBoard.com/docs/manual.pdf
or call our offices at 1-800-599-9581 or 352-388-1092
to request one to be sent to you.
FlyBoard User and Safety Manual © 2012 FlyBoard Inc. All Rights Reserved.
Please See Manual for legal information and warranty information.
FlyBoard Manual © 2012 FlyBoard Inc. All Rights Reserved.

SNOITCURTSNI
001 : CONNECTED TO THE PWC INSTEAD OF THE OUTLET CONE USING THE ADAPTER KIT AS EXPLAINED IN THE “FLYBOARD
ADAPTER ASSEMBLY” SHEET ACCORDING TO THE PWC MODEL (SEE PICTURE)
014: TORQUE: 13 LB/ft, BEFORE TORQUE PLACE THE PROTECTION SOCK REP.006 UPWARDS (SEE PICTURE)
SNOITCURTSNI
010 :CONNECT TO THE FRONT STRAP
011 :ADJUST THE STRAP AS SHOWN IN THE PICTURE
012 : CONNECT TO THE BACK CARABINER
PHASE 01: PWC CONNECTION ASSEMBLY
PHASE 2: TUBE ATTACHMENT ASSEMBLY
STRAP ASSMBLY REP.011
FACING THE PWC

SNOITCURTSNI
014 : TORQUE 13 LB/ft
PHASE 03 : PIVOTAL HOSE CONNECTION
SNOITCURTSNI
022 : TORQUE 7 LB/ft USE LIGHT TORQUE BRAKE
PHASE 04 : Y CONNECTOR ASSEMBLY
1” Screws

SNOITCURTSNI
022 : TORQUE 7 LB/ft USE LIGHT TORQUE BRAKE
028 : TORQUE 7 LB/ft USE LIGHT TORQUE BRAKE
PHASE 05 : LEFT NOZZLE AND PIVOTAL ASSEMBLY
SNOITCURTSNI
022 : TORQUE 7 LB/ft USE LIGHT TORQUE BRAKE
028 : TORQUE 7 LB/ft USE LIGHT TORQUE BRAKE
PHASE 06 : RIGHT NOZZLE AND PIVOTAL ASSEMBLY
7/8” Screws
1” Screws
7/8” Screws
1” Screws

SNOITCURTSNI
034 : TORQUE 12 LB/ft USE LIGHT TORQUE BRAKE
035 :TIGHTEN THE SHOES IN ORDER TO GUARANTEE A GOOD FEET MAINTENANCE AND STABILITY
036 : TORQUE 7 LB/ft USE LIGHT TORQUE BRAKE
PHASE 07 : BOARD ASSEMBLY
SNOITCURTSNI
039 : TORQUE 7 LB/ft
PHASE 08: LEFT STABILIZER TUBE ASSEMBLY
NOTE : SAME FOR THE RIGHT STABILIZER TUBE ASSEMBLY
1” Screws
1 3/8” Screws

SNOITCURTSNI
039 : TORQUE 7 LB/in
A05 : BEFORE TIGHTENING THE CLAMP REP.036 DIRECT THE HANDLES TOWARDS THE FRONT OF THE FLYBOARD
A05: TIGHTEN MODERATELY THE VELCRO ON THE ARMS WHEN USING THE FLYBOARD
NOTE: SAME FOR THE RIGHT STABILIZER ASSEMBLY, REPLACE REP.005 BY REP.006
PHASE 09 : LEFT STABILIZER ASSEMBLY PHASE 10: FULL ASSEMBLY
Length not to scale

NOTES
FLYBOARD ADAPTER KIT 01 – SEADOO
201 04 CHC M8x30 SCREW
200 04 1 SPECIAL RING
FOR A KAF01
KAF01 ASSEMBLY: SEADOO FLYBOARD ADAPTER
SNOITCURTSNI
201 : TORQUE 21 LB/ft USE MEDIUM TORQUE BRAKE

NOTES
FLYBOARD ADAPTER KIT 02 – SEADOO 2010
204 03 CHC M8x80 SCREW
203 01 SEADOO 2010PUMP ADAPTER
202 03 SEADOO 2010 PUMP BRACE
FOR A KAF02
KAF 02 ASSEMBLY SEADOO 2010 FLYBOARD ADAPTER
SNOITCURTSNI
204 : TORQUE 21 LB/ft USE MEDIUM TORQUE BRAKE

NOTES
FLYBOARD ADAPTER KIT 03 – KAWASAKI 15F
206 04 2 SPECIAL RING
205 01 KAWASAKI 15F PUMP ADAPTER
201 04 CHC M8x80 SCREW
FOR A KAF03
KAF 03 ASSEMBLY KAWASAKI 15F FLYBOARD ADAPTER
SNOITCURTSNI
201 : TORQUE 21 LB/ft USE MEDIUM TORQUE BRAKE

NOTES
FOR A KAF04
KAF 03 ASSEMBLY KAWASAKI ULTRA FLYBOARD ADAPTER
SNOITCURTSNI
201 : TORQUE 21 LB/ft USE MEDIUM TORQUE BRAKE
FLYBOARD ADAPTER KIT 03 – KAWASAKI ULTRA
207 04 KAWASAKI ULTRA PUMP ADAPTER
206 01 SPECIAL RING 2
201 04 CHC M8x80 SCREW

NOTES
FOR A KAF05
KAF 05 ASSEMBLY YAMAHA FLYBOARD ADAPTER
SNOITCURTSNI
210 : TORQUE 21 LB/ft USE MEDIUM TORQUE BRAKE
FLYBOARD ADAPTER KIT 05 – YAMAHA
210 04 M10x120 SPECIAL CREW
209 04 YAMAHA PUMP BRACE
208 01 YAMAHA PUMP ADAPTER