I finally got round to making a start last night, afraid that the
guys that previously had a go have disconnected and dismantled just
about everything and left it hanging :-(

I've plugged the controller board back in so that it doesn't get lost
or stood on.

First thing was to make safe and power up for testing - found the
battery voltage was down to about 16V (should be 72), so the priority
was to get some charge back into the batteries.

Plugged the charger in and ..... nothing.

Inside the charger of course all the cables are the same colour, no
markings and tied into a tight loom, lots of fun trying to figure out
the circuit. Finally figured out that the full charge cut out was
faulty and bypassed it temporarily (that's another job to add to the
list). and whooppeee!!! it starts charging. after getting a bit of
power in I tried testing again and at least can confirm that the
dc/dc converter is working to give a 12v system, next thing is to get
the controls reconnected again.

So that's as far as I've got so far, but at least I can start trying
to figure it out. If anyone has any info on ZAPI controllers or can
point me towards any sources of info I'd appreciate it.

I've uploaded the first few photos, nothing exciting yet.

Cheers,
Martin