Montgomery Ward ZDW-57008A Bedienungsanleitung

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.

Montgomery Ward ZDW-57008A Bedienungsanleitung

Beliebte Roller Handbücher anderer Marken