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MAINTENANCE

GEAR BOX OIL

BRAKE FLUID

After 500 miles you will want to change the oil in the gear box.
1) Remove the square head drain plug at the bottom of the gear box and drain the oil into a pan. Be careful how
much torque you put on the bolts, the plug bolts are made of a semi-soft metal and you don't want to strip them.
2) Replace the bottom drain plug bolt and remove the square head side overflow plug. Take your time and go
easy.
3) Remove the white oil spout plug at the top of the gear box and SLOWLY pour the oil into the spout area until it
begins to come out the side overflow hole. It will take about 6-8 oz. of lubricant.
4) Replace the overflow plug and the oil spout plug.
5) Look in the phone book for a place that recycles oil or disposes of oil.
6) After the break-in period, check periodically with a dipstick and change when dirty.
It is recommended to use Lucas Heavy Duty Oil Stabilizer at 100%. A gear oil weighted at 80/90 will be
suitable, too.

Inside the front deck lid and to the right is the brake fluid reservoir. Check the level
regularly. Gently twist the cap and lift off. You will see directly into the brake fluid
reservoir. If the fluid level is low, fill with DOT Type 4 brake fluid, using a funnel. Do
not spill fluid on tires, brakes or paint. Also, the brake light on the voltage meter will illuminate if the master
brake cylinder needs attention or if the brake fluid is low.

WINDSHIELD WIPER FLUID TANK

The Xebra steel Sedan comes with a windshield wiper fluid tank inside the front deck lid to the left. Check the
level regularly. As with the brake fluid reservoir, gently twist the cap and lift off. You will see directly into the
wiper fluid tank and fill appropriately when needed.

15

Owner

s Manual

ZERK FITTING

SEAT ADJUSTMENT

HEATER

Periodically lube the Zerk fitting with a high-quality, marine-grade, waterproof lubricant. It is located just
above the front tire.

It is recommended to have regular maintenance performed on your Xebra by a trained technician. At
1000 miles, your dealer should change the gear oil. Also, the batteries should be checked with a digital
volt meter. This will catch a failed charger early. For maintenance schedules, please refer to your
Service Intervals Sheet. After that, your dealer will recommend a maintenance schedule based upon
your driving conditions.

The seat adjustment lever is below the front edge of the driver's and passenger's seats. We recommend that you
make the adjustments BEFORE you get in, you could hit your knees on the steering wheel or dashboard if you
move forward too fast, or hurt someone's legs or feet in the back seat if you move back suddenly. Be sure to keep
fingers, feet and any other objects out of the seat track.

Adjust the back of the seat forward or back by turning the large dial on the side of the driver's or passenger's seats.
This is something you can do while seated, but be aware of people in the back seat. Their knees and feet can be
cramped or hurt while you are making the adjustments.

The switch for the heater is located on the mid console. There are two vents, both in the front, one on the driver's side and one on the
passenger's side. The heater is a 72-volt unit. It is primarily used to defog the windshield. Using it will rapidly deplete the batteries,
shortening your range.

ADDITIONAL EQUIPMENT AND INFORMATION

16

Owner

s Manual

Summary of Contents for XEBRA ZAPCAR 2009

Page 1: ...THE GROUND IF YOU HAVE QUESTIONS ABOUT THE OPERATION OF THIS VEHICLE YOU SHOULD CONSULT YOUR AUTHORIZED DEALER IT IS EXTREMELY IMPORTANT THAT YOU FOLLOW THE SAFETY GUIDELINES CONTAINED IN THIS MANUAL IN ORDER TO ENSURE MAXIMUM SAFETY FAILURE TO COMPLY WITH THE STANDARDS OUTLINED IN THIS MANUAL COULD RESULT IN FIRE AND OR SERIOUS INJURY ZAP IS NOT LIABLE FOR ANY DAMAGE OR INJURIES CAUSED BY UNSAFE ...

Page 2: ...edan or to the right of driver s seat truck 8 Turn direction knob to F for forward or to R for reverse and press red reverse button If going in reverse you will hear the reverse beeper 9 Remove foot from brake and place foot on accelerator SLOWLY 10 Drive carefully with gentle turns of the steering wheel 11 Anticipate stops your Xebra does Not have power brakes 12 The most common reason the Xebra ...

Page 3: ...er s Manual 6 7 8 Xebra Sedan Panel Xebra ZAPTRUCK Panel 1 2 3 4 5 6 7 8 1 Speedometer 2 V oltage meter 3 Ammeter 4 Odometer T rip odometer 5 T rip odometer reset button 6 Hazard lights flasher button 7 Hand brake engage light 8 Low Battery indicator IGNITION MASTER OFF BUTTON DIRECTION KNOB POWER CORD Put the key into the ignition and turn it clockwise one or two clicks Unlike a traditional engin...

Page 4: ...operate the Xebra if any such damage has occurred To close the hatchback lower close and gently press at center until it clicks Do not slam it Rough handling can cause damage to the latch and or body hatchback windshield s 7 7 Owner s Manual Fig 1 The following parts and components are Not intended to be serviced by the user only a ZAP trained technician Any repairs or alterations made to the vehi...

Page 5: ...ra that you can control is the batteries This section contains the procedure to follow in order to optimize the batteries performance and life If the batteries are not maintained properly the ZAP as well as the manufacturer s battery warranty may not be valid 1 Before you operate the Xebra for the first time you must fully charge the batteries using only the supplied internal charger This is an im...

Page 6: ...3 minutes to remove surface charge Leave heater on Place a lead on each terminal of the first battery Record the reading It should be 12 6V or higher Repeat for all six batteries Avoid shorting terminals together with tools or your body Add the six readings together and compare with analog meter reading Alternately make one reading across the entire pack by placing one lead of your meter on the be...

Page 7: ...in the Conditioning the Batteries section Be sure your brakes are properly adjusted and are not rubbing when not engaged 13 Owner s Manual Until the better battery arrives here are some things you can do to extend your range RECYCLING BATTERIES Do not attempt to destroy or disassemble the battery pack or remove any of its components Also never touch both terminals with metal objects or body parts ...

Page 8: ...the brake fluid reservoir gently twist the cap and lift off You will see directly into the wiper fluid tank and fill appropriately when needed 15 Owner s Manual ZERK FITTING SEATADJUSTMENT HEATER Periodically lube the Zerk fitting with a high quality marine grade waterproof lubricant It is located just above the front tire It is recommended to have regular maintenance performed on your Xebra by a ...

Page 9: ... The turn signals are self centering so they will return to neutral after the turn However if the turn is too gradual manual re setting may be required 17 Owner s Manual LIGHTS The Xebra has three lights in the front The center is the running light It is always on when the key is on It has two settings high and low The center light high low switch is located on the console Toggle the switch for hi...

Page 10: ...d will require longer charging or give less range if very cold See the BATTERY MAINTENANCE section for important information on how temperature affects the batteries In cold climates your Xebra should be kept warm in a garage or enclosure In hot climates park in the shade or keep in a cool garage or enclosure 19 Owner s Manual DO NOT POUR WATER ON THE MOTOR MOTOR CONTROLLER DC TO DC CONVERTER OR B...

Page 11: ...ling Fan 4 Horn 5 Batteries 6 Charger 7 Controller 1 2 3 4 5 6 7 Owner s Manual ZAPTRUCK SPARE TIRE DUMPINGAND SECURING THE BED The spare tire is located under the rear of the bed Remove it by inserting the long tool provided through the hole on the bed and into the receiver above the tire Fig 1 Rotate the handle until the tire drops far enough to release it Some spares are bolted on When replacin...

Page 12: ...y ZAP Other batteries may explode causing personal injury and damage 2 DO NOTPLACETHE BATTERYNEAR FIRE OR HEAT It could explode 3 Batteries can emit explosive gases while being charged Read the instructions supplied before attempting to charge your battery 4 1 Before charging read the applicable sections including BATTERYCharger Battery Maintenance and Power Cord 2 USE ONLY THE APPROVED GAUGE POWE...

Page 13: ...URY 25 Owner s Manual THE MANUFACTURER IS NOT LIABLE FOR ANY DAMAGE OR INJURIES CAUSED BY UNSAFE OR FAULTY REPAIRS ANY REPAIRS MADE TO THIS PRODUCT BY UNAUTHORIZED SERVICE TECHNICIANS ARE THE SOLE RESPONSIBILITY OF THE OWNER ANYALTERATIONS WILL THE FOLLOWING WARRANTY Batteries covered by Battery Manufacturer Charger covered by Charger Manufacturer VOID WARRANTY January 2009 1 WARRANTY COVERAGE PER...

Page 14: ...cture or tire repair also is not covered Parts and labor needed to maintain the Xebra and the replacement of parts due to normal wear and tear 27 Owner s Manual w w Surface rust and deterioration of paint trim upholstery and other appearance items that result from use and or exposure to the elements including sun damage Using the Xebra to tow other vehicles trailers etc may void warranty Batteries...

Page 15: ...PPLICABLE WARRANTY PERIOD A NEW VEHICLE OR FACTORY RECONDITIONED VEHICLE OR COMPONENT THEREOF WHICH IS IDENTICAL OR REASONABLY EQUIVALENT TO THE WARRANTED PRODUCT OR COMPONENT AT NO COST TO THE PURCHASER REPAIR SHALL MEAN REMEDYING A DEFECT IN THE VEHICLE OR COMPONENT THEREOF AT NO COST TO THE PURCHASER DURING THE APPLICABLE WARRANTY PERIOD IF THE MANUFACTURER ELECTS TO REPAIR THE VEHICLE IT MAY P...

Page 16: ...d vehicle to come to the USA In these days of record high gas prices daily discussions of global warming and dependence on foreign oil we appreciate your commitment to change Investing in an electric vehicle company and or buying an electric vehicle are two of the best things you can possibly do for the environment We are looking for dealers If you are interested please contact us We are proactive...

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