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Summary of Contents for Zundapp Z801
- Page 1 Operating manual Zündapp Z801 Mountain bike - with electric motor / 250 W rated power Translation of the original operating manual...
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Page 2: Table Of Contents
Operating Manual – Mountain bike with electric motor / 250 W rated power Contents Unpacking and assembly ......................... 7 Notes on the manual and the manufacturer .................. 8 Keep the manual available for reference at all times............. 8 ... - Page 3 Operating Manual – Mountain bike with electric motor up to 250 W Avoid fire or explosion hazards ..................... 16 Avoid serious injuries due to contact of body parts with the components of the bike ..17 Avoid serious injuries caused by damaged components ............17 ...
- Page 4 Operating Manual – Mountain bike with electric motor / 250 W rated power Brake force fine adjustment ....................27 Gear shift ..........................27 Pedals ............................ 28 Unpacking and checking delivery ....................28 Assembling components of the bike ..................29 ...
- Page 5 Operating Manual – Mountain bike with electric motor up to 250 W Distance display ........................47 Resetting the trip meter ......................47 Switching the display background lighting on and off ............48 Selecting the assistance level ....................48 ...
- Page 6 Operating Manual – Mountain bike with electric motor / 250 W rated power Care of the electric motor and controller ................64 Setting and adjusting the rear derailleur ................64 Adjusting the stops ........................ 65 Setting and adjusting the front derailleur ................66 ...
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Page 7: Unpacking And Assembly
Operating Manual – Mountain bike with electric motor up to 250 W 1. Unpacking and assembly I M P O R T A N T The first charge is crucial! Please fully charge the battery before using your bike for the first time! Dear Customer, Please note that your bike is delivered to you 98% pre-assembled. -
Page 8: Notes On The Manual And The Manufacturer
Operating Manual – Mountain bike with electric motor / 250 W rated power 2. Notes on the manual and the manufacturer This manual is intended to help you use you to use the electric mountain bike safely. These e-bikes are referred to in the further course of this manual as “bike” for short. This manual has been pre- pared in accordance with IEC 82079-1 (Preparation of instructions for use. -
Page 9: Statutory Warranty And Warranty Claims
Operating Manual – Mountain bike with electric motor up to 250 W 3. Statutory warranty and warranty claims Explanation of the statutory warranty The manufacturer grants a 24-month warranty (“liability for defects”) on new goods (§ 439 and 476 German Civil Code (BGB)). -
Page 10: Information About The Guarantor
Operating Manual – Mountain bike with electric motor / 250 W rated power The wear parts that the manufacturer excludes from the guarantee include the following: Brake pads and brake discs, and wheel rims if the system is a rim brake system The complete drive train including rear derailleur, front derailleur, crankset and chain ... -
Page 11: Theft Prevention
Operating Manual – Mountain bike with electric motor up to 250 W 4. Theft prevention I M P O R T A N T The frame number is not filed by us together with the buyer’s purchase order. Record the frame number in your bike passport or on your invoice and register your bike with the police free of charge! Use a suitable bike lock to protect your bike from theft. -
Page 12: Safety
Operating Manual – Mountain bike with electric motor / 250 W rated power 7. Safety Intended use N O T E The intended use also implies reading and understanding the operat- ing manual! Bicycles are used to transport a single person. Because the necessary safety equipment according to StVZO is not included in the scope of delivery, your bike is not intended for use on public roads. -
Page 13: Attachment Of Luggage Racks And/Or Trailers
Operating Manual – Mountain bike with electric motor up to 250 W Attachment of luggage racks and/or trailers The attachment of other of further luggage racks and/or trailer couplings is only permitted by agree- ment with the manufacturer. Unauthorised modifications or attachments of load carriers of any kind without the consent of the manufacturer will void the declaration of conformity supplied and the entire risk must be borne by the user. -
Page 14: Orthographic Features Of Warnings
Operating Manual – Mountain bike with electric motor / 250 W rated power Orthographic features of warnings The following types of warning can be found in this manual: W A R N I N G Texts introduced with the word WARNING warn of a hazardous situation that could result in serious injury or even death. -
Page 15: Basic Safety Instructions
Operating Manual – Mountain bike with electric motor up to 250 W Basic safety instructions Permissible total payload Your bike is for a total payload of 120kg designed. The total pay- load includes the empty weight of the bike including the battery (this is 22.7kg), the driver and additional luggage. -
Page 16: Avoid Electric Shocks Or Explosions Due To Improper Handling Of The Battery And Charger
Operating Manual – Mountain bike with electric motor / 250 W rated power 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. -
Page 17: Avoid Serious Injuries Due To Contact Of Body Parts With The Components Of The Bike
Operating Manual – Mountain bike with electric motor up to 250 W Avoid serious injuries due to contact of body parts with the components of the bike C A U T I O N Risk of injury from reaching into the drive chain. -
Page 18: Avoid Serious Injuries Or Death In Twilight Or At Night
Operating Manual – Mountain bike with electric motor / 250 W rated power Avoid serious injuries or death in twilight or at night N O T E We generally recommend riding with your lights on even during the day. Riding with lights is crucial in twilight or at night! Riding in twilight or at night is more dangerous than during the day. -
Page 19: Avoid Serious Injuries Or Death Due To Replacing Components Or Adding Accessories
Operating Manual – Mountain bike with electric motor up to 250 W Avoid serious injuries or death due to replacing components or adding accessories Numerous components and accessories are available that can improve the comfort, performance and appearance of your bike. You add components or accessories at your own risk. It is possible that these components or accessories have not been tested for compatibility, reliability or safety by the bike manufacturer. -
Page 20: Avoid Injuries To Your Legs
Operating Manual – Mountain bike with electric motor / 250 W rated power Avoid injuries to your legs Injuries to your legs can occur if the pedal spacing (Q-fac- tor) is too small or too large. There is a risk that riders will have problems with the crankset installed. -
Page 21: Avoid Frostbite
Operating Manual – Mountain bike with electric motor up to 250 W Avoid frostbite Cycling in cool or cold temperatures can cause frostbite. Always be sure to wear appropriate clothing, including a face mask, in cool or cold tempera- tures. -
Page 22: Safety Instructions And General Information On The Battery
Operating Manual – Mountain bike with electric motor / 250 W rated power 8. Safety instructions and general information on the battery Be sure to read the instructions supplied with your lithium ion battery (where applicable). Use only the charger included in the scope of supply with the technical specifications: 42 V output voltage / 2 A max. -
Page 23: Description
Operating Manual – Mountain bike with electric motor up to 250 W 9. Description Assembly The mountain bike is intended for use in light terrain and on unpaved trails. It is not intended for use on paved and public roads and paths. The equipment required in accordance with the road traffic li- censing regulations is generally supplied with the bike. -
Page 24: Position Of The Type Plate
Operating Manual – Mountain bike with electric motor / 250 W rated power Position of the type plate The type plate can be found on the front of the seat post. Technical description Your bike has the following technical specification: Hub motor in rear wheel 21-speed derailleur Drive rated power 250 W... -
Page 25: Scope Of Supply
Operating Manual – Mountain bike with electric motor up to 250 W Scope of supply Pre-assembled bike with battery Two pedals (not mounted) Battery charger Two keys (keep a spare key in a safe place) for battery removal An operating manual in printed form ... -
Page 26: Disc Brakes
Operating Manual – Mountain bike with electric motor / 250 W rated power Disc brakes Item No. Designation / description Mounting bolts: These bolts are used to install the brake calliper on the brake calliper mounting Adjusting screw This screw is used to adjust the brake pressure and the fixed brake pad Brake cable mounting bolt: Fixes the brake cable to the brake arm and serves for rough adjustment of the brake force... -
Page 27: Brake Force Fine Adjustment
Operating Manual – Mountain bike with electric motor up to 250 W Brake force fine adjustment On each of the brake handles there is an adjustment screw with which the tension of the brake cable can be finely adjusted. Turn this adjustment screw in anticlockwise direction to increase the tension and in clockwise direction to decrease the tension. -
Page 28: Pedals
Operating Manual – Mountain bike with electric motor / 250 W rated power C A U T I O N The chain and the drive system should not be under load when changing to a higher or lower gear. This is especially true when the drive motor is running. -
Page 29: Assembling Components Of The Bike
Operating Manual – Mountain bike with electric motor up to 250 W Assembling components of the bike Your bike is pre-assembled on delivery. The following components still have to be fitted (or have them fitted) and must be adjusted and/or checked (or have them adjusted/checked). The handlebar has to be adjusted The saddle position and height has to be adjusted The pedals have to be screwed on... -
Page 30: Installing And Turning The Handlebars
Operating Manual – Mountain bike with electric motor / 250 W rated power Installing and turning the handlebars Clamping Screws Adjustment Handle Bar Screw Handle Clamping Screws Head Set 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... -
Page 31: Adjusting The Saddle
Operating Manual – Mountain bike with electric motor up to 250 W Adjusting the saddle Saddle height C A U T I O N There is a "min insert" mark on the immersion tube of your seat post. This mark must not be visible and thus shows the mini- mum insertion depth of your seat post in the seat tube. - Page 32 Operating Manual – Mountain bike with electric motor / 250 W rated power Proceed as follows to adjust the saddle height: Close the quick-release fastener of the Close the quick-release fastener of the seat post clamp seat post clamp 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...
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Page 33: Saddle Position
Operating Manual – Mountain bike with electric motor up to 250 W 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 to your personal preference is explained be- low. -
Page 34: Fitting The Pedals
Operating Manual – Mountain bike with electric motor / 250 W rated power 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. -
Page 35: Before Riding The Bike For The First Time
Operating Manual – Mountain bike with electric motor up to 250 W 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 experience, expertise and special tools. -
Page 36: Checking The Chain Tension
Operating Manual – Mountain bike with electric motor / 250 W rated power Checking the chain tension Highest chain tension Correct chain tension is essential for correct driving behavior. If the chain tension is too low while you are driving in a heavy gear, the chain can jump off even with slight jolts. If the chain tension is too high while you are driving in a low gear, this leads to an unnecessarily high load on the chain. -
Page 37: Check The Size Of The Bike
Operating Manual – Mountain bike with electric motor up to 250 W Check the size of the bike WARNING Fall from the bicycle possible due to loss of control because of wrong bicycle size. This can result in serious injuries. Make sure that the bike size is suitable for your height. -
Page 38: Charging The Battery
Operating Manual – Mountain bike with electric motor / 250 W rated power Charging the battery W A R N I N G Risk of explosion of the battery due to the use of an incorrect charger. This may cause serious or even fatal injuries. Use only the charger supplied. -
Page 39: Adjusting The Spring Rate At The Suspension Forks
Operating Manual – Mountain bike with electric motor up to 250 W Adjusting the spring rate at the suspension forks CAUTION Do not make any adjustments to the suspension forks while rid- ing! You could fall and seriously injure yourself. The spring rate can be adjusted at the suspension forks. -
Page 40: Checking The Tyre Pressure
Operating Manual – Mountain bike with electric motor / 250 W rated power Checking the tyre pressure There are essentially three different types of bike tyre valve (see figure below): Car valve Schrader valve American valve Presta valve Sclaverand valve French valve Dunlop valve Wood’s valve... -
Page 41: Using The Bike
Operating Manual – Mountain bike with electric motor up to 250 W Using the bike Installing and removing the battery WARNING Dropping the battery may result in an explosion hazard. This may cause serious or even fatal injuries. Never drop the battery when installing or removing. The battery has to be removed from the holder for charging or prolonged storage, ... -
Page 42: Actuating The Brakes
Operating Manual – Mountain bike with electric motor / 250 W rated power Actuating the brakes Front brake Rear brake Left brake lever Right brake lever Brakes are there to control speed, not only to stop the bike. The maximum braking power of the wheels is available just before the wheels "lock"... -
Page 43: Operating The Gears
Operating Manual – Mountain bike with electric motor up to 250 W Operating the gears Your bike is equipped with trigger shifters that are actuated by pressing with your index finger or thumb. A T T E N T I O N When changing gears, try not to change under load. -
Page 44: Actuating The Front Derailleur
Operating Manual – Mountain bike with electric motor / 250 W rated power Actuating the front derailleur 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. -
Page 45: Controlling The Pedal Assistance
Operating Manual – Mountain bike with electric motor up to 250 W Controlling the pedal assistance Control unit – overview and functions Item Designation LC display Button for selecting the assistance level and for menu navigation Button for selecting the assistance level and for menu navigation Button for switching on and off and for opening the menu 25.08.2021 REV 1.1... -
Page 46: Display Functions And Key Functions
Operating Manual – Mountain bike with electric motor / 250 W rated power Display functions and key functions Item Designation Display of the current speed Display of the selected assistance level (level 1 to level 5) Display of the unit for the speed (mph or km/h) Error code display Display of the unit for the distance travelled (miles or km) SETUP display that comes on when settings are being made... -
Page 47: Switching On And Off
Operating Manual – Mountain bike with electric motor up to 250 W Switching on and off Hold the button pressed for approx. two seconds to switch on the display. Hold the button pressed for approx. two seconds again to switch off the display. Pedal assistance is not activated if the display is not switched on. -
Page 48: Switching The Display Background Lighting On And Off
Operating Manual – Mountain bike with electric motor / 250 W rated power Switching the display background lighting on and off To switch on the display background lighting, press the button for around two seconds until the light symbol in the display appears. Pressing the button again for around two seconds switches the display background lighting off again and the light symbol in the display disappears. -
Page 49: Pushing And Starting Aid
Operating Manual – Mountain bike with electric motor up to 250 W Pushing and starting aid The pushing and starting aid (referred to hereinafter as pushing aid) is only an assistant. It should not be assumed that you can travel forward with the starting aid completely with- out pedalling. -
Page 50: Battery And Charge Capacity Indicator
Operating Manual – Mountain bike with electric motor / 250 W rated power Battery and charge capacity indicator C A U T I O N If your charge capacity is only 10 to 19% (one bar of the charge capacity indicator is lit), you should only ride a maximum of 2 km more before the battery needs to be charged, otherwise there is a risk of the battery slipping into deep discharge. -
Page 51: Error Code Information
Operating Manual – Mountain bike with electric motor up to 250 W Error code information If a problem occurs with the electric motor, the controller or an electrical component, this is indicated by an error code in the display. If an error code is displayed, the system or component concerned must be checked accordingly. -
Page 52: Basic Settings
Operating Manual – Mountain bike with electric motor / 250 W rated power Basic settings Proceed as follows to make various basic settings: Press the button briefly to switch on the display Press the buttons at the same time for approx. two seconds to enter the menu Press the button for approx. -
Page 53: At What Temperatures May A Battery Be Charged
Operating Manual – Mountain bike with electric motor up to 250 W At what temperatures may a battery be charged? A Li ion battery should only be charged in the temperature range from 5°C to max. 45°C. Here again, the optimum charging temperature is roughly 20°C. -
Page 54: Tips For Safe Riding
Operating Manual – Mountain bike with electric motor / 250 W rated power Two yellow reflectors in the spokes of each wheel offset by 180° from one another, alterna- tively reflective white stripes on the sides of the tyres. Battery-operated front lights and rear lights are permitted in Germany only if they have StVzO ap- proval. -
Page 55: Riding With Pedal Assistance
Operating Manual – Mountain bike with electric motor up to 250 W manufacturer's recommendations for the child seat or child trailer regarding weight re- strictions. Never transport anything that could obstruct your vision, interfere with your full control of the bike or become entangled with the moving parts of the bike. Never allow yourself to be towed by another vehicle. -
Page 56: Riding Without Pedal Assistance
Operating Manual – Mountain bike with electric motor / 250 W rated power Riding without pedal assistance You can use your bike even without pedal assistance. To do this, you only need to switch off the pe- dal assistance. You can then use your bike as a bike without pedal assistance, e.g. when the battery is empty. -
Page 57: Troubleshooting
Operating Manual – Mountain bike with electric motor up to 250 W Troubleshooting Problem Possible cause Remedy The display does not function. Battery discharged or no con- Ensure that the battery is fully tact between bike and battery charged and correctly in- stalled. - Page 58 Operating Manual – Mountain bike with electric motor / 250 W rated power Problem Possible cause Remedy My bike has reduced braking Wrong setting Check your brakes for proper power adjustment and have them ad- justed, if necessary. Worn brake parts Check your brake pads and wheel rim flanks for wear.
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Page 59: Frequently Asked Questions (Faq)
Operating Manual – Mountain bike with electric motor up to 250 W Frequently asked questions (FAQ) How far can I travel with a fully charged battery? The range of a battery depends on many different factors, such as: Weight of the rider Luggage weight Tyre pressure: Tyre type (coarse lugged tyres or smooth road tyres) -
Page 60: General Questions
Operating Manual – Mountain bike with electric motor / 250 W rated power General questions Question Answer Where do I find the frame On most bikes, the frame number is stamped on the underside number? of the bottom bracket. As the frame number cannot be stored for logistical reasons, we ask you to record it in your bike pass- port. -
Page 61: Questions About Guarantee And Warranty
Operating Manual – Mountain bike with electric motor up to 250 W Questions about guarantee and warranty Question Answer What can I do if I have First of all, we recommend that you read the operating manual problems with my bike? supplied with your bike carefully. - Page 62 Operating Manual – Mountain bike with electric motor / 250 W rated power Question Answer Why do my brakes squeak? Squeaking brakes are not a sign of a defect, which is why the function is usually guaranteed. Your current trip can therefore be safely completed.
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Page 63: Transporting Your Bike
Operating Manual – Mountain bike with electric motor up to 250 W Transporting your bike W A R N I N G During transport, the bike can fall over, slide or fall off the vehi- cle. This can result in serious injuries. Secure the bike to prevent tipping, slipping or falling during transport in a vehicle or on public transport. -
Page 64: Care Of The Electric Motor And Controller
Operating Manual – Mountain bike with electric motor / 250 W rated power Care of the electric motor and controller W A R N I N G Moisture, soiling or mechanical damage can cause a short cir- cuit. This could lead to a fire or explosion of the battery. Clean the electric motor and the controller only from the outside with a damp sponge. -
Page 65: Adjusting The Stops
Operating Manual – Mountain bike with electric motor up to 250 W Adjusting the stops The purpose of the stops is to prevent the chain from jumping off the chain ring and to ensure that the chain shifts smoothly from the smallest to the largest sprocket. These stops are adjusted as follows: Shift the rear derailleur to the smallest sprocket. -
Page 66: Setting And Adjusting The Front Derailleur
Operating Manual – Mountain bike with electric motor / 250 W rated power Setting and adjusting the front derailleur Meaning Adjusting screws for top (screw H) and bottom (screw L) stops Outer deflector Inner deflector Clamping screw for the shift cable Gear shift cable Proceed as follows to adjust the front derailleur correctly: Move the chain to the smallest sprocket of the crank using the left-hand shifter. -
Page 67: Maintenance Intervals
Operating Manual – Mountain bike with electric motor up to 250 W Move the chain to the largest sprocket using the left-hand shifter. Now adjust the front de- railleur at screw H so that the chain runs freely without contact between the inner and outer deflector. - Page 68 Operating Manual – Mountain bike with electric motor / 250 W rated power Interval Component Action Before every trip Brakes Check the proper function of your brakes. After every long or hard Complete bike Inspect the bike for damage. Have the bike repaired by a qualified use or every 20 riding dealer, if necessary..
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Page 69: Service Booklet
Operating Manual – Mountain bike with electric motor up to 250 W 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. 25.08.2021 REV 1.1... - Page 70 Operating Manual – Mountain bike with electric motor / 250 W rated power 05.08.2021 REV 1.1...
- Page 71 Operating Manual – Mountain bike with electric motor up to 250 W 25.08.2021 REV 1.1...
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Page 72: Disposal Of The Bike
Operating Manual – Mountain bike with electric motor / 250 W rated power Disposal of the bike Proceed as follows to dispose of the 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. -
Page 73: Bike Passport
Operating Manual – Mountain bike with electric motor up to 250 W Bike passport First name and surname Street Post code / city Phone / Mobile phone Date of purchase Bike designation Frame No. Wheel size Colour Special features / accessories 25.08.2021 REV 1.1... -
Page 74: Service And Contact
Operating Manual – Mountain bike with electric motor / 250 W rated power 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... -
Page 75: Ec Declaration Of Conformity
Operating Manual – Mountain bike with electric motor up to 250 W EC Declaration of Conformity 25.08.2021 REV 1.1... -
Page 76: Important Information For Sending Back Your E-Bike
Operating Manual – Mountain bike with electric motor / 250 W rated power Important information for sending back your E-bike W I C H T I G E I N F O R M A T I O N I M P O R T A N T I N F O R M A T I O N Für den Rückversand Ihres E-Bikes: For sending back your E-bike:... -
Page 77: Important Information For Sending Back A Battery
Operating Manual – Mountain bike with electric motor up to 250 W Important information for sending back a battery W I C H T I G E I N F O R M A T I O N I M P O R T A N T I N F O R M A T I O N Für den Rückversand Ihres E-Bike-Akkus: For sending back your E-bike battery:... -
Page 78: Transport Document For Hazardous Goods (Battery)
Operating Manual – Mountain bike with electric motor / 250 W rated power Transport document for hazardous goods (battery) Transport document for hazardous goods in accordance with section 5.4 ADR GOODS LADEN: UN 3480 lithium ion battery, 9, II (E) Number of packages: 1 cardboard box (4G) Total net weight: 3.2 kg...
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