Montgomery Ward ZDW-57008A, 61M-208B Owner's Manual

MOPED

Model

ZDW-570
ZDW-57061A
ZDW-57062A

Form No. ·

61M-208

Nos

08A

B*

.'

Fuel

Two Cycle

Mixture-

50

:1

.IMPORTANT

SAFE OPERATION PRACTICES

Local

licensing,

age and

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 (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.

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

understanding that

this

uni

t

is

not a fie

ld bike.

Any

licens

ing needed to

comply

with

the

existing

local

or

state

vehicle

requirements in

any

given area

is

the sole

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 for 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 with

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

operat ion.

See Spoke

Adjustment

on page 15.

CONTENTS

Safe Operation Practices
Index and
Cons
Tire Reserve Load
Identification
Assembly
Prepare

Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Maintenance . .
Adjustments
Wiring

Know

umer

Information

Instructions ...

for

Operation

....................

Diagram

Your

..........

...................

........

.....

......

MOPED

.......

..........................

.......................

...............

.......

. .

................

................

. .

...............

...

.....

. .....

.........

......

. 3

...

..

.

..

...

10

. 13

... 17

KNOW YOUR MOPED

Exploded

2

Parts
Exploded

4

Parts

5

Exploded

6

Exploded View and Parts

6

Exploded View and Parts

8

E

xploded

E

xploded

Parts Ordering Procedure

View for Fork and Handle Bar

List

for
View

List for Main Frame

View

View and Parts
View and Parts

Fork and Handle Bar

for

Main Frame

for

Torque Converter

.....

................

List

for

List

for

List

for

List

for

...........

.......

...........

. . .... . .

..........

Front Wheel 24
Rear Wheel .
Controls
Engine

....

BackCover

21, 22

.....

27-31

..

..

18

. 19

20
23
25

26

FIGU

RE

1. RIGH T

1. Brake / Tail

2.

Seat
Breather Cap

3.

4. Fuel Tank and Cap

HAND VIEW

Light

5. Choke Lever

Throttle Twist

6.

7.

Start/Stop

8. Brake Lever

9.

Front

Internal Drum Brake

10. Front Fork Extension

11.

Right

Hand Pedal

12.

Pedal Chain
Rear Internal Drum Brake

13.

Rear

14

Swing

.

Grip

Switch

(Front)

Arm Shock

FIGURE

Amber

1.

Headl ig

2.

Speedometer

3.

Rear View

4.

Starter Lever

5.

Brake Lever (Rear)

6.

Seat

7.

8.

9.

10.

11.

12.

13.

3

Adjusti
Red Reflector (Rear)
Chain

Rear Wheel
Kickstand
Muffler
Front

2. LEFT HAND VIEW

Reflector (Front)

ht

Mirror

ng

Bolt

Adjuster

Wheel

!'

1979 MOPED

This sheet
ability
Administration

Data
optimum
vehicle,

contains

as required

tor

stopping

road

for

mrny

This figure indicates braking performance that can be met
to

which

and

results
the

CONSUMER

information

by

the Consumer

of

the

Unit

distances

conditions

road

conditions, or

on

stopp

ing

distances,

Inf

ormation R

ed

States Department

and passing

by

skilled test drivers and are

tor

ability

the

abilities

were derived from tests

INFORM

tire reserve loads and acceleration and passing

egulatio

of

Transportation.

ns issued by the

not

of

most

·ATION

conducted

necessarily repres

operators.

VEHICLE STOPPING DISTANCE

or

exceeded

it

applies,

with

partial failures

obtainable

information

by

may

without

not

locking

of

the braking system. The

skilled

drivers under

be correct under

the wheels, under

information

controlled

other

road and vehicle

conditions

different

.

National

condit

presented represents

Highwa

with

new vehicles under

enta

tive data

by

the

vehicles

ions

of

loading

conditions,

y Traffic Safety

and

for

a used

Descript

A.

B.

C. Brake Power

*The
start

ion

of

vehicles

Fully

Operational Service Brake Load

Emergency Service Brakes (with Partial

Service Brake System Failure)

Unit

maximum

for

one mile.

to

which

this

Light

Maximum

Failure

Maximum

speed attainable

table

applies:

~t

.

.Ft.

Load

0

Stopping

by

accelerating a maxi

All Models of "

••••••••••••••••••••••••

NOT

CAPABLE

NOT CAPABLE

100

200 300 400

Distance

mum

MOPED

(130 LB. Operator)

(225 LB. Operator)

in

Feet

rate

"

M

aaaaaa

500

from

22

mph.

from a standing

•

4

TIRE RESERVE LOAD

Th

is

table

lists the

tire

size

designations

recommended

by

the

manufacturer

for

use

on

the

vehicles

to

which

it

applie

s,

with

the

recommended inflation pressure

tor

maximum

loading

and

the

tire reser

ve

load

, percentage f

or

each

of

the tires

listed. The

tire

reserve load percentage

indicated

is

met

or

exceeded

by

1

eac h ve

hicle

to

which

the tab

le

applies.

:

Descr

ipt

ion

of

Vehicles

to

Which 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

ecommended. Cold

Inflati

on Pressu

re

Front

25 PSI

for

Maximum Loaded Vehi

cle

Weight

Rear 32 P

SI

*

The

difference,

expressed as a

percentage

of

tire

load rating,

between (a)

the

load

rating

of

a tire at

the

ve

hicle

manufacturer's

recommended

inflation

pressure

at

the

maximum loa

ded

vehicie

weight

and (b)

the

·

load imposed upon

the

tire

by

the

vehi

cle

at

that

condition.

WARNING. Failu

re

to

maintain

the

recommended

tire

inflation

pressure

or

to

increase

tire

pres

sure

as

recom

mended

when

operating

at max

imum

loaded

vehicle

weight,

or

load i

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 perce

ntage

is

a meas

ure

of

tire

capacity,

not

of

vehicle

capacity.

Loadi

ng

beyond

the

specified

vehicle

capaci

ty

may result in

failure

of

the

vehicle

components.

ACCELERATION

AND

PASSING ABILITY

This

figure

indicates

passing

times

and

distan

ces

that

can

be

met

or

exceeded

by the

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

ainable by

skilled

drivers

under

~;

controlled

road and

vehicle

cond

itions

and

the

information

may

not

be

corre

ct

..

under other

cond

ition

s .

Desc

rip

.\i

on

of vehicles

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 CAPA

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)

INITIAL 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
cle model
on

the

identifi

frame on the
assembly.

number

main

cation

frame

number

left

side,

number

plate (See

under

will

the

is also stamped

just

under

figure

handle bars. The

be

on

the rear

3.)

the

locat

into

vehi-

ed

the

fork

TOOLS REQUIRED FOR
ASSEMBLY

One

7/16"
One
One
One

Open end

12"

Adjustable

6"

Adjustable

1f4"

Standard

or box end wrench.

wrench.

wrench.

flat

screwdriver.

OTHER MATERIALS

REQUIRED

One

can of t

wo-cyc

le

oil

and gasoline.

ASSEMBLY
INSTRUCTIONS

FIGURE 3.

2. The Engine Type
stamped
figure

4.

into

the

Number

metal

on

and

Letter

the

crankcase. See

is

The MOPED
the

exception

and

pedals

Reference
normal

FIGURE 5.

riding

comes

of

. See

figures 5 and

to

right

position,

completely

the

handle

and

left

hand

facing

assembled

bar, rear

6.
side

forward.

view mirror

are

from

with

,

the

'2 ..

FIGURE 4. •

f).

'.J

"ttL

/:)

~

FIGURE 6.

6

7-

o

~·

. __ ,.

CONTENTS

1.

Rear view

2.

R.H.

3.

Plug

4. Head

5.

Handle

6. Hex

7.

Lockwashers

Two

8.

OF

mirror

and

L.H

button

tube

bar plate

screws

steel

balls

HARDWARE PACK

. pedals

nut

for

handle

.._,NOTE

Remove

Retain

block

bolt

of

wood

and head

HANDLE BAR ASSEMBLY

1.

Leave

two

2.

Place
figure?.

spacer

the

steel balls

washers on head

mount

and

discard.

tube

nut.

tube.

(8) in upper fork. See

4. Place

5.

the

handle bar In place over

balls

(8). Place handle bar
handle
(6) and
7/ 16"

Secure
tube
wrench

bar and secure

lockwashers (7). See f

wrench

nut (4). See figure

Is required.

handle

is

requi red. Press

FIGURE 9.

VIEW MIRROR ASSEMBLY

REAR

plate

with

four

hex screws

igur

bar plate (5) in place

9. A 12"
in

plug

button

the

steel

(5) over
e 8. One
with

head

adjustab

(3).

le

FIGURE 7.

3.

Before assem
tightness.

bly,

check

adjusting

cone

for

Position

clamp

rear view

in desired

mirror

position.

on handle bar. Secure

See

figure 10.

FIGU

RE

8.

FIGURE

7

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

2112

ounces

of

SAE 30

or

snowmobile

oil

or

2

cycle

oil

per

gallon

of

regular

gasoli

ne.

This

mixture

assures

positive

lubrication.

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 ope n 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

the dr

ive

pulley, left

hand side

of

bike.

2. You

must

engage

the

shut

-off

block

in order

to

start your

MOPED. See f

igure

14 and 15.

3. The drive

pulley

is

marked ( + )

posit

ive,

which

is

the

engaged

position.

See fifJure 1

4.

Shown "

Off"

Valve

FIGURE

4. The drive

FIGURE 15.

~.

is

the

:p

!~'~

14.

disengaged

pulley

!~;~

is

marked (0) negative,

position.

lf~~~~

See

mf

ri~··

figure

the

FIGURE 16.

which

15.

FIGURE 17.

engaged

6. The

7. To change

shut-off

you

to

engine

turn

to

block

free-wheel

off.

the

shut-off

(0)

or

(

+)

positioned
or

pedal

block

by hand.

OPERATING

STARTING

--·1:---o;;;;~uel

- -

v;,:')ee

../

figures

in

the

(0)

allows

the

bike

with

position

16, 17 and 18.

simpl

the

y

FIGURE 18.

2. Engage

3.

9

15.

Turn the
See

figure

on the

right

the

shut-off

engine

19

. Engine

hand handle.

stop

block.

switch

stop

Shown

~~Reserve"

See figures 14 and

to

RUN

position

switch

is

locat

ed

.

PUTTING MOPED IN MOTION

Accelerate

run. The torque converter engages as
revolution increases and
recommendej:i() use the pedals

inc

lines.

slowly

··

···

after

the

engine has begun

the

bike moves

for

help when on

off.

the

It

to

is

FIGURE 19.

4:

-Move

Gi_a

off

l as

twist

grip

At

···

·moving

ley~r

(cold starts

rter £Q!l!IQ.Llwer)oward handle bars

the engine starts .
starter
choke

starts, runs
fuel. See

lever

control

figures

on

a bicyctg, opening

at

the

same time'> S

fast

enou h, ull choke

or

cold

engine

to

run, then release

immediately.

lever as soon as the engine

smoothly

19

and 20.

Also

and receives

release the

throttle

figure

19.)

control

only)

and

until

sufficient

the

STOPPING

The MOPED
control
on

the
located on
rear wheel brake lever is located on

side.

THE BIKE

is

stopped

and applying the hand brake levers located

handle bars.The

the

right

See

figure

20.

by closing

front

wheel brake lever

hand side. See

~CAUTION

Braking
brake
left
stopping,
is
left
gency
applies
loss

STOPPING THE ENGINE

Shut

off

on

right

shut

off

lever. ALWAYS SHUT

procedure-Use

for

stopping

hand brake lever. To

the

to

be

applied

hand brake lever.

stop sit

front

of

control

engine
hand handle bar. See

engine

with

by

by

right

hand

AFTER
uat

ion

brake

only

of

the

engine

applying

OFF

If

MOPED.

stop

FUEL VALVE

rear wheel

actuating

assist

brake lever

actuating

in

an emer-

the

it

can cause

figu

the

the

figure

the

left hand

the

in

the

operator

switch,

re

19. Do not

starter

throttle

is

19. The

located
contro

l

FIGURE20.

If

the engine c

so

that

and

try
applying
dry and
starting procedure.

Avoid unnecessary acceleration
engine

wise

hoke

control

the engine

to start engine several
the

reinstall

clutch

will

not

choke

control.

the

spark plug- then repeat

~CAUT

when

will

I

not

in

engage.

ON

lever is pulled

start, shut fuel valve

If

necessary, remove,

motion

too

times without

of

, other-

long

OPERATION OF LIGHTS AND HORN

Push

lig

ht

switch which
handle bar
tail

lights.

figure
To operate horn, push the

the

control

See

in

Middle

20.

switch

figure 20.

either

position

direction

located on

MAINTENANCE

AIR CLEANER

1.

Remove
two
wrench is required.

2. Loosen (do
carburetor

21.

10

the

left hand

screws and

not

with a fla

step

two

belleville washers. A 3/

remove) band clamp at

t screw driver. See

is located

to

turn on head and

Is the

off

position

button

on the side of

the

l~ft

plate,

on

the l

. See

handle bar.

by

removing

figure

eft

8"

the