Montgomery Ward ZDW-57008A User manual

MOPED Model
Nos .'
ZDW-570 08A
ZDW-57061A
ZDW-57062A
Form No. ·
61M-208 B*
Two Cycle
Fuel
Mixture- 50 :1

.IMPORTANT
SAFE OPERATION PRACTICES
Local licensing, ageand traffic regulations may vary from state to state. Check existing local laws .
TRAINING
1. Read the Owner 's Manua l carefully. Be
thoroughly familiar with the controls and
proper use
of the equipment.
2. Never allow children to operate a MOPED
without proper and close adult supervision.
Children should be of sufficien t age,
understanding and capacity.
PREPARATION
1. Check fuel before starting engine. Fuel
mixture 50:1 (21 12 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 an y spilled
gasoline before starting the engine.
2. Never
start this MOPED without being in
proper starting position. See page 9.
OPERATION
1. It is recommended the operator use a safety
helmet and eye protection.
2.
Manufacturer recommends running with
lights on.
2
3. It is the absolute underst an ding th at this uni t
is
not a fie ld bike. Any licens ing needed to
comply with the existing local or state vehi cl e
requirements in
any given area is the so le
responsibility 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 RIDER
ONLY. Carrier is not fo r passengers.
6.
This MOPED should not be used in a reckless
manner, such as
jumping obstacles, racing or
hill climbing.
7. This MOPED is designed for hard surfaces,
such as pavement.
8. Never operate
this MOPED on wet or slippery
surface.
MA INTENANCE AND STORAGE
1. Keep all nuts, bolts , and screws tight to be
sure
the unit is in a safe operating con dit ion.
2. Never
store the unit inside of a building wi th
gasoline in the tank where the fumes may
reach an open flame
or spark. Allow the
engine to cool before storing 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. Maxi mum 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.

CONTENTS
Safe Operation Practices ..... ...... ... ...... 2
Index and Know Your MOPED ... . ... .. ...... . 3 Exploded View for Fork and Handle Bar
....... 18
Parts List for Fork and Handle Bar ..... . ..... .19
Cons
umer Information .... . .. ....... ..... ... 4 Exploded View
for Main Frame ..... ... .. ... .. 20
Tire Reserve Load .......................... 5 Parts
List fo r Main Frame ................ 21, 22
Identification .......... . . ................ .. 6 Exploded View
for Torque Converter .......... 23
Assembly Instructions .. . ...... . ......... . .. 6
Prepare for Operation ...... . ................ 8
Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Maintenance . .
.... . .... . .... .. ... . . .. .. ... 10
Exploded View and Parts List for Front Wheel 24
Exploded View and Parts List for Rear Wheel . .. 25
E
xploded View and Parts List for Controls ..... 26
E xploded View and Parts List for Engine .... 27-31
Adjustments .... .. .. . ........... ......... .13 Parts Ordering Procedure
........... BackCover
Wiring Diagram ... . .... . . .... .. ......... .. . 17
KNOW YOUR MOPED
FIGU RE 1. RIGHT HAND VI EW FIGURE 2. LEFT
HA ND VIEW
1. Brake/Tail Light
1.
Amber Reflector (Front)
2. Seat 2. Headlig
ht
3. Breather Cap
3.
Speedometer
4. Fuel Tank and Cap 4. Rear View
Mirror
5. Choke Lever 5. Starter Lever
6.
Throttl e Twist Grip 6. Brake Lever (Rear)
!'
7. Start/Stop Switch
7.
Seat Adjusti ng 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.
Muffler
13. Rear Internal Drum Brake 13.
Front Wheel
14 . Rear
Swing Arm Shock
3

1979 MOPED
CONSUMER
INFORM ·ATION
This sheet contains information on stopp ing distances, tire reserve loads and acceleration and passing
ability as required by the Consumer Inf ormation R egulatio ns issued by the National Highwa y Traffic Safety
Administration of the Unit ed States Department of Transportation.
Data
tor 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 repres enta tive data for a used
vehicle,
for mrny road conditions , or tor the abilities of most operators.
VEHICLE STOPPING DISTANCE
This figure indicates braking performance that can be met or exceeded by the vehicles
to which it applies, without locking the wheels, under different condit ions of loading
and
with partial failures of the braking system. 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 .
Descript
ion of vehicles to which this table applies: All Modelsof " MOPED "
•••••••••••••••••••••••• M aaaaaa
A. Fully Operat io nal Service Brake Load
Light
~t .
(130 LB. Operator)
Maximum
.Ft.
(225 LB. Operator)
B. Emergency Service Brakes (with Partial
Service Brake System Failure)
NOT CAPABLE
C. Brake Power Unit Failure
Maximum Load NOT CAPABLE
0 100 200 300 400 500
Stopping Distance in Feet from 22 mph. •
*The
maximum speed attainable by accelerating a ma xi mum rate from a standing
start for one mile.
4

TIRE RESERVE LOAD
Th is table list s the tire size designations recommended by the manufacturer for use on the vehicles to
which it applie s, with the recommended in flatio n pressure tor maximum loading and the tire reser ve load
, percentage f or each of the ti res listed . The tire reserve load percentage indicated is met or exceeded by
1 each ve
hicle to which the tab le applies. :
Descr ipt ion of Vehicles to Whic h the Table Appl ies: _A_II _M_ o_d _e_l_s_o_f_ "_M_O_P_E _D_" __ _ __ _ __ __ _
-
R
ecommended Tire Size Designations
2-1/4-17
-
R
ecomme nd ed . Cold Infl at i on Pr essu re
Front 25 PSI
for Maximum L oaded Ve hi cle Weight
Rear 32 P SI
* The difference, expressed as a percentage of tire load r ating, between (a) the load rating of a tire at the
ve hicle manufa c turer's recommended inf la tion pressure at the maximum l oa ded vehicie weight and (b) the ·
load im posed up on the tire by the vehi cle at that cond it ion.
WARNING. Fa ilu re to maintain the rec om mended tire inflation pressure or to increase tire pres sure as
recom mended when operating at ma x imum loaded vehicle weight, or loadi ng the vehicle beyond the
capacities specified on the tire placard affixed to the vehicle , may result in unsa fe operating conditions due
to premature tire failur e, unfav orable handling characteristics, and e xcessive tir e wear. The tire reserve
load pe rce ntage is a meas ure of tire capacity, not of vehicle capacity. Loadi ng beyond the specified vehicle
capaci ty may r esul t in failure of the vehicle components.
ACCELERATION AND PASSING ABILITY
This figure indi ca tes passing times and distan ces that can be met or exceeded by th e
ve hicl es to which it applies in the situation diagrammed below.
. . r
The low speed pass assumes an initial speed of 20 MPH and a limiting speed of '35 MPH .
The
hi gh speed pass assumes an initial speed of 50 MPH and a limiting speed of 80 MPH.
NOTIC~: The info rmation presented represe nts results obt ainabl e by skilled drivers under
~;
controlled road and vehicle cond itions and the information may not be corre ct
..
under o ther cond ition s.
Desc rip .\i on of ve hicles to which this table app lie s: All Models of "MOPED"
LOviSPEED PASS
SUMMARY TABLE:
1,500 FEET
46 SECONDS
HIG!i ·SPEED PASS FEET
SECONDS
NOT CA PA BLE
LOW SP.EED
INITIAL SPEED : 20 MPH
LIMITING SPEED: 35 MPH
I
TOTAL PASSING DISTANCE FEET I
TOTAL PASSING TIME SECONDS
·······························-·············-~
r40b·-···· ····· ······ · ·········~ t-.4~
55 TRUCK CONSTANT 20 MPH
HIGH SPEED (MOPED NOT CAPABLE)
INITIA L SPEED: 50 MPH LIMITING SPEED: 80 MPH
L~
TOTAL PASSING DISTANCE FEET
I
TOTAL PASSING TIME SECONDS
····························································-~
~100~ r::::l····· ····· ···· ···· ····· - ·····~~~100~
55 TRUCK CONSTANT 50 MPH
5

IDENTIFICATION
1. The identification number will be on the vehi-
cle model number plate (See figure 3.) locat ed
on
the main frame under the handle bars. The
identifi cation 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.
'2.. f). /:)
FIGURE 4. • '.J "ttL ~
6
TOOLS REQUIRED FOR
ASSEMBLY
One 7/16" Open end or bo x end wrench.
One 12" Adjustable wrench.
One 6" Adjustable wrench.
One 1f4" Standard flat screwdriver.
OTHER MATERIALS
REQUIRED
One can of t wo-cyc le oil and gasoline.
ASSEMBLY
INSTRUCTIONS
The MOPED comes completely assembled with
the exception of the handle bar, rear view m irror ,
and pedals . See figures 5 and 6.
Reference
to right and left hand side are from the
normal riding position, facing forward.
FIGURE 5.
7- o ~· .__,.
FIGURE 6.

CONTENTS OF HARDWARE PACK
1. Rearview mirror
2. R.H. and L.H . pedals
3. Plug button
4. Head tube nut
5. Handle bar plate
6. He x 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 spacer washers on head tube.
2. Place the steel ba lls (8) in upper fork. See
figure?.
FIGURE 7.
3. Before as sem bly, check adjusting cone for
tightness.
FIGU RE 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 f
igur e 8. One
7/ 16"
wrench Isrequired.
5. Secure
handle bar plate (5) in place with head
tube nut (4). See figure 9. A 12" adjustab le
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 .

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.
FIGURE 11.
PREPARE FOR OPERATION
1. Fuel mixture 50:1. Mix in a clean container
21 12 ounces of SAE 30 or snowmobile oil or 2
cycle oil per gallon of regular gasoli ne. This
mixture assures positive lubr i cation. Do not
use 10W-30 type oils. See figure 12.
~NOTE
Never fill fuel tank with engine
running.
8
21/2 oz. Oil
To 1 Gal.
Gasoline
FIGURE 12.
FUEL
TANK CAPACITY 2% QUARTS.
Remove gas cap and open vent
to fill. You must close vent befor e
starting. See figure 13.
FIGURE 13.
FREE-WHEELING FEATURE
1. Your MOPED has a shut-off block located on
th e dr ive pulley, le ft hand side of bike.
2. You
must engage the shut -off block inorder to
start yo ur MOPED. See f igure 14and 15.
3. The drive
pulley is marked ( + ) posit ive, which
is the engaged position. See fifJure 1 4.

FIGURE 14.
4. The drive pulley is marked (0) negative, which
is the disengaged position. See figure 15.
FIGURE 15.
~. :p !~ ' ~ !~ ; ~ lf~~~~ mf ri ~ ·· the engaged
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 simpl y
turn to (0) or ( +) by hand.
OPERATING
STARTING
-- · 1 : -- - o;;;;~uel v;,:')ee figures 16, 17 and 18 .
- - ../
9
Shown" Off" Valve
FIGURE 16.
FIGURE 17.
Shown ~~Reserve"
FIGURE 18.
2. Engage the shut-off block. See figures 14 and
15.
3. Turn the engine stop switch to RUN position .
See figure 19 . Engine stop switch is locat ed
on the
right hand handle.

FIGURE 19.
4: -Move off las on a bicyctg, opening throttle
twist grip at the same time'> S figure 19.)
At ··· ·moving fast enou h, ull choke control
ley~r (cold starts or cold engine only) and
Gi_a rter £Q!l!IQ.Llwer)oward handle bars until
the engine starts . to run, then release the
starter lever immediately. Also release the
choke control lever as soon as the engine
starts, runs smoothly and receives sufficient
fuel. See figures 19 and 20.
FIGURE20.
If the engine c hoke control lever is pulled too long
so that the engine will not start, sh ut fuel valve
and
try to start engine several times wi thout
applying the choke control. If necessary, remove,
dry and reinstall the spark plug-then repeat
starting procedure.
~CAUT I ON
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
recommende j: i() use the pedals for help when on
inc lines. ·· ···
STOPPING THE BIKE
The MOPED is stopped by c los i ng 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 figure 20.
~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 s it uat ion 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 figu re 19. Do no t
shut off engine by applying the starter contro l
lever. ALWAYS SHUT OFF FUEL VALVE
OPERATION OF LIGHTS AND HORN
Push lig ht switc h which is located on the l eft
handle bar in either direction to turn on head and
tail lights. 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 l~ft handle bar.
See figure 20 .
MAINTENANCE
AIR CLEANER
1. Remove the left hand step plate, by removing
two screws and two belleville washers. A 3/ 8"
wrench is required.
2. Loosen (do not remove) band clamp at the
carburetor with a fla t screw driver. See figure
21.