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Zap TWO SEAT BICYCLE TRAILER OWNER’S MANUAL This manual contains safety, assembly, use and maintenance instructions. Read these instructions carefully before use and keep them for future reference. Your child’s safety may be affected if you do not follow these instructions. The Schwinn Bicycle Trailer must be assembled by an adult who has read and understands the instructions in this manual. Keep the packaging away from children and dispose all packaging before use. Do not return to store.
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Thank You For purchasing the Schwinn Bicycle Trailer. You will be sure to enjoy hours of pleasurable exercise and family time. If you have any questions or comments our customer service hours are: 8:00 AM - 5:00 PM Monday through Friday CST. You may also reach us through the following: Web: www.pacific-cycle.com Email: customerservice@pacific-cycle.com Mail: P. O. Box 344 4730 E. Radio Tower Lane Olney, IL 62450 Important! Do not return the product to the store.
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Contents 1 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Assembly Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Child Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Trailer Use Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safe Riding Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Recommendations . . . . . . . . . . . . . . . . . . . . .
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1 Safety WARNING! FAILURE TO FOLLOW THE SAFETY INSTRUCTIONS LISTED BELOW MAY RESULT IN SERIOUS INJURY OR DEATH. Always read and understand the information and warnings in this manual before using the Bicycle Trailer. If you are unsure of any information in this manual or have a question regarding assembly or use please call customer service. Always keep this manual for reference and include it with resale of the Bicycle Trailer.
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WARNING! • Always use the crotch strap in combination with the waist belt. • Do not allow any of the child’s body, clothing, shoe laces, or toys come into contact with a moving trailer. • Take proper steps (clothing, ventilation, hydration) to protect the child from exposure hazards such as wind chill and heat exhaustion. These hazards will have a greater impact on the less active passenger.
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WARNING! • Do not ride over curbs, bumps or holes. • Do not use the trailer in hazardous weather or at night. • Do not pull or push the trailer with a vehicle. • Routinely check that all fasteners and equipment (wheels, reflectors, flag, etc) are tight and properly assembled. • Red reflectors must be visible on the rear of the trailer • Check the tire pressure often. The recommended tire pressure range is printed on the tire. Only use a foot or hand pump to inflate.
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2 Parts and Features Elastic bands for weather shield Safety Flag with pole Safety harness system Canopy Storage area Weather shield(rolls up and fastens in elastic bands) Zip-in/zip-out bug screen Back panel Front panel Bicycle coupler Wheels (2) Safety strap Tow bar Clear plastic windows Schwinn Zap Trailer 4
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3 Assembly UNFOLD THE FRAME WARNING! • There are pinch points between the sidewalls and the frame of the trailer that may cause injury. Fold or unfold the trailer slowly using caution. • Keep children clear when folding or unfolding the trailer. Locking spring pin hole Front panel • Ensure that all locking devices are engaged before use. Note: The trailer comes with the frame collapsed and the side walls folded down. The front and back panels are tucked under the side walls.
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❷ Expand the frame out by pulling on the side rails until the locking spring pins insert into the holes on both ends. Be sure the frame is securely locked together. Figure 3.2 ❸ Lift the right side wall up into a vertical position. Figure 3.3 Locking spring pin in hole 2 Side rail Side rail 3 Figure 3.2 Right wall Figure 3.
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❹ Lift the left side wall up into a vertical position. The crossbar will rotate towards the crossbar latch. Figure 3.4 ❺ Lock the crossbar into the crossbar latch. Figure 3.5 ❻ Check the crossbar is locked into place by pulling up and down on it. Figure 3.5 Left wall 6 4 5 Release button L oc k Crossbar latch Crossbar Figure 3.4 7 Schwinn Zap Trailer Figure 3.
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❼ Pull the back panel up and over the crossbar. Figure 3.6 ❽ Snap the panel closed. Figure 3.6 ATTACH THE CANOPY ❶ Starting at the bottom corner of the trailer, snap the first set of snaps from the canopy to the frame on both sides. Figure 3.7 1 7 Back panel 8 Figure 3.6 Figure 3.
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❷ Pull the canopy up and over the top of the frame and snap the second set of snaps at the top of the frame. Figure 3.8 ❸ Snap the third set of snaps located at the back of the frame. Figure 3.8 EXTEND AND SECURE THE TOW BAR ❶ Place the trailer on its side with the tow bar facing up. ❷ Remove the locking pin from the tow bar bracket. Figure 3.9 ❹ Roll the weather shield up into the bands at the top of the canopy if you are not using it. Figure 3.8 4 2 1 2 3 Figure 3.
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❸ Rotate the tow bar out and away from the trailer. The tow bar should be resting on the front of the frame. Figure 3.10 ❹ Insert the locking pin completely through the hole in the end of the tow bar and bracket. ❺ Slide the end of the metal safety loop over the end of the locking pin. Check the locking pin is securely in place. Figure 3.10 4 4 3 5 Figure 3.
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ATTACH THE WHEELS INSERT THE SAFETY FLAG WARNING! Wheels that are not securely locked in place may fall off the trailer and cause serious injury or death. Always check the wheels are securely locked in place before use. ❶ Insert the axle of the wheel into the wheel hole located towards the rear of the trailer. Figure 3.11 Important! The safety flag is an important safety feature that warns others a trailer is present and on the bicycle. Always have the safety flag on the trailer when in use.
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4 Trailer Attachment WARNING! Use of the trailer without the safety strap attached to the bicycle may result in serious injury or death. Always attach the safety strap to the bicycle when using the trailer. 2 mm 2 mm 2 mm 1 Important! This section provides instructions for attaching the trailer coupler to the bicycle’s REAR WHEEL with a hub nut or quick release lever. The coupler attaches to most bicycles. Figure 4.
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❸ Remove the safety loop from the end of the locking pin on the end of the coupler. Figure 4.4 ❺ Insert the coupler plate onto the wheel axle. Place the coupler in a horizontal position so that it is in line with the tow bar. ❹ Remove the locking pin from the coupler and slide the coupler off the end of the tow bar. ❻ Place the hub nut and washer back onto the axle and tighten. Figure 4.5 3 Incorrect coupler placement Coupler 5 4 6 Washer Hub nut Figure 4.4 13 Schwinn Zap Trailer Figure 4.
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❼ Slide the tow bar into the open end of the coupler. Important! Ensure the coupler is completely in line with the tow bar. This reduces stress on the tow bar. ❽ Insert the locking pin into the hole on the top of the coupler. Slide the safety loop over the end of the lock pin. ATTACHMENT WITH QUICK RELEASE ❶ Release the quick release lever, skewer and remove the nut and spring from the opposite side of the wheel. ❷ Remove the axle skewer and spring. Leave the wheel in place. Figure 4.
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❸ Place the tab washer on the axle. Fit the tab into the slot on the bicycle frame dropout. Note: If your bicycle frame doesn’t have a slot in the drop out, rotate the tab to fit into the axle slot. Figure 4.8 Slot ❹ Insert the coupler plate onto the wheel axle. Figure 4.9 ❺ Insert the quick release lever, spring and nut that were removed in step 1 through the wheel. ❻ Rotate the quick release lever up and tighten. When properly tightened, the quick release lever should leave an imprint in your hand.
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❼ Slide the tow bar into the open end of the coupler. ❾ Slide the safety loop over the end of the lock pin. Figure 4.11 Important! Ensure the coupler is completely in line with the tow bar. This reduces stress on the tow bar. Figure 4.10 ❽ Insert the locking pin into the hole on the top of the coupler. Important! Ensure the loop of the safety pin is facing away from the wheel to prevent possible friction against the wheel and spokes of the bicycle. 9 8 9 7 Figure 4.10 Figure 4.
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ATTACH THE SAFETY STRAP WARNING! Use of the trailer without the safety strap attached to the bicycle may result in serious injury or death. Always attach the tow bar safety strap to the bicycle when using the trailer. ❶ Wrap the tow bar safety strap around the bicycle frame. Figure 4.12 ❷ Clip the safety strap to the tow bar ring on the end of the tow bar. Be sure the tow bar safety strap is securely attached before using the trailer. Figure 4.
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5 Using the Safety Harness USING THE SAFETY HARNESS WITH TWO CHILDREN WARNING! 2 • Avoid serious injury from falling or sliding out. Always properly secure the passenger(s) with the safety harness. • It may be dangerous to leave your child unattended. Never leave your child unattended in or near the bicycle trailer. ❶ Unbuckle the shoulder straps from the center of the lap buckle. ❷ Child must be seated in the center passenger compartment. ❸ Place the lap buckle between the child’s legs.
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CONVERTING THE SAFETY HARNESS FOR ONE CHILD ❶ Start with the straps in the two-child position. Unfasten the shoulder straps from the center lap buckle on both sets of safety harnesses. Figure 5.2 Left Safety Harness Right Safety Harness 1 1 ❷ Snap the left shoulder strap from the right set of safety harnesses into the center lap buckle. Then, snap the right shoulder strap from the left set of safety harness into the center buckle. Figure 5.
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USING THE SAFETY HARNESS WITH ONE CHILD WARNING! 1 • Avoid serious injury from falling or sliding out. Always properly secure the passenger(s) with the safety harness. • It may be dangerous to leave your child unattended. Never leave your child unattended in or near the bicycle trailer. ❶ Child must be seated in the center passenger compartment. ❷ Place the center lap buckle between the child’s legs. ❸ Place the shoulder straps over the child’s shoulders and the waist straps under the child’s arms.
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6 Disassembly and Storage WARNING! ❸ Remove the locking pin from the tow bar coupler. Figure 6.2 • There are pinch points between the sidewalls and the frame of the trailer that may cause injury. • Always fold or unfold the trailer slowly and with caution. • Keep children clear when folding or unfolding the trailer. ❹ Remove the tow bar from the coupler. ❺ Insert the locking pin through the end of the tow bar and secure it with the safety loop.
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DISASSEMBLE THE TRAILER ❷ Remove the wheels by: a. Sliding the safety loop from the end of the locking pin. ❶ Remove the flag pole and separate the flag pole sections. Figure 6.3 b. Remove the locking pin from the axle, and pull the wheel out of the hole in the frame bracket. c. Slide the locking pin back into the frame hole ❸ Remove the locking pin from the tow bar bracket. Figure 6.4 3 1 2 Figure 6.3 Figure 6.
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❹ Fold the tow bar underneath the trailer. Figure 6.5 ❼ Carefully fold the trailer side walls down. Figure 6.7 ❺ Place the locking pin back through the tow bar and bracket and secure with the safety loop. Figure 6.6 ❽ Press the locking spring pins down and push the side rails in. Figure 6.7 ❾ Place any loose items such as the canopy, flag and wheels inside the passenger compartment. 5 ❿ Store in a dry place. Important! If the storage area is hot then release the some air from the tires.
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7 Warranty Pacific Cycle warrants this product to be free of defective materials and workmanship for 1 year from the date of original purchase. THIS LIMITED WARRANTY IS THE ONLY WARRANTY APPLICABLE TO THIS PRODUCT, AND IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTY. ANY IMPLIED WARRANTIES, INCLUDING ANY WARRANTY OF MERCHANTABILITY AND WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS LIMITED IN DURATION TO THE DURATION OF THE EXPRESS WARRANTY.
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Manufactured for Pacific Cycle, Inc. (A Division of Dorel Industries) Pacific Cycle, Inc. 4902 Hammersley Road Madison, WI 53711 ©2016 Pacific Cycle, Inc. Schwinn® is a registered trademark of Pacific Cycle, Inc. www.schwinnbikes.