ZooZ THE URBAN ULTRALIGHT User manual

Assembly Guide and User Manual
v2

It’s Oicial, YOU are a #ZOOZER
In order to properly operate your ZOOZ Urban Ultralight, you must thoroughly read the owner’s manual to
become familiar with your bike’s assembly, adjustment, controls, features, capabilities and limitations. It is
the owner and rider’s responsibility to ride within the limits of their capabilities and to abide by local laws
and regulations.
This manual is intended to guide you through the proper assembly and maintenance procedures; to ensure
safe and proper function of your ZOOZ electric bicycle. However, it is intended to serve as a general
guideline, not a substitute for best bicycle practices, proper care and good judgment. If you are unfamiliar
or unsure of the assembly, adjustment and use of this bike, it is strongly encouraged that you nd a
professional bicycle shop to perform such assembly and maintenance. Just like any other bike, your ZOOZ
will need proper adjustment and systematic checks regularly. You should routinely perform these checks,
especially if the bike is geing heavy use.
Please check your country or state’s regulations on electric bikes before riding. There are variations on age
limit, speed, motor waage and road accessibility. Visit this website for more information:
www.peopleforbikes.org/electric-bikes/policies-and-laws
No liability or warranty shall be accepted if the use of the ZOOZ Bikes electric bicycle deviates from this
intended use, if safety instructions are not observed, in the event of overloading, or if faults are not properly
rectied. Similarly, no liability and warranty shall be accepted in the case of assembly errors, willful intent,
accidents and/or if care and maintenance specications are not followed. Any modications or alterations
to the electrical system (tuning) voids all claims under warranty and guarantees. Your ZOOZ Bikes electric
bicycle is designed for use on paved paths only. You should therefore never ride on stairs, jump, or perform
wheelies or similar activities. ZOOZ Bikes electric bicycles are not approved for participation in competi-
tions. Commercial use does not form part of the intended use. Operation parameters, maintenance, guide-
lines and service instructions described in this manual are part of the intended use.
If you have any questions or concerns, please contact [e-mail].
pg. 1

pg. 2
SEPARATE ITEMS IN THE BOX:
Bike Elements
Low seat height oers a neutral,
upright riding position that allows
the rider to sit in a natural place,
forward or rearward depending on
rider size. Best for riders 5’5” to 6’4”.
Seat.
18650 Lithium-ion cells with
an industry standard housing
and mounting system.
Battery.
Hydraulic disc
brakes provide
superior stopping
power.
Brakes.
For throle, display, brakes and
cut-o sensors.
Cables.
Forged aluminum.
2 piece stem. 4 bolt
clamp.
Stem.
Square taper, forged aluminum
with cadence pedal assist sensor.
Crankset.
Standard, interchangeable pedals.
Pedals.
Lightweight double wall aluminum
wheels with reinforced spoke eyelets.
Round tire prole and sticky rubber
oers maximum traction for fast,
high lean cornering.
Wheels & Tires.
Chrome plated, 4130 chromoly
steel is lightweight, absorbs
road shock and delivers superb
ride feel.
Frame.
Charger.
Pedals.
Keys.
250w 44.1 lbs
750w 55.7 lbs
1100w 62.6 lbs
with baery
Weight.
250w/750w geared hub
motor, or 1100w direct
drive hub motor.
Motor.

Assembly Guide
pg. 3
STEP 1
Open box. Be careful to not to damage you the bike or hurt yourself with any
sharp tool. Locate and remove smaller box containing the charger. The bike will
be mostly assembled inside the bike box with the front wheel and handlebars
strapped to the frame of the bike. Li the bike out of the box with another
person's assistance. Carefully remove the zip ties and foam from the bike. Set
the front wheel to the side. Damage occurring from unboxing or assembling is
not covered in the warranty. Please have a professional assemble the bike.
Unbox the charger and baery. Plug the charger into any standard wall
socket, then plug the other end of the charger into the baery port, which has a
rubber plug that can be apped open next to the power switch. The light on the
charger will turn red when plugged in and not completely charged. Charge the
baery until the light turns green before taking your rst ride. Indicator lights on
the side of the baery display general charge when baery is removed from the
bike. Baery charge indicator lights on the side of the baery will only work
when the power switch is on. A red blinking light indicates an error.
STEP 2
Warning: This bike must be assembled by a professional for proper
and safe function. Improper unpacking and assembly can cause damage to the
bike and/or bodily harm and is not covered by the ZOOZ Bikes warranty.

pg. 4
STEP 3
Hold the bike steady in an upright position on a so oor surface to avoid
scratching the frame or fork. Unscrew the 4 bolts from the top of the handlebar
stem and remove the stem clamp. Position the handlebars with the knurling
centered inside the handlebar clamp. Make sure that the control cables are not
tangled, twisted, or kinked. Position the handlebars at an upright angle with a
slight rearward or forward angle as per your preference. Tighten the handlebar
clamp so the gaps of the clamp in the front and the rear of the clamp are equal.
Give a gentle tighten on the handlebar clamp bolts for now. We will return to
these bolts during adjustment and torquing.
STEP 4
Remove the plastic brake caliper spacer and axle brace. Be sure not to squeeze
the brake while the clip or the wheel is removed. If you have accidentally done
this, use the brake caliper clip to gently spread the brake pads inside the brake
caliper. Prepare the front wheel axle for mounting by removing the front axle
nuts, at washers and hook washers.

pg. 5
STEP 5
Each pedal screws into the crank arms with threads that spin in the opposite
direction. Identify the pedals for each side by nding an R and L stamped on the
threaded spindle of the pedals. Thread them onto the crank arms by hand.
Rotating the pedals toward the front of the bike will tighten the pedals. Once
threaded, tighten with a 15mm open-end wrench to tighten snugly. We will return
to the pedals during adjustment and torquing.
Li the bike from the handlebars to lower the forks onto the front axle and
guide the disc into the brake caliper and the axle slots into the axle plates.
This is easiest to do with the help of another person. Slide on the hook washers
so that the hook is seated in the small hole on the axle plate. Slide the at
washer on next, then thread the axle nut on by hand and give a gentle tighten
with a 15mm closed-end wrench. We will return to these bolts during
adjustment and torquing.
STEP 6

pg. 6
Stop
The bike is now assembled, but you will need proper
adjustment and systematic checks regularly,
especially if the bike is geing heavy use. You
should routinely perform the following checks in the
following ‘Adjustment & Torquing’ section of this
manual. Checking all bolts before each ride is highly
recommended.
At times, it will be necessary to remove the baery; for cleaning, replacement or
charging in small spaces. To do so, insert and turn the key 180 degrees into the
“unlock” position. Grasp the baery in the middle and tug forward to slide it o.
When placing the baery back on the bike, reverse the process, placing the
baery at the front of the mounting plate and ensuring the tongue-and-groove
is fully engaged, and slide it back. Give it a good tug rearwards to make sure
it’s fully seated. Insert and turn the key back to the locked position to secure it.
It should be eortless to turn the key. If it’s not turning easily, it means the
baery is not properly seated. Remove it and try again.
STEP 7

Adjustment & Torquing
pg. 7
REAR WHEEL ALIGNMENT, CHAIN ADJUSTMENT
Rear wheel alignment and chain tension should be checked oen. Electric bikes sustain higher speeds and forces than standard bikes. Movable/adjustable parts can
move more frequently than regular bikes. Make sure that the rear wheel is properly aligned by equalizing the spaces between the rear wheel/tire and the frame on either
side using the adjusters. You must also make sure that there is chain tension for proper function. To do this, slightly loosen each axle nut on the rear axle and the lockout
nut on the adjusters until the axle slides freely in the axle slot. Align rear wheel while maintaining chain tension by tightening the adjuster bolts incrementally on each
side. Aer the axle is in the right position, tighten the adjuster lock nuts then tighten axle nuts to 350 in/lbs. The rear tire should be pressurized to t rider weight and
terrain. Lower pressures help smooth out rough terrain and provide more traction on some surfaces. 30-35 PSI for normal road terrain and rider 120-180 lbs. Add more PSI
up to the maximum recommended pressure labeled on the side of the tire for heavier riders as needed.

pg. 8
FRONT WHEEL ALIGNMENT
The front wheel should not ever come loose under proper assembly and
torquing. However, you should be sure that the axle is completely seled in the
axle slots, hook washers are in place and the axle nuts are torqued to 250
in/lbs. The front tire should be pressurized to t rider weight and terrain. Lower
pressures help smooth out rough terrain and provide more traction on some
surfaces. 30-35 PSI for normal road terrain and rider 120-180 lbs. Add more PSI
up to the maximum recommended pressure labeled on the side of the tire for
heavier riders as needed.
Brake caliper alignment/adjustment. It is common to get some noise from
brake discs if not perfectly aligned and in proper working order. This can occur
aer heavy use. Loosen the adjustment bolts and lightly position the brake
caliper on the disc. An easy method to do this is to lightly hold the brake lever
to center the brake caliper on the disc. Then tighten the bolts incrementally up
to 50 in/lbs. This can take a couple tries and may take some manual/eyeball
adjustment. The brake caliper mounting brackets (frame/fork to brake caliper
bracket) should always be securely tightened to 70 in/lbs.
BRAKE CALIPER ALIGNMENT

pg. 9
STEM, FORK, HANDLEBAR
This controls your handlebar alignment and must be snugly ed for safe
riding. The steerer tube and stem must be tight and exhibit no "play" or wobble
in the steering head. You can check this by loosening the bolts on the side of
the stem and tightening the cap bolt to pull the "stack" of steering bearings
and spacers together. Do not over-tighten the cap bolt, but the stack of
bearing and spacers on the steerer tube should be tight. Ensure that the stem is
aligned with the front wheel. Once aligned, re-tighten the stem bolts that
clamp the steerer tube. Now check alignment and angle of the handlebars and
then tighten handlebar clamp bolts. All bolts on the stem should be torqued to
250 in/lbs.
Crank bolts can come loose with excessive wear or heavy use. These should be
checked and torqued oen to 350in/lbs. Apply light grease whenever
re-assembling. Do not over tighten for risk of stripping the bolts.
CRANK BOLTS