Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2010 ZAP XLFACTORY OEM SERVICE PROCEDURE
Maintenance of Controller
- Periodically clear away dust and grime from the exterior of the controller.
- The inspection period of the electric capacitor in the device is one year. If there the shell is deformed or leaks, replace immediately.WARNING:
- Controller circuit has high voltage, which can be harmful.
- Enable the emergency disconnect switch when disassembling or reassembling the controller.
- Only trained professionals should work on the controller
- Maintenance, repair, and changing wires should occur only after cutting off the power for two minutes, otherwise, an electric shock may occur that can damage electronics.
- Do not wash the controller with water.
Factory Service Tools
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.