Montgomery Ward ZDW-57008A User manual

.
MOPED
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Model
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ZDW-57008A '!
ZDW-57061A !
ZDW-57062A
Form
No.·
61M-208B*
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IMPORTANT
SAFE OPERATION PRACTICES
Local licensing, ageand
traffic
regulatl.
ons
may vary
from
state
to
state. Check existing local laws.
TRAI
NI
NG
1. Read
the
Owner's Manual carefully. Be
thor
oughly
familiar
with
the
controls
and
properuse
of
the equipment.
2. Never
allow
children
to
operate a MOPED
without
proper and close
adult
sup
ervision.
Children should be of
sufficient
age,
understanding and capacity.
PREPARAT
IO
N
3.
It
is the absolute understanding that
this
unit
is
not
a field bike.
Any
licensing needed
to
comply
with
the
existing local
or
state vehicle
requirements In any given area is the sole
responsibi
lity
of
.the purchaser.
4. The operator should never place
his
hands,
feet
or
any part
of
his body near any moving
parts.
5. This MOPED is designed for ONE AIDER
ONLY. Carrier
is
not
for
passengers.
6. T
his
MOPED should not be used in a reckless
manner, such as
jumping
obstacles, racing
or
hill
climb
ing.
7. This MOPED
is
designed
for
hard surfaces,
such as pavement.
I •
1.
Check fuel before starting engine. Fuel
mixture
50:1
(2112
oz.
two
cycle
oil
to 1 gallon
of
regular gasoline). Do
not
·
fill
gasoline tank
Indoors, when engine is running,
or
while
the
engine is
still
hot.
Wipe
off
any spilled
gasoline before starting the engine.
8. Never operate
this
MOPED on wet
or
slippery t
i:
surface.
2.
Never start
this
MOP
ED
without
being in
properstarting position.
See
page
9.
OPERATION
1. It
is
recommended
the
operator use a safety
helmetand eye protection.
2.
Manufacturer recommends running
with
lights
on.
2
MA
IN
TE
NANCE AN D STORAGE
1. Keep
all
nuts,
bolts
, and screws
tight
to
be
sure the
unit
is
in
a safe operating
condition.
2.
Never store the unit inside
of
a
building
with
gasoline in the tank where the fumes may
reach
an
open flame
or
spark.
Allow
the
engine
to
cool
before
stor
i
ng
in any
enclosure.
3.
Prior
to
each use, the tire pressure should be
checked and maintained. Front: 25 P.S.I.,
Rear: 32 P.S.I. Maximum
36
P.S.I.
front
and
rear.
4. The tightness
of
the spokes should
be
checked after every few hours
of
operation.
See Spoke Adjustment on page 15.

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--
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CONTENTS
Safe Operation Practices
....................
2 Exploded VIew for Fork and Handle Bar
....
...
18
Parts List
for
Fork and HandleBar
............
19
Exploded View
for
Main Frame
.......
..
......
20
Parts
List
for
Main Frame
................
21,
22
Exploded View forTorque Converter . .
........
23
Exploded View and Parts
List
for FrontWheel
24
Exploded View and Parts
List
for
Rear Wheel
...
25
Exploded View and Parts
List
for
Controls
....
.
26
Exploded View and Parts List for Engine
....
27
-
31
Parts Ordering Procedure
...........
Back Cover
Index and Know Your MOPED
.....
..
....
. .
...
3
ConsumerInformation
....
.
.................
4
Tire Reserve Load
............
.
.........
.
...
5
Identification
..............
.
...............
6
Assembly
Instructions
......................
6
Prepare
for
Operation
.......................
8
Operating
....
.........
...
.................
9
Maintenance
..........
..
.........
.
........
10
Adjustments
........................
..
....
13
Wiring Diagram
............
.....
.
......
.
...
17
l
KNOW
YOUR MOPED
1 FIGURE
1.
RIGHT HANDVIEW FIGURE 2. LEFT HAND VIEW
1. Brake/TalI Light
1.
Amber Reflector (Front)
,._
2. Seat
I 2. Headlight
3.
BreatherCap 3. Speedometer
4. Fuel Tank and Cap 4. Rear View Mirror
5. Choke Lever 5. Starter Lever
6. Throttle Twist Grip 6. Brake Lever (Rear)
7.
Start/Stop
Switch 7. Seat Adjusting
Bolt
8.
Brake Lever (Front) 8.
Red
Reflector (Rear)
9. Front Internal Drum Brake 9. Chain Adjuster
10
. Front Fork Extension 10. Rear Wheel
11. Right Hand Pedal 11. Kickstand
/12. Pedal Chain 12.
Muff
ler
13. Rear Internal Drum Brake 13. Front Wheel
14.
Rear Swing Arm Shock
3
h

-----
-.
1979 MOPED
CONSUMER
INFORM
·ATION 0
• 0
This sheet contains Information on stopping distances, tire reserve loads and acceleration and passing
ability
asrequired by the Consumer Information Regulations issued by the National Highway Traffic Safety
Administration
of
theUnited States Department
of
Transportation.
Datafor stopping distances and passing
ability
were derived from tests conducted
with
new vehicles under
optimum
road
conditions
by skilled test drivers and are not necessarily representative data for a used
vehicle, for
mrny
road conditions,
or
for the
abilities
of
most operators.
VEHICLE STOPPING DISTANCE
This figure Indicates braking performance that can be met
or
exceeded by thevehicles
to which
it
applies, witho
ut
locking the wheels, under different conditions
of
loading
an
d
with
par
ti
al failures
of
the braking system.
Th
e Information presented represents
resul
ts
obtainablebyskilled drivers undercontrolled road and vehicle conditions, and
the Information may n
ot
be correct underotherconditions.
De
scription
of
vehicles
to
which
thi
s tableapplies: All Models
of
"
MOPED
"
························M
····
··
A. F
ully
Operational Service Brake Load
Light
Maximum
B. Emergency Service Brakes (with Partial
Service Brake System Failure)
C.
Brake PowerUnit Failure
Maximum Load
28Ft.
(130 LB. Operator)
,.Ft.
(225 LB. Operator)
NOT CAPABLE
NOT CAPABLE
0 100
200
300
400 500
Stopping Distance in Feet from 22 mph.•
*The maximum speed
att
ainable by accelerating a maximum rate from a standing
start
for
one
mi
le.
4
-
-----
-

1
•
TIRE RESERVE LOAD
This
table
lists
the tire size designations recommended by the manufacturer for use on the vehicles
to
which
it
applies,
with
the recommended inflation pressure for maximum
lo
ading and the
ti
re reserve load
~
percentage
for
each
of
the tires listed. The tjre reserve load percentage
indic
ated is met
or
exceeded by
V Ieach vehicle
to
which
the table applies.
Descript
ion
of
Vehicles
to
Which
theTableApplies:
_
A
:....:..:..:.
II
_
M
_
o
_;
d_e
_
l
s
_
of
.:...
'_;'
M
~
O
.:...
P
-=
E
:..::
O
_"
_
__
_ _
_____
_
R
ecommended Tire Size Designations 2-
1/4-17
R
ecommended.Cold
Inflation
Pressure Front 25
PSI
for Maximum Loaded VehicleWeight Rear 32
PSI
*The difference, expressed as a percentage
of
tire load rating, between (a) the load rating
of
a tire at the
vehicle manufacturer's recommended inflation pressure at the maximum loaded vehicle weight and (b) the .
load imposed
upon
the tire by thevehicle at that
condition
.
WARNING. Failure
to
maintain the recommended tire
inflation
pressure
or
to
increase
tire
pressure as
recommended when operating at maximum loaded vehicle weight, or loading the vehicle beyond the
capacities specified on the tire placard affixed
to
the vehicle, may result in unsafe operating conditions due
to
premature tire failure, unfavorable handling characteristics, and excessive tire wear. The tire reserve
load percentage
is
a measure
of
tirecapacity,
not
of
vehiclecapacity. Loading beyond the specified vehicle
capacity may result In failure of thevehicle components.
ACCELERATION
AND
PASSING ABILITY
This figure indicates passing times and distances that can be met
or
exceeded by the
vehicles
to
which
it
applies
in
the situation diagrammed below. '
The
low
speed pass assumes an initial speed
of
20 MPH and a
limiting
speed
of
35 MPH.
The high speed pass assumes an initial speed
of
50 MPH and a
limiting
speed
of
80 MPH.
NOTI
Cl:
The
information
presented represents results obtainable by skilled drivers under
. controlled road and vehicle
conditions
and the information may not be correct
·
;;
under other
conditions.
l
Descripllon
of
vehicles
to
which this tableapplies:
All
Mo
dels of "MO
PED
"
LOWfSPEED PASS SUMMARY TABLE:
1,500
FEE
T 46 SECONDS
HIGJ-tSPEED PASS FEET SECONDS NOT CAPABLE
LOW SPEED
INITIAL SPEED: 20 MPH LIMITING
SP
EED: 35 MPH
I TOTAL PASSING DISTANCE FEET I
TOTAL PASSING TIME SECONDS
············
·
················
·
···············
-
~
140o
••
•
•••••••••
••
••
••
••••••
•
-·~
1+
40+1
55 TRUCK CONSTANT 20 MPH
HIGH SPE
ED
(MOPED NOT CAPABLE)
INITIALSPEED: 50 MPH LIMITING
SP
EED: 80 MPH
I
~
TOTAL PASSING DISTANCE FEET I
l TOTAL PASSING TIME SECONDS
·····························
·
······
·
·
·······
· · ·
······
·
······~
~
100
~
c::::J···
····
······
·
····
··
········-~~~
100
~
55TRUCK CONSTANT50 MPH
5

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i
IDENTIFICATION
1. The identification number
will
be on
the
vehi-
cle model numberplate (See figure3.) located
on the main frame under the handle bars. The
identification number
is
also stamped
into
the
frame on
the
left side,
just
under the rear fork
assembly.
FIGURE 3.
2.
The
Engine Type Number and Letter is
stamped
into
the metal on the crankcase. See
figure
4.
FIGURE
4.
.
'2J1
~
~
~
1167
~
6
TOOLS REQUIRED FOR
ASSEMBLY
One
7/16"
Open end
or
box end wrench.
One
12"
Adjustable wrench.
One 6" Adjustable wrench.
One
1f4"
Standard flat screwdriver.
OTHER MATERIALS
REQUIRED
One can
of
two-cycle oil and gasoline.
ASSEMBLY
INSTRUCTIONS
The MOPED comes completely assembled wi
th
the exception
of
the handle bar, rear view
mirror
,
and pedals. See figures 5and 6.
Reference
to
right and left hand side are from the
normal riding position, faci
ng
forward.
FIGURE 5.
t
1
4--..-
('
FIGURES.

1
CONTENTSOFHARDWAREPACK
1. Rear view mirror
2. R.H. and L.H. pedals
3. Plug button
4.
Head tube nut
5.
Handle bar plate
6. Hex screws
for
handle mount
7. Lockwashers
8. Two steel balls
.NOTE
Remove
block
of
wood and discard.
Retain
bolt
and head tube nut.
HANDLE BAR ASSEMBLY
1. Leave
two
spacerwashers on head tube.
2.
Place the steel balls (8) in upper fork. See
figure7.
FIGURE 7.
3. Before assembly, check adjusting cone for
tightness.
FIGURE 8.
7
4. Place the handle bar In place over the steel
balls (8). Place handle bar plate (5) over
handle bar and secure with four hex screws
(6)
and lockwashers (7).
See
figure
8.
One
7/16"
wrench
is
required.
5. Secure-handle bar plate
(5)
in place with head
tube nut (4). See figure 9. A 12" adjustable
wrench is required. Press In plug button (3).
FIGURE 9.
REAR VIEW MIRROR ASSEMBLY
Position rear view mirror on handle bar. Secure
clamp
in
desired position.
See
figure 10.
FIGURE 10.

I !
I
I
SEAT ASSEMBLY
1. Place the seat post clamp on seat post.
2.
Line
up
the
two
rear clamps
on
seat with
holes In rear frame
of
MOPED.
3.
Tighten
the
pillar
clamp nut and
bolt
securely.
4. Tighten the rear seat clamp
nuts
and screws.
PEDAL
ASSEMBLY
Assemble pedals to crank using an adjustable
wrench. Tighten securely. See figure 11.
~NOTE
Threaded ends
of
pedals are marked
"R"
and
"L"
for
right
and
left
hand
sides. See figure 11.
Right
and
left
hand
side
Is determined from the
operator's
position.
FIGURE11:
PREPARE FOR OPERATION
1. Fuel mixture 50:1.
Mix
in a clean container
2112
ounces
of
SAE
30
or
snowmobile
oil
or
2
cycle
oil
per gallon
of
regular gasoline. This
mixture
assures positive lubrication. Do
not
use 10W-30 type oils. See figure 12.
~NOTE
Never
fill
fuel tank
with
engine
running.
8
2V2
oz. Oil
To
1 Gal.
Gasoline
FIGURE 12.
FUEL
TANK
CAPACITY
23,4
QUARTS.
Remove gas cap and open vent
to
fill.
You
must
close vent before
starting.
See
figure 13.
FIGURE 13.
FREE-WHEELING FEATURE
1. Your MOPED has a shut-
off
block
located
on
the drive pulley, lefthand side
of
bike.
2.
You
must
engage the
shut-off
block inorder
to
start
your
MOPED.
See
figure 14 and 15.
3.
The drive pulley
is
marked
(+)positive,
which
is theengaged position. See
figure
14.
~I

=IGURE 14.
4. Thedrivepulley
is
marked (0) negative, which
is
the
disengaged
position.
See
figure
15.
IGURE 15.
6. The
shut-off
block
positioned
in
the (0) allows
you
to
free-wheel
or
pedal the 'bike
with
the
engine
off.
7. To change the
shut
-
off
block
position
simply
turn
to
(0)
or
( + ) by hand.
OPERATING
STARTING
oc;-·
Open fuel
valve.)ee
figures 16,
17
and 18.
9
FIGURE 16.
FIGURE 17.
Shown"Reserve"
FIGURE 18.
2.
Engage the
shut-off
block. See figures 14and
15.
3.
Turn the engine stop switch to
RUN
position.
See
figure 19. Engine stop switch
is
located
on the
right
hand handle.

I
l
FIGURE 20.
If
theengine chokecontrol lever
is
pulled
too
long
so that the engine
will
not
start, shut fuel valve
and try
to
start engine several times
without
applying the choke
contr
ol.
If
necessary, remove,
dry and reinstall the spark plug-then repeat
starting procedure.
~CAUTION
Avoid unnecessary acceleration
of
engine when
not
in motion, other-
wise
clutch
will
engage.
10
PUTTING MOPED IN MOTION
Accelerate
slowly
after
the
engine has begun
to
run. The torque converter engages as the
revolution increases and the bike moves
off.
It
Is
recommended
to
use the pedals for help when on
inclines.
STOPPING THE BIKE
The MOPED
is
stopped
by
closing the
throttle
control and applying the hand brake levers located
on the handle bars.The
front
wheel brake lever Is
located on the right hand side.
See
figure 19. The
rear wheel brake lever Is located on the
left
hand
side. See figure20.
~CAUTION
Braking
procedure-Use
rear wheel
brake
for
stopping
by
actuating the
left
hand brake lever. To
assist
In
stopping, the right hand brake lever
is
to
be applied AFTER actuating
the
left
hand brake lever.
If
In
an
emer-
gency
stop
situation
the operator
applies
front
brake
only
it
can cause
loss
of
control
of
the MOPED.
STOPPING THE ENGINE
Shut
off
engine
with
engine stop switch, located
on right hand handle bar. See figure 19. Do
not
shut
off
engine by applying the starter control
lever. ALWAYS SHUT OFF
FU
EL VALVE
OPERATION OF LIGHTS AND HORN
Push li
ght
switch
which
is
located on the
left
handle bar in either direction to turn on head and
ta
i
llights.
Middle position is the
off
position.
See
figure
20
.
To operate horn, push the button on the side
of
the control switch located on the
left
handle bar.
Seefigure 20.
MAINTENANCE
AIR CLEANER
1. Remove the left hand step plate,
by
removing
two
screws and
two
bellevillewashers. A 3/8"
wrench
is
required.
2.
Loosen (do not remove) band clamp at the
carburetor with a flat screw driver. See figure
21.

••
'l
FIGURE 21.
3.
Slip
the air cleaner and band clamp
off
of
the
carburetor. Pull the fiber element out
of
housing and wash in gasoline, dry and
lubricate with a
1/2
teaspoon
of
light oil.
See
figure
22.
FIGURE 22.
FIGURE 23.
Clear
--B
,..ther
Tube
11
4. Check the clear breather tube
to
be
sure It Is
free
of
any
dirt.
Breather tube
can
be
cl
ea
ned
with airpressure. Blow dirt from housing thru
housing,
out
of
tube.
See
figure
23.
5. When reinstalling air clea
ne
r
be
sure breather
tube is pointed upward and clears the wiring.
..
NOTE
The air cleaner should be cleaned
every
600
miles.
BELT REPLACEMENT
The belt
is
self-tensioning at all times. No belt
adjustment
is
necessary.
1.
Remove the left hand step plate from MOPE
D.
Remove
two
screws and belleville washers. A
3/8"
wrench
is
required.
2.
Remove the mufflerby removing two hex nuts
at the muffler flange
to
cylinder head
of
engine. A 9mm socket wrench
is
required.
Remove
two
allen head screws from bottom
of
muffler.
See
figure
24.
FIGURE24.
3.
Pop
off
the left hand engine side cover with a
screw driver.
See
figure
25.
Screwdl·~fvAr
FIGURE 25.

•
4.
Disconnect
the starter cable
from
the
starter
lever,
by
pressing
Inward
to
release
the
tension
on
the
cable.
See
figure
26.
FIGURE 26.
5.
Remove
the
starter
lever
by
removing
two
hex
head
screws
from
bottom
of
engine. A
5/16
"
wrench
Is
required. See figure 27.
FIGURE 27.
FIGURE 28.
12
6. Remove
two
belt
guard
bolts
at
drive
pulley
Two
1/2"
wrenches are required. See
flgun
28
.
..
NOTE
Upon
reassembly
of
belt
guard
bolts,
be
sure
you
have
approxi
-
mately
1/8"
clearancebetween
bolts
and
the
belt.
You
may
have
to
bend
the
bolts
up
or
down
to
make
this
adjustment.
7.
Pull
the
starter
cable
back
out
of
way.
With
one
hand push
the
engine
down,
and remove
the
belt.
See
figure
29.
FIGURE 29.
8.
Place
new
belt
back
on
drive
pulley
and
torque
converter. Reverse
the
above
steps
for
reassembly
.
&cAUTION
The
extension
springs
on
your
MOPED are under pressure. Exer-
cise
caution
if
you remove them
for
any reason. See figure 30.
FIGURE 30.
~·

r.
I
I
(A)
FIGURE 31.
SPARK PLUG
Electrode Gap
The electrode gap expands during opera
tion
from
heat. T
his
Is
why
the
electrode gap has
to
be
adjusted
to
specification from
time
to
time. This
in
turn
is
done
by
bending ground electrode (A).
The
specific
gap
is
.020 inch. See figure3
1.
C
LEANING
The spark plug.should be cleaned every 600 miles.
Use a piece
of
sandpaper
or
emery board
to
clean
the ground electrode and between the electrodes.
Blow
out any
dust
or
sand. Replace spark plug
afterresetting
the
gap to .020 inch.
CHECK
ING
FUNCTION
Unscrew spark plug, install plug connector, place
plug threads against ground (cylinder head) and
operate starter.
If
plug
is
in perfect condition, :
there
must
be strong sparking between the
electrodes.
Only
touch the insulated part
of
the
plug connector
to
avoid a
"shock"
although
it
is
completely harmless. See figure32.
FIGURE 32.
13
ADJUSTMENTS
ENGINE CO
OL
ANT
Engineheat
is
dissipated byan amount
of
coolant
sealed in the cylinder block. Mlxture
is
1/ 3
anti-freeze
to
2/3
water and gives protection
to
about -13degrees Fahrenheit.
Coolant should never need checking
or
changing.
However,
if
leaks are noticed, have a qualified
person determine
the
cause and replace any parts
or
coolant necessary. A fill plug Is located on the
top
of
the cylinder head.
C
HA
IN ADJUSTMENT
Your MOPED
is
equipped with
two
chains, the
drivechain and pedal chain.
Drive
Ch
ain- Is located on the
left
hand side
of
MOPED. The drive chain should have 1/ 2"
deflection. See figure 33. Lubricate at least every
100 miles with a light
oi
l for maximum chain life.
Replace wi
th
chain shown in parts
list
of
this
manual only. This is a special chain size.
FIGU
RE
33.
The MOPED must rest on the kick stand
with
the
left hand step plate removed. See figure 34.
Loosen rear axle
nuts
slightly
. Make sure that
bo
th
chain adjusters are adjusted the same rate.
The rear wheel must always
be
parallel
to
the
frame and front wheel. Be sure
to
retighten the
axle nuts secure
ly
.

FIGURE 34.
Pedal
Chain-Is
located on the right hand side
of
MOPED. The pedal chain has
an
automatic chain
adjuster(Idler). Noadjustment is required.
.,_.NOTE
J3oth the drive chain and pedal chain
are equipped with master link
for
easy removal and maintenance.
REMOVING
AND
INSTALLING FRONT WHEEL
1. Place bike on kick stand.
2.
Remove the axleand nut from the
front
wheel.
Lift
the speedometer out
of
the way
if
your
MOPED
is
soequipped.
Lift
the brake hub out
of
the way and remove
the
front wheel.
3. Upon reassembly
of
front wheel, place the
speedometer arm in one
of
the
two
holes on
left hand side
of
front wheel.
See
figure
35.
FIGURE
35.
14
4. Place
the
brakeand
hub
back
in
the
right
hand
side
of
wheel. Next, place the spacer on axle.
See figure 36.
FIGURE 36.
~CAUTION
Be sure
to
replace spacers and
washers in proper positions.
5. Make sure that the fork holder on the
right
hand
side
engages in the
slot
of
front
wheel
hub lever. Place flat washer next
to
fork and
secure the axle
with
hex locknut. See figure 1
36.
REMOVING
AND
INSTALLING
REAR
WHEEL
1.
Place bike on kick stand.
2.
Remove black
bolt
at rear wheel
hub
lever.
See figure37.
3. Remove the hex locknut, axle
bolts
and chain
adjusters. See figure37.
4. Remove the chain and brake hub. See figure
37.
FIGURE
37.
' I

t
CD
)
~
I
5. Upon reassemblyeof rear wheel place the
spacers between the wheel and fork.
6.
Replace the chain, brake hub, axle bolt, hex
locknut, chain adjusters and tighten by hand.
Be sure
slot
in rear wheel hub lines up
with
hole
in
frame and replace the black bolt. See
figure
37
.
..
NOTE
Be sure
to
insert axle bolt from
left
side
of
bike.
7.
To readjust the chain, see chain adjustment
on page 13
of
this
manual.
SPEEDOMETER (OPTIONAL)
Thespeedometer drive on the
left
front wheel hub
has a lubrication nipple. Always lubricate here
every 600
to
900 miles.
See
figure38.
FIGURE 38.
CLEANING FUEL VALVE
It is recommended to remove and clean the fuel
valve thoroughly once each year. Clean with
gasoline by moving the lever through all of
its
positions. Cleanliness is especially important for
filter
screen. Flushing with clean gasoline
is
just
as important as blowing through with the air
pump.
Don't forget
to
insert the fuel tank connection
seals correctly when reinstalling.
HEADLIGHT
AND
TAIL LIGHT
The headlight
is
always
at
low;
it
has a 6V-18W
sealed beam
which
is replaceable.
The
taillight
has a 6V-5W bulb and the brake
light
has a 6V-10W bulb, which can be replaced by
removing
two
screws and
taillight
lens. See figure
39.
FIGURE 39.
SPOKE ADJUSTMENT
1. The tightness
of
spokes should bemade every
few hours
of
operation.
2. To check
for
correct spoke tension, wiggle
each spoke gently.
If
the spoke nipple
at
the
rim is able
to
move, the spoke
is
too
!oose.
3. Another way
to
check spoke tension is by
gently tapping a metal object, such" as a
screwdriver, against each spoke.
If
the spokes
are equally tightened, they
will
produce the
same sound
or
pitch.
4. To tighten a spoke use a spoke wrench
or
an
adjustable wrench.
BRAKE ADJUSTMENT
1.
A
10
mm wrench is required.
2.
Loosen jam nut on brake cable and turn the
barrel nut on brake cable counterclockwise for
more adjustment and clockwise for less
adjustment.
See
figures
40
and 41.
FIGURE 40.
15 .

FIGURE
41.
3. Brake Wear
limit
When brake lever on wheels reach the wear
limit
mark, remove the lever and turn over
for
moreadjustment. Then when the wear
limit
is
reached again, brake shoes must
be
replaced.
.see figures 40 and
41.
16
CARBURETOR
ADJUSTMENT
1. The idle screw is preset at thefactory.
2.
If
adjustment becomes necessary use the
~
following steps.
~
·;
3. The idle screw
is
located on the right hand
side
of
carburetor.
See
figure
42.
FIGURE
42.
4. Turning the idle screw clockwise will speed
up the engine. Turning the idle screw
counterclockwise will slow theengine.

t
'
f.
t
~
A = Green-Black
B = Green
C = Gray
D = Yellow
E = Blue
i -
Attach
at
•
Black
Coil
or
Terminal
Block
Mounting
Engine
I
\
1
Black
Blue
Blue
Coil
Yellow
Red
PARTS LIST FOR ELECTRICAL SYSTEM
REF. PART DESCRIPTION
NO. NO.
1 725-0637 Wire
Harness-Comp.
2 725-0598 Terminal Block Ass'y.
3 725-0599
Kill
Button Switch
4 725-0539 Horn
5 725-0600 Accessory Switch
6 725-0592 Headlamp Ass'y.
for
Speedometer (Optional)
725-0591 Headlamp Ass'y. w/ o
Speedometer(Optional)
7 725:0541 Electric Wi
re
(2 Req'd.)
8 725-0533 Taillamp Ass'y.
9 725-0538 Brake Light Switqh (2 Aeq'd.)
1/
f,
3

I
I. r
I
~
r
I
\ '
~
' 1
ZDW-57008A .
ZDW-57061A
ZDW-57062A
32
31
FORK ASSEMBLY
~
I
77
18

...
PARTS LIST FOR FRONT FORK ASSEMBLY COMPLETE #06894
REF
. P
ART
NO. NO. DESCRIPTION
1 06895 Handle
Bar
2 736-0329
L-Wash.1/4"
Scr.•
3 710-0747 Hex Scr.
1/4
-28 x 1.25" Lg.
4 726-0186 Plug
Button
.
81"
1.0.
5 712-0304 Fork Lock
Nut
1.0-24 N.S.I.
6 745-0167 Rear View
Mirror
7
06891
Telescope
Fork
Ass'y.
9
741
-0285 Cone-
Adj.
Fork
10 741-0287
Fork
Bearing
11
730-0114 Side
Reflector
2.0"
Dia.
Amber
12
741
-0284 Ball F
ork
Cup
13
741
-0283 Cone-
Lower
14 732-0340 Compression Spring
15 731-0400 Bushing
Nylon
J6
06827 Fork
Extension-L
.H.
17
06838
Front
FenderAss'y.
18 731-0400 Bushing
Nylon
19
731
-
0401
Rubber
Boot
20 710-0289 Hex Scr.
1/4
-20 x .50" Lg.•
21
710-0258 Hex Scr.
1/4
-20 x .62" Lg.•
22 712-0107 Hex Cent. L-
Nut
1/4-20
Thd.
23 736-0329 L-Wash.
1/4"
Scr.•
24 745-0171 Speedometer Gear Box(Optional)
25 06828 Fork
Extension-R.H.
26 745-0170 Speedometer Cable 650mm (Optional)
27
712-0107 Hex Cent.
L-Nut
1/4
-20 Thd.
28 725-0539 Horn 6V-18W
29 710-0289 Hex Scr.
1/4-20
x .50" Lg.•
30 725-0590 Sealed Beam 6V-18W
31
710-0725 Truss Mach.
AB
Tap Scr.
#8
x
32 731-0426 1.00" Lg. *
Headlight Bezel Chrome
34 731-0424 Headlight
Housing
for
Speedometer
731
-0468
Headlight
Housing
wlo
Speedometer
35 745-0169 Speedometer (Optional)
36 710-0258 Hex Scr. 1/ 4-20 x .62" Lg.•
37 -Supplied
with
Ref. No.
11
38 -Supplied
with
Ref. No.
11
39 741-0219 Steel Ball .125" Dia.
40 06858 Handle Bar Plate
41
736-0329 L-Wash. 1
I
4"
Scr.•
42 712-0107 Hex Cent. L-Nut 1I4-20 Thd.
*Common Hardware may be purchased
locally.
Important: Do not order
by
Reference Number (Ref. No.).
/
19

1 I
I'
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:
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ZDW-57008A
I ZDW-57061A
ZDW-57062A
MAIN
FRAME
20
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