Mavic Z.A.P Rear Derailleur

The ZAP rear changer is sold with the ZMS 8000 group of parts and recently in an separate upgrade kit. The system uses an electro-mechanical rear derailleur with a microprocessor controlled switch system that activates a selenoid inside the rear derailleur mechanism. There are two major assemblies to the ZAP system. One is the wire harness and electric system, the other is the rear changer. The electric/electronic system has a cylindrical Black plastic case that slides into the end of the handlebar leaving just a steel cap exposed. The steel cap is removable conductive cover for the battery compartment. Three sets of wires exit the electric case between the end plug and the handlebar. One set of wires goes to a switch intended to be below the brake lever clamp area on the right side. This wire is 7 inches long with a harness that holds 2 switches. Another wire set is 17" (430mm) long with a harness that also has 2 switches. This longer wire is for a switch set that's positioned on the front face of the top of the handlebar.



The third wire leads to the rear derailleur and is 89" (2260mm) long. On both switch sets one button controlls an upshoift function, and the other a downshift. What actually happens is the switch closure activates a selenoid that pushes a pin into threaded drive rod that is connected to the jockey or guide pulley of the front derailleur. The rotating pulley turns the drive rod which mechanically moves the derailleur toward or away from the frame making an up or down shift. When the microprocessor determines that enough time has elapsed for the pulley to complete the shift, the power to the selenoid is turned off and the drive pin is withdrawn from the drive shaft. Understanding this you realize that the bicycle must be in motion to achieve a shift. The rear derailleur has a B-tension adjustment. The ZAP system uses a K28A 6 volt photographic battery with an estimated 10,000 shift life. If the battery fails you can continue riding and if needed the derailleur can be pushed to the desired cog until the battery can be replaced. The system is capable of working on 7 or 8 speed cogsets with cogs that are spaced 4.8mm on center, including Mavic, Campy, Shimano, Suntour and Sachs. The handlebar electronic unit and the wire harness and switch system weighs 78 grams, of which 10.5 grams is the weight of the battery and another 8.5 grams is the metal battery cap. The rear derailleur unit weighs 241.5 grams. The total on bike weight of the system 319.5 grams

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