Zundapp Z800 Operating Manual Download Page 71

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Operating Manual – Mountain bike with electric motor up to 250 W

25.08.2021 REV 1.1

24.

Service and contact

To the assembly video

To the service form

Please note that only service orders requested using the service form can be processed. Thank you

for your understanding!

Zündapp Vertriebsgesellschaft mbH

Steinstraße 54
81667 Munich

Germany

www.zuendapp.com

Summary of Contents for Z800

Page 1: ...Operating manual Zündapp Z800 Mountain bike with electric motor 250 W rated power Translation of the original operating manual ...

Page 2: ... and preventive maintenance 10 4 Theft prevention 11 5 Performance tuning forbidden 11 6 Recommendation for insurance cover 11 7 Safety 12 Intended use 12 Unauthorised modifications forbidden 12 Attachment of luggage racks and or trailers 12 Minimum age 13 Personal qualifications 13 Personal protective equipment 13 Orthographic features of warnings 14 Orthographic features of warnings of material ...

Page 3: ...ry due to inadequate maintenance cleaning and care 19 Avoid burns 19 Avoid injuries to your legs 20 Avoid vibrations 20 Vibration 20 Noise 20 Avoid illnesses 20 Avoid dehydration from cycling 20 Avoid frostbite 21 Avoid falls due to sudden engagement of the electric motor assistance 21 Avoid pollution 21 Avoid explosions 21 Avoid material damage 21 8 Safety instructions and general information on ...

Page 4: ...g the spring rate at the suspension forks 36 Checking the tyre pressure 37 13 Using the bike 38 Installing and removing the battery 38 Removing the battery 38 Installing the battery 38 Actuating the brakes 39 Operating the gears 40 Actuating the rear derailleur 40 Actuating the front derailleur 41 14 Controlling the pedal assistance 42 Control unit overview and functions 42 Display functions and k...

Page 5: ...s deep discharge mean 50 What is the service life of my battery 50 Can I generally allow my battery to charge over night 50 17 Riding your bike 50 Tips for safe riding 51 Riding with pedal assistance 52 Riding without pedal assistance 53 Foot position on the pedals 53 18 Troubleshooting 54 19 Frequently asked questions FAQ 56 How far can I travel with a fully charged battery 56 General questions 5...

Page 6: ...r 05 08 2021 REV 1 1 6 23 Bike passport 70 24 Service and contact 71 25 EC Declaration of Conformity 72 26 Important information for sending back your E bike 73 27 Important information for sending back a battery 74 28 Transport document for hazardous goods battery 75 ...

Page 7: ... the pedals on p 32 Adjust the handlebars see 11 Assembling components of the bike Installing and turning the handlebars on p 29 Adjust the saddle see 11 Assembling components of the bike Adjusting the saddle on p 30 Check the proper function of all the brakes see 13 Using the bike Actuating the brakes on p 39 Check the function of the derailleur see 13 Using the bike Operating the gears on p 40 a...

Page 8: ...lements in a legend or in the running text these are indicated with a num ber Further applicable documents Further details instructions and information on the components of the bike can also be found in the documentation from the respective manufacturers These documents form an integral part of this manual Keep these documents together with this manual Hand over these documents if you sell or othe...

Page 9: ...tubes bearings gear shift mechanism brake pads chain sprockets pinions bottom bracket gear shift and brake cables as well as paintwork and stickers The warranty does not cover damage caused by failure to observe the assembly instructions or by im proper use jumps stunts tricks wheelies downhill The bike is intended exclusively for private use Damage caused by rental leasing or participation in com...

Page 10: ...n the first 6 months from the date of purchase the customer is entitled to a remedy of the defect in the form of a repair or a replacement of the defec tive component Service and preventive maintenance Please note that you are only entitled to the manufacturer s warranty if you observe the service intervals and have the preventive maintenance carried out The customer is responsible for observing t...

Page 11: ...nce tuning are strictly prohibited In the event of an accident damage without insurance cover the rider is liable with his entire private assets Performance optimisation tuning of EPACs is illegal According to the German Road Traffic Licensing Regulations StVZO an EPAC whose motor accelerates the bike to more than the permitted 25 km h is considered a motor vehicle This requires an insurance numbe...

Page 12: ...rstanding this manual Unauthorised modifications forbidden F O R B I D D E N Modifications are permitted only with the consent of the manufac turer Modifications not approved by the manufacturer will void the declaration of conformity Unauthorised modifications or changes to the bike can result in serious injuries and voiding of the guarantee This applies in particular to manipulating and modifyin...

Page 13: ...use of the bike can result in accidents The rider can use the bike in accordance with this manual Personal protective equipment Riding a bike can result in serious injuries or even death When riding always wear an approved helmet and follow the manufacturer s instructions in the respective manual for adjustment use and care of the helmet Always wear sturdy shoes with a non slip sole e g profiled r...

Page 14: ... the word WARNING warn of a hazardous situation that could result in serious injury or even death C A U T I O N Texts introduced with the word CAUTION warn of a situation that could result in minor to moderate injuries Orthographic features of warnings of material damage W A R N I N G These texts warn of a situation that could result in material damage Orthographic features of tips Tips contain ad...

Page 15: ... Familiarise yourself with the brakes pedals and gears before riding Always ride at a speed appropriate to the riding conditions Avoid electric shocks or explosions due to improper handling of the battery and charger F O R B I D D E N Never open the electric motor battery and other components Improper handling of the battery and charger can result in an electric shock or explosion This may cause s...

Page 16: ... battery in a temperature range between 10 and 30 C Ensure that the charger is used only by persons who do not have limited physical sensory or mental abilities Avoid fire or explosion hazards F O R B I D D E N Cleaning your bike and its components Never clean your bike with a water hose high pressure or steam cleaner Moisture electrically conductive soiling or mechanical damage can cause a short ...

Page 17: ...damaged This can lead to serious injuries Use the bike only on the approved surfaces If you encounter obstacles dismount and lift the bike over the obstacle In the event of damage have the bike inspected by a dealer Avoid serious injuries or death in wet weather C A U T I O N Wet and or slippery roads and paths influence the road grip and braking behaviour Wet weather affects road grip braking beh...

Page 18: ...avoid road obstacles Ride on familiar routes if possible Avoid serious injuries or death caused by damaged bent or loose reflectors and lights Bike reflectors catch the light from street lamps and car headlights and reflect it so that you can be recognised as a cyclist Damaged bent or loose reflectors can result in you being poorly recognised by other road users This may cause serious injuries or ...

Page 19: ...lead to serious injuries or even death Always consult your dealer before installing using and maintaining the component Always read and follow the instructions for use supplied with the accessories Avoid serious injury due to inadequate maintenance cleaning and care Improper maintenance care and cleaning can result in injuries or even death Carry out only the activities listed in the maintenance p...

Page 20: ...p If you hear grating or grinding noises or discover obvious signs of damage contact a dealer and have the bike repaired Using the bike on the road or off road causes vibrations to be transmitted from the ground to your body Use the bike only on approved surfaces Vibration When used for the intended purpose the values of 2 5 m s for the hand arm system and 0 5 m s for the whole body are not exceed...

Page 21: ...components e g batteries electrical or electronic components This can result in environmental pollution Dispose of used batteries and the electrical or electrical or electronic components of the bike in accordance with the legal requirements Observe also the instructions from the manufacturers of these products Avoid explosions C A U T I O N Risk of explosion when riding in potentially explosive a...

Page 22: ...the charger only when it is free from electronic or mechanical damage Charge the battery only when it is free from electronic or mechanical damage Never throw the battery into a fire Do not expose the battery to direct sunlight or high temperatures Always park your bike in the shade if possible If in doubt remove the battery from the bike frame Lithium ion batteries are not residual waste and must...

Page 23: ...equipment required in accordance with the road traffic li censing regulations is generally supplied with the bike If you want to participate in public road traffic with the mountain bike this must be supplemented and fitted by you or a specialist dealer Item No Designation Item No Designation 1 Handlebars 7 Crankset 2 Frame 8 Rear derailleur 3 Battery 9 Brake disc 4 Suspension forks 10 Electric mo...

Page 24: ...he road traffic licensing regulations Important note on electrical attachments All electrical attachments on your bicycle have protection class IP 54 This protection class means Protected against the penetration of solid foreign bodies with a diameter 1 0 mm Protected against water jets nozzle from any angle splash proof The protection class does not prevent the ingress of water if the bicycle is ...

Page 25: ...ower supply to external devices Lock for locking the battery Folding handle for pulling the battery out of the frame Like most large rechargeable batteries lithium ion batteries are classified as hazardous goods under shipping regulations If the battery container is attached to the bike transport by land and water is permitted For transport by air the regulations for hazard ous goods apply In this...

Page 26: ...adjustment of the brake force 4 Brake cable Pulling the cable ensures that the moving brake pad is pressed against the brake disc when the brake lever is pulled 5 Brake cable tension adjusting nut This adjusting nut is used to adjust the moving brake pad and the brake pressure Mechanical disc brakes are installed on the front and rear wheels With mechanical disc brakes a moving brake pad is presse...

Page 27: ...ion There is a locking nut on the adjusting screw that prevents the setting from changing by itself Gear shift Your bike is equipped with derailleur gears The following terms are used in the following texts Changing down means changing to a lower gear where it is easier to pedal Changing up means changing to a higher gear where it is harder to pedal Your derailleur has the following components A s...

Page 28: ... changing up and down to get a feel for different sprocket combinations Practice changing gears in traffic situations where there are no obstacles or hazards until you are comfortable with it The less strain you put on your drive motor and the more power you put into the pedals yourself the longer your battery and the entire system will last Pedals Your bike is equipped with platform pedals 10 Unp...

Page 29: ...n of the brakes Installing and turning the handlebars Proceed as follows to install the handlebars Loosen the adjusting screw Loosen the stem clamping bolts Turn the handlebars until they reach their end position Tighten the adjusting screw finger tight Tighten the stem clamping bolts securely tightening torque 10 Nm Tighten the adjusting screw securely tightening torque min 10 Nm Proceed as follo...

Page 30: ...ube or the seat tube of your frame will become per manently deformed A good presetting for your seat height is the 109 principle Measure your crotch height and multiply it by 1 09 If you have a crotch height of about 70 cm this gives you a seat height of about 76 cm This 76 cm Then check the seat height again and adjust it if necessary Proceed as follows Sit on the saddle Place your heel on the pe...

Page 31: ...Open the saddle clamp Push the saddle up or down Close the saddle clamp again In order to set the correct clamping force on the seat post there is a knurled nut on the saddle clamp that can be tightened and loosened as necessary Saddle position As a rule the correct saddle position is parallel to the road However this setting may differ from your personal preference Adjusting the saddle position t...

Page 32: ...clamping screw securely Fitting the pedals A T T E N T I O N Irreparable damage to the threads by attempting to screw in the wrong pedal Make sure that the thread of the pedal marked R is screwed into the right hand crank as seen in riding direc tion Make sure that the thread of the pedal marked L is screwed into the left hand crank as seen in riding direc tion The pedals have different threads Th...

Page 33: ...threaded bore in the left hand crank in anti clockwise direction Tighten the pedal in anti clockwise direction using the wrench supplied 12 Before riding the bike for the first time The correct adjustment of the bike is crucial for safety performance and comfort while riding Mak ing changes to your bike for a correct adjustment of the bike to suit your body and the riding condi tions requires expe...

Page 34: ... your bike On a bike that you ride only on paved surfaces and never off road this distance should be at least 5 centimetres On a bike that you ride on unpaved surfaces this distance should be at least 7 5 centimetres On a mountain bike that you ride in diffi cult terrain this distance should be at least 10 centimetres Proceed as follows to determine the standover height Stand with your legs apart ...

Page 35: ...harging with battery on bike You can charge the battery directly at the charging socket of the battery without having to remove it from the bike You will find the charging socket for this at the lower end on the left side as seen in riding direction of your battery behind a rubber cover Charging with battery removed from bike Proceed as follows to charge the battery Remove the battery from the hol...

Page 36: ...ng rate can be adjusted at the suspension forks Turn the left and or right fork cap as seen in riding direction in direction to increase the spring rate and in direction to decrease the spring rate The two suspension tubes left and right can be ad justed independently of one another However we strongly recommend that you always adjust both equally Bear in mind that the braking behaviour changes wi...

Page 37: ...ecking and correcting the tyre inflation pressure Note for Presta valve Loosen the union nut by one to two turns Press the valve end briefly in the direction of the wheel rim If there is air in the tyre it will escape audibly Screw the union nut tight again after inflating Proceed as follows to check the tyre pressure Unscrew the valve cap from the bike valve If necessary follow the specific instr...

Page 38: ...ystem has been switched off at the display see 14 Controlling the pedal assistance Switching on and off on p 44 Open the battery lock in clockwise direction using the key supplied and hold the key in this position Pull the battery out of the holder at the folding handle on the left hand side of the battery as seen in riding direction Release the key Remove the key from the battery lock Installing ...

Page 39: ...e braking and stopping smoothly and without locking the wheels This technique is known as progressive brake modulation Your bike is equipped with a front wheel brake and a rear wheel brake The function of the left brake lever here is for the front wheel brake and that of the right brake lever for the rear wheel brake Pull the brake lever towards the handlebar and gradually increase the braking for...

Page 40: ... the chain is only slightly under tension This procedure is necessary to protect your entire drive train including the electric mo tor These components are not designed for changing gear under load Actuating the rear derailleur Proceed as follows to operate your rear derailleur with the right hand shift levers Pedal forwards Press the lower lever 2 forwards with your thumb to shift to a larger spr...

Page 41: ...leur Proceed as follows to operate your front derailleur with the left hand shift levers Pedal forwards Pull the upper lever A towards you with your index finger to shift to a larger sprocket i e to a higher gear Press the lower lever B forwards with your thumb to shift to a smaller sprocket i e to a lower gear ...

Page 42: ...Controlling the pedal assistance Control unit overview and functions Item No Designation 1 LC display 2 Button for selecting the assistance level and for menu navigation 3 Button for selecting the assistance level and for menu navigation 4 Button for switching on and off and for opening the menu ...

Page 43: ...lay of the current speed 2 Display of the selected assistance level level 1 to level 5 3 Display of the unit for the speed mph or km h 4 Error code display 5 Display of the unit for the distance travelled miles or km 6 SETUP display that comes on when settings are being made 7 Distance display for trip meter 8 Battery and charge capacity indicator ...

Page 44: ...ed When the display is switched on the current speed is shown Press the and buttons at the same time to change from the display of the current speed to the display of the average speed If this procedure is repeated the highest riding speed is displayed Distance display ODO Total distance travelled TRIP Trip meter When the display is switched on the total distance travelled appears This adds up the...

Page 45: ...rs Pressing the button again for around two seconds switches the display background lighting off again and the light symbol in the display disappears With background lighting switched off With background lighting switched on Selecting the assistance level Without assistance Level 3 Level 5 To select the assistance level press the button to increase the level or the button to decrease the level The...

Page 46: ...ard with the starting aid completely with out pedalling Pushing aid not active Pushing aid active The pushing aid helps you to push your bike on uneven ground or uphill Proceed as follows to activate the pushing aid Press and hold push button to activate the pushing aid The pushing aid accelerates your bike to max 6 km h An active pushing aid is signalled by flashing of all the LEDs The pushing ai...

Page 47: ... switches off because the voltage of the battery is no longer sufficient your battery is in deep discharge In this case do not charge the battery for the time being and contact our service personnel Full charge state Half charge state Low charge state Very low charge state The battery charge capacity indicator on the display shows you the battery status in five levels When the battery is fully cha...

Page 48: ...23 Motor irregularity Check the motor cables 24 Hall sensor irregularity Check the motor cables Check whether the Hall sensors on the crankset and magnetic disc are functioning correctly 25 Irregularity at one or both brake levers Check whether both brake levers return completely to their starting position when released 30 Communication error Check the complete wiring between Brake levers and cont...

Page 49: ...in the menu item for setting the intensity of the background lighting The intensity is set to 1 ex works Change the intensity by pressing the or button 1 stands for low 2 for medium and 3 for high intensity Then press the button to confirm your se lection Intensity level 1 bL 1 Intensity level 2 bL 2 Intensity level 3 bL 3 16 Li ion battery Questions answers tips What is the optimum temperature fo...

Page 50: ... it can no longer be charged That is why a battery should be re charged below a charge capacity of 15 What is the service life of my battery A Li ion battery can be charged up to 1000 times This value is only achieved however with opera tion under optimum conditions and constant and proper care of your battery Any deviation from the optimum conditions shortens the service life of your battery Furt...

Page 51: ...d to comply with them You share the road or cycle path with motorised road users pedestrians as well as other cy clists Respect their rights Always switch on your lights Ride with foresight Always assume that others may not see you Look ahead and be pre pared for the following Vehicles braking or turning onto your road in front of you and vehicles coming from behind Opening doors of parked vehicle...

Page 52: ...of the pedal assistance is unfamiliar at first but you will quickly get used to this support Sit on the saddle before you start pedalling Start with the low est level of pedal assistance and practice everyday riding situations such as Starting Accelerating Braking Cornering It is possible that the pedal assistance may continue to assist for a short time after you have stopped pedalling For this re...

Page 53: ...bike as a bike without pedal assistance e g when the battery is empty Foot position on the pedals The foot position on the pedals is important for ergonomic and comfortable riding The ball of the foot should rest on the pedals not the heels or the metatarsus An incorrect foot position on the pedals is indicated by a feeling of numbness in the toes In the worst case an incorrect foot position on th...

Page 54: ...charger is connected to the mains plug socket The green LED on the charger lights up but the battery is not yet charged Battery and charger not con nected in the correct se quence Ensure during charging that the charger is connected to the battery before the charger is connected to the mains plug socket The handlebar can be twisted Bolts on the handlebar and or stem have come loose due to vibratio...

Page 55: ...y Incorrect riding behaviour Check your riding style and ad just it if necessary Weak or old drive motor Replace the weak or old mo tor if necessary Weak or old battery Check your riding style and ad just it if necessary Replace the weak or old bat tery if necessary My bike suddenly has no pedal assistance without an error code being shown on the dis play the pushing and starting aid is working In...

Page 56: ...r Below are two examples of how the range of 30 to 135km is made up Example 1 Total moving mass 120kg Tyre pressure 0 5 bar below the lower limit Tyre type coarse MTB lug tread Environment city traffic Route profile hilly terrain Surface including rough cobblestones Wind conditions headwind Ambient temperature 0 to 2 C Age of the drive motor 3 years Age of the battery 1 year Riding behaviour highe...

Page 57: ...r factors the service life of these parts depends very much on the personal riding style Typical wear parts are for example Gear and brake cables Chains Cranks and sprockets Bottom bracket and steering head bearings Brake pads discs and cables Seals and lubricating oil of suspension elements Grips Tyres and inner tubes Mudguards Batteries Where can I get spare parts for my bike We usually always h...

Page 58: ...r 24 Service and contact on p 71 Technical questions Question Answer Can I fit any tyres on my bike No The tyres and inner tubes must match the specifications of the wheel rim Furthermore in line with the enclosed declaration of conform ity no modifications to the bike are permitted without the manufacturer s consent Can I connect any trailer to my bike No The attachment of trailers is not intende...

Page 59: ...pension fork and shock absorber then coat them with a small amount of the lubricant Attention When applying the lubricant make sure that it does not come into contact with the brakes The braking effect can be lost and there is a risk of injury How long will my bike chain last The function of a chain is usually guaranteed up to a maximum distance of 2000 km to 2500 km If this range is exceeded a ch...

Page 60: ...not count as a full charge cycle only as 1 of a full charge cycle 500 charging cycles usually take more than two years You can store the battery with a charge level of 75 for about five months without re charging At a charge level of 50 roughly three months In order not to shorten the service life of your battery proceed as follows Charge the battery when the charge level is between 30 and 50 afte...

Page 61: ...cidentally immersed in water disconnect the motor from the battery immediately and do not use it again until it has been inspected by the manufacturer Clean the electric motor and the controller only from the outside with a damp sponge Observe the instructions of the respective manufacturer Setting and adjusting the rear derailleur No Meaning 1 Rear derailleur 2 Gear shift cable 3 Gear shift cable...

Page 62: ... adjust the stop turn the adjusting screw marked with an L in clockwise direction to move the rear derailleur away from the rear wheel or in anti clockwise direction to move the rear derailleur towards the rear wheel When the stops have been adjusted shift the rear derailleur back to the smallest sprocket Now shift up all the gears one by one If the chain has problems shifting to larger sprockets ...

Page 63: ...clockwise direction Back off the adjusting nut for fine adjustment of the shift cable at the left hand twist shifter in anti clockwise direction for four clicks One click corresponds roughly to a quarter turn Loosen the clamping screw for the shift cable until the shift cable is completely free Check whether the front derailleur is aligned with the chain This means that there is no an gle between ...

Page 64: ...at this procedure until the chain shifts up smoothly If the chain has difficulties shifting down i e shifting from a larger to a smaller sprocket turn the nut for fine adjustment of the shift cable roughly half a turn in clockwise direction Re peat this procedure until the chain shifts down smoothly Maintenance intervals I M P O R T A N T N O T E Preventive maintenance must be carried out regularl...

Page 65: ... neces sary or replace defective components Every 3 500 km or every year Brakes Replace the brake pads Inspect the wheels for lateral runout and wear on the brake flanks Thoroughly clean the brake flanks on the wheel rims Inspect the brake cables for rust and damage replace if necessary Inspect the brake levers for proper function and damage Every 3 500 km or every two years Chain Replace the chai...

Page 66: ...lectric motor 250 W rated power 05 08 2021 REV 1 1 66 Service booklet In order to assert your warranty claims we recommend in addition to adhering to the maintenance intervals a careful inspection of your bike at least once or twice a year ...

Page 67: ...Operating Manual Mountain bike with electric motor up to 250 W 25 08 2021 REV 1 1 67 ...

Page 68: ...Operating Manual Mountain bike with electric motor 250 W rated power 05 08 2021 REV 1 1 68 ...

Page 69: ... bike at the end of its service life Dispose of the bike and its components e g the battery and electrical and electronic components in accordance with the local legal regulations and guidelines e g via a recycling centre Observe also the instructions from the battery manufacturer and the man ufacturer of the electrical and electronic component ...

Page 70: ...ith electric motor 250 W rated power 05 08 2021 REV 1 1 70 23 Bike passport First name and surname Street Post code city Phone Mobile phone Fax Date of purchase Bike designation Frame No Wheel size Colour Special features accessories ...

Page 71: ... 1 1 71 24 Service and contact To the assembly video To the service form Please note that only service orders requested using the service form can be processed Thank you for your understanding Zündapp Vertriebsgesellschaft mbH Steinstraße 54 81667 Munich Germany www zuendapp com ...

Page 72: ...Operating Manual Mountain bike with electric motor 250 W rated power 05 08 2021 REV 1 1 72 25 EC Declaration of Conformity ...

Page 73: ...er Akku des E Bikes darf keine sichtbaren Gehäuseschäden aufweisen Der Akku des E Bikes darf keine elektrischen Schäden aufweisen Das E Bike muss gut verpackt und gepolstert in einem stabilen Versandkarton versendet werden Nutzen Sie hierzu bitte den Versandkarton in dem das E Bike zu Ihnen geliefert wurde Please observe the following points when sending back your E bike The battery must be fitted...

Page 74: ...pping carton a label for hazardous goods an accompanying document and a reply paid receipt Use only this shipping carton for sending back your battery Verpacken sie den Akku zwischen den mitgelieferten Folienmem branen So ist dieser gegen jegliche Stöße und Einflüssen von außen geschützt Pack the battery between the membranes Packed like this the bat tery will be protected against all kinds of sho...

Page 75: ... gross weight 4 2 kg Total quantity of each dangerous substance see above General Information Sum of the hazardous goods points in accordance with paragraph 1 1 3 6 4 ADR 9 6 3 2kg x 3 Transport in exempted quantity in accordance with paragraph 1 1 3 6 4 ADR No restriction The driver was informed about the details of the transport and the hazardous goods Place date Signature Transport document for...

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