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MOPED Model Nos.' ZDW-57008A ZDW-57061A ZDW-57062A Form No . · 61M-208B* Two Cycle Fuel Mixture- 50:1 .IMPORTANT SAFE OPERATION PRACTICES Local licensing, age and traffic regulations may vary from state to state. Check existing local laws. TRAINING 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 responsibility of. the purchaser. 1. Read the Owner' s Manual 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 sufficient age, understanding and capacity. 4. The operator should never place his hands, feet or any part of his body near any moving parts. 5. This MOPED is des igned f or 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. PREPARATION 7. This MOPED is designed for hard surfaces, such as pavement. 8. Never operate this MOPED on wet or slippery surface. 1. Check fuel before starting engine. Fuel mixture 50:1 (2 112 oz. two cycle oil to 1 gallon of regular gasoline}. Do not ·f ill gasoline tank indoors, when engine is running, or while the engine is still hot. . Wipe off any spilled gasoline before starting the engine. MAINTENANCE AND STORAGE 1. Keep all nuts, bolts , and screws tight to be sure the unit is in a safe operating condition. 2. Never start this MOPED without being in proper starting position. See page 9. 2. Never store the unit inside of a building wi t h gasoline in the tank where the fumes may reach an open f lame or spark. Allow t he 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. Max imum 36 P.S.I. fron t and rear. OPERATION 1. It is recommended the operator use a safety helmet and eye protection. 2. Manufacturer lights on. recommends running 4. The tightness of the spokes shou ld be checked after every few hours of operat ion . See Spoke Adjustment on page 15. with 2 CONTENTS Exploded View for Fork and Handle Bar ....... 18 Parts List for Fork and Handle Bar ..... . ..... . 19 Exploded View for Main Frame ..... . . . .. . . . .. 20 Parts List for Mai n Frame ................ 21, 22 Exploded View for Torque Converter .......... 23 Exploded View and Parts List for Front Wheel 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 ........... BackCover Safe Operation Practices ..... ...... ... ...... 2 Index and Know Your MOPED ... . ... .. ... ... . 3 Con sumer Information .... . .. ....... ..... ... 4 Tire Reserve Load .......................... 5 Identification .......... . . ................ .. 6 Assembly Instructions .. . ...... . ......... . .. 6 Prepare for Operation ...... . ................ 8 Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Maintenance . . .... . .... . .... .. ... . . .. .. ... 10 Adjustments .... .. .. . ........... ......... . 13 Wiring Diagram ... . .... . . .... .. ......... .. . 17 KNOW YOUR MOPED FIGU RE 2. LEFT HAN D VIEW FIGURE 1. RIGH T HAND VIEW 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Brake/ Tail Light Seat Breather Cap Fuel Tank and Cap Choke Lever Throttle Twist Grip Start/Stop Switch Brake Lever (Front) Front Internal Drum Brake Front Fork Extension Right Hand Pedal Pedal Chain Rear Internal Drum Brake Rear Swing Arm Shock 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13 . 3 Amber Reflector (Front) Headl ight Speedometer Rear View Mirror Starter Lever Brake Lever (Rear) Seat Adjusti ng Bolt Red Reflector (Rear) Chain Adjuster Rear Wheel Kickstand Muffler Front Wheel !' 1979 MOPED CONSUMER INFORM·ATION This sheet contains information on stopp ing distances, tire reserve loads and acceleration and pass ing ability as required by the Consumer Information Regulations issued by the National Highway Traffic Safety Administration of the United 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 representative 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 conditions of load ing 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 . Description of vehicles to which this table applies: •All Models of "MOPED" • • • • • • • • • • • • • • • • • • • • • • • M aaaaaa A. Fully Operational Service Brake Load ~t. .Ft. Light Maximum B. Emergency Service Brakes (with Partial Service Brake System Failure) (130 LB. Operator) (225 LB . Operator) NOT CAPABLE C. Brake Power Unit Failure NOT CAPABLE Maximum Load 0 100 200 300 400 500 Stopping Distance in Feet from 22 mph. • *The maximum speed attainable by accelerating a maximum rate from a standing start for one mile. 4 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 tor maximum loading and the t ire reserve load , percentage for each of the ti res listed . The tire reserve load percentage indicated is met or exceeded by 1 eac h vehicle to which the table applies. : Descript ion of Vehicles to Which the Table Appl ies: _A_II_M_o_d_e_l_s _o_f _"_M_O_P_E _D _ " _ __ _ __ _ __ __ Recommended Tire Size Designations 2-1/4-17 - Front Rear Recommended.Cold In f lation Pressure for Maximum Loaded Vehicle Weight 25 PSI 32 PSI *The difference, expressed as a percentage of tire load rating, between (a) the load rating of a t ire at the vehicle manufac turer's recommended inflation pressure at the maximum loaded vehicie weight and (b) the · load imposed upo n the tire by the veh icle at that cond it ion. WARNING. Failure to maintain the recommended tire inflation pressure or to increase tire pressure as recommended when operating at max imum loaded vehicle weight, or load ing the vehic le beyond the capacities specified on the tire placard affixed to the vehicle , may result in unsafe operating conditions due to premature tire failure, unfavo rable handling characteristics, and excessive tire wear. The tire reserve load percentage is a measure of tire capacity, not of vehicle capacity. Loading beyond the specified vehicle capaci ty may resul t 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 vehicles 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 information presented represents results obtainabl e by skilled drivers under controlled road and vehicle cond itions and the information may not be correct under other cond itions . Descrip.\i on of vehicles to which this table applies: All Models of "MOPED" LOviSPEED PASS HIG!i· SPEED PASS LOW SP.EED INITIAL SPEED : 20 MPH I SUMMARY TABLE: 46 SECONDS FEET SECONDS 1,500 FEET NOT CAPA BLE LIMITING SPEED: 35 MPH TOTAL PASSING DISTANCE FEET TOTAL PASSING TIME SECONDS ·······························-·············-~ I r40b·-········· ······ · ·········~ t-.4~ 55 TRUCK CONSTANT 20 MPH HIGH SPEED (MOPED NOT CAPABLE) INITIAL SPEED: 50 MPH LIMITING SPEED: 80 MPH TOTAL PASSING DISTANCE FEET TOTAL PASSING TIME SECONDS L~ ····························································-~ ~100~r::::l····· ····· ···· ···· ····· - ·····~~~100~ 55 TRUCK CONSTANT 50 MPH 5 I IDENTIFICATION TOOLS REQUIRED FOR ASSEMBLY 1. The identification number will be on the vehicle model number plate (See figure 3.) 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. 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 with the exception of the handle bar, rear view mirror, and pedals . See figures 5 and 6. Reference to right and left hand side are from the normal riding position, facing forward. FIGURE 3. 2. The Engine Type Number and Letter is stamped into the metal on the crankcase. See figure 4. FIGURE 5. 7- o FIGURE 4. '2..f). •'.J /:) "ttL ~ FIGURE 6. 6 ~· ._,. 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 igure 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 requi red. Press in plug button (3). CONTENTS OF HARDWARE PACK 1. 2. 3. 4. 5. 6. 7. 8. Rear view mirror R.H. and L.H . pedals Plug button Head tube nut Handle bar plate Hex screws for handle mount Lockwashers 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 balls (8) in upper fork. See figure?. FIGURE 9. REAR VIEW MIRROR ASSEMBLY Position rear view mirror on hand le bar. Secure clamp in desired position. See figure 10 . FIGURE 7. 3. Before assem bly, check adjusting cone for tightness. FIGURE 10. FIGU RE 8. 7 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. 21/2 oz. Oil To 1 Gal. Gasoline PEDAL ASSEMBLY Assemble pedals to crank using an adjustable wrench. Tighten securely. See figure 11. ~NOTE FIGURE 12. 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. FUEL TANK CAPACITY 2% QUARTS. Remove gas cap and open vent to fill. You must close vent before starting. See figure 13. FIGURE 11. PREPARE FOR OPERATION FIGURE 13. 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. FREE-WHEELING FEATURE 1. Your MOPED has a shut-off block located on the drive pulley, left hand side of bike. 2. You must engage the shut-off block in order to start yo ur MOPED. See f igure 14 and 15. ~NOTE Never fill fuel tank with engine running. 3. The drive pulley is marked ( + ) posit ive, which is the engaged position. See fifJu re 14. 8 Shown " Off" Valve FIGURE 16. FIGURE 14. 4. The drive pulley is marked (0) negative, which is the disengaged position. See figure 15. FIGURE 17. FIGURE 15. ~. :p!~'~!~;~lf~~~~mfri~··the engaged 6. The shut-off block positioned in the (0) allows you to free-wheel or pedal the bike with the engine off. Shown ~~Reserve" 7. To change the shut-off block position simpl y turn to (0) or ( +) by hand. FIGURE 18. 2. Engage the shut-off block. See f igures 14 and OPERATING 15. 3. Turn the engine stop switch to RUN position . See figure 19. Engine stop switch is located on the right hand handle. STARTING --·1:---o;;;;~uel v;,:')ee figures 16, 17 and 18. - - ../ 9 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 recommendej:i() use the pedals for help when on inclines . ·· ··· STOPPING THE BIKE The MOPED is stopped by c losing t he 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 FIGURE 19. 4:- Move offl as 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_arter £Q!l!IQ.Llwer)oward hand le 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. 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 emergency stop s ituat 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 figure 19. Do not shut off engine by applying the starter control lever. ALWAYS SHUT OFF FUEL VALVE OPERATION OF LIGHTS AND HORN Push lig ht switch which is located on the left handle bar in either direction to t urn 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 . FIGURE20. If the engine choke control 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 control. If necessary, remove, dry and reinstall the spark plug - then repeat starting procedure. MAINTENANCE AIR CLEANER 1. Remove the left hand step plate, by removing two screws and two belleville washers. A 3/ 8" wrench is required. ~CAUTION Avoid unnecessary acceleration of engine when not in motion, otherwise clutch will engage. 2. Loosen (do not remove) band clamp at the carburetor with a flat screw driver. See figure 21. 10 4. Check the clear breather tube to be sure it is free of any dirt. Breather tube can be cleaned with air pressure. Blow dirt from housing th ru housing, out of tube . See figure 23. 5. When reinstalling air c leaner be sure breather tube is pointed upward and clears the wiring . .._,NOTE The air cleaner should be c leaned 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 MOPED . Remove tw o screws and belleville washers. A 3/8" wren ch is required. 2. Remove the muffler by removing two hex nuts at the muffler f lange to cylinder head of engine. A 9mm socket wrench is required . Remove two allen head screws from bottom of muffler. See f igure 24. 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 24. FIGURE 22. 3. Pop off the left hand engine side cover with a screw driver. See f igure 25. FIGURE23. FIGURE25. 11 6 . Remove two belt guard bolts at drive pulley. Two 1/2" wrenches are required. See figure 28. 4. Disconnect the starter cable from the starter lever, by pressing inward to release the tension on the cable. See figure 26. ~NOTE Upon reassembly of belt guard bolts, be sure you have approximately 1 /8" clearance between 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 f igure 29. 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 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. Exercise caution if you remove them for any reason . See fig ure 30. FIGURE 27. FIGURE 28. FIGURE 30. 12 ADJUSTMENTS (A) ENGINE COOLANT Engine heat is dissipated by an amount of coolant sealed in the cylinder block. Mixture is 1/3 anti-freeze to 2/3 water and gives protection to about -13 degrees Fahrenheit. Coo lant should never need checking or chang ing. However, if leaks are noticed, have a qualified person determ ine the cause and replace any parts or coolant necessary. A fill plug is located on the top of the cylinder head. .0201nch FIGURE 31. SPARK PLUG Electrode Gap The electrode gap expands during operation from heat. This 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 figure 31 . CHAIN ADJUSTMENT Your MOPED is equipped with two chains, the drive chain and pedal chain. Drive Chai n- 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 oil for maximum chain life. Replace with chain shown in parts list of this manual only. This is a special chain size. CLEANING 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 after resetting the gap to .020 inch . CHECKING FUNCTION Unscrew spark plug, install plug connector, place plug threads against ground (cylinder head) and operate starter. If plug is in perfect condition , · t here 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 figure 32. FIGURE33. The MOPED must rest on t he kick stand with the left hand step plate removed. See figure 34. Loosen rear axle nuts slightly . Make sure that both chain adjusters are adj usted t he same rate. The rear wheel must always be parall el t o the frame and front wheel. Be sure to retighten the axle nuts securely. FIGURE 32. 13 4. Place the brake and hub back in the right hand side of wheel. Next, place the spacer on ax le. See figure 36. FIGURE 34. Pedal Chain--Is located on the right hand side of MOPED. The pedal chain has an automatic chain adjuster (idler). No adjustment is required. FIGUR E 36. & c AUTION Be su re to replace spacers and washers in proper positions. .NOTE J3oth the drive chain and pedal chain are equipped with master link for easy removal and maintenance. 5. Make sure t hat the fork holder on t he right hand side engages in the slot of front wheel hub lever. Place f lat washer next to fork and secure the axle w ith hex locknut. See fi gure 36. REMOVING AND INSTALLING FRONT WHEEL 1. Place bike on kick stand. REMOVING AND INSTALLI NG REAR WHEEL 2. Remove the axle and nut from the front wheel. Lift the speedometer out of the way if your MOPED is so equipped. 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. 1. Place bike on kick stand. 2. Remove black bolt at rear wheel h ub lever. See figure 37. 3. Remove the hex locknut, ax le bolts and chai n adjusters. See figure 37. 4. Remove the chain and brake hub. See f igure 37. FIGURE 35. FIGURE37. 14 5. Upon reassembly of 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 li nes up with hole in frame and replace the black bolt. See figure37 . ....,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. FIGU RE 39. SPEEDOM ETER (OPTIONAL) The speedometer drive on the left front wheel hub has a lubrication nipple. Always lubricate here every 600 to 900 miles. See figure 38. SPOK E ADJUSTMENT 1. The tightness of spokes should be made every few hours of operation. 2. To check for correct spoke tension, w iggle each spoke gently. If the spoke nipple at the rim is able to move, the spoke is too loose. 3. Another way to check spoke tension is by gently tapping a metal object, such'' as a screwd river, against each spoke. If the spokes are equally tightened, t hey will produce the same sound or pitch. 4. To tighten a spoke use a spoke wrench or an adjustab le w rench . BRAKE ADJUSTMEN T 1. A 10 mm wrench is required. 2. Loosen jam nut on brake cable and turn the FIGURE 38. barrel nut on brake cable counterclockwise for more adjustment and clockwise t or less adjustment. See figures 40 and 41. CLEANING F UEL 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. HEA DLIGHT A ND TAIL LIGHT The head I ight 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-1 OW bulb, which can be replaced by removing two screws and taillight lens. See figure 39. . FIGURE 40. 15 CARBURETOR ADJUSTMEN T 1. The idle screw is preset at the factory. 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 41 . 3 . Brake Wear Limit When brake lever on wheels reach the wear limit mark, remove the lever and turn over for more adjustment. Then when the wear limit is reached again, brake shoes must be replaced. ~-e~ figures 40 and 41. FIGURE 42. 4. Turning the idle screw clockwise will speed up the engine. Turning the idle screw counterclockwise will slow the engine. 16 Black Engine A-+B._ c---:..-. D . = = A Green-Black B Green C = Gray D == Yellow E Bl ue = 2 Blue E -;:::+:::j::±:::t:l:-...J Black 3 Blue Coil c Q) f Q) Attach at Coil or Terminal Block Mounting (; Yellow Red PARTS LIST FOR ELECTRICAL SYSTEM REF. NO. PART NO. 1 725-0637 725-0598 725-0599 725-0539 725-0600 725-0592 2 3 4 5 6 725-0591 7 8 9 725.:0541 725-0533 725-0538 DESCRIPTION Wire Harness-Camp. Terminal Block Ass'y. Kill Button Switch Horn Accessory Switch Head lamp Ass'y. for Speedometer (Optional) Headlamp Ass'y. w/o Speedometer (Optional) Electric Wire (2 Req'd.) Taillamp Ass'y . Brake Light Switsh (2 Req'd .) 17' ZDW-57008A ZDW-57061A ZDW-57062A -, I ~~:: 1 ,} f , I I I I I 31 I I 72~ 70~ ' ,___73 ~ ---..__., 74 24 FORK ASSEMBLY 18 PARTS LIST FOR FRONT FORK ASSEMBLY COMPLETE #06894 REF. PART NO. NO. 1 2 3 4 5 6 7 10 11 06895 736-0329 710-0747 726-0186 712-0304 745-0167 06891 741-0285 741-0287 730-0114 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 741 -0284 741 -0283 732-0340 731-0400 06827 06838 731-0400 731-0401 710-0289 710-0258 712-0107 736-0329 745-0171 06828 745-0170 712-0107 725-0539 710-0289 725-0590 710-0725 32 34 731-0426 731-0424 731-0468 35 36 37 38 39 40 41 42 745-0169 710-0258 9 - - 741-0219 06858 736-0329 712-0107 DESCRIPTION Handle Bar L-Wash. 1/4" Scr. * Hex Scr. 1/4-28 x 1 .25" Lg. Plug Button .81" 1.0. Fork Lock Nut 1.0-24 N.S.I. Rear View Mirror Telescope Fork Ass'y. Cone-Adj. Fork Fork Bearing Side Reflector 2.0" Dia. Amber Bal l Fork Cup_ _ Cone-Lower Compression Spring Bushing Nylon Fork Extension-L.H . Front Fender Ass'y. Bushing Nylon Rubber Boot Hex Scr. 1/4-20 x .50" Lg. • Hex Scr. 1/4-20 x .62" Lg. * Hex Cent. L-Nut 1/4-20 Thd . L-Wash . 1/4" Scr. • Speedometer Gear Box (Optional) Fork Extension - R.H . Speedometer Cable 650mm (Optional) Hex Cent . L-Nut 1/4-20 Thd . Horn 6V-18W Hex Scr. 1/4-20 x .50" Lg. • Sealed Beam 6V-18W Truss Mach. AB Tap Scr. #8 x 1 .00" Lg. * Headlight Bezel Chrome Headlight Housing for Speedometer Headlight Housing w/o Speedometer Speedometer (Optional) Hex Scr. 1/4-20 x .62'' Lg. * Supplied with Ref. No. 11 Supplied with Ref. No. 11 Steel Ball .125" Dia. Handle Bar Plate L-Wash. 1 /4" Scr. • Hex Cent. L-N ut 1/4-20 Thd . *Common Hardware may be purchased locally. Important: Do not order by Reference Number (Ret. No.). 19 ZDW-5700BA ZDW-57061A ZDW-57062A 18 \ 6J MAIN FRAME 20 \ 62 60 ~I PARTS LIST FOR MAIN FRAME REF. NO. PART NO. 1 2 3 4 5 6 757-0293 757-0294 757-0287 710-0289 06840 710-0289 06910 732-0368 7 731-0400 8 9 10 731-0474 06922 710-0403 11 12 13 14 06843 731-0307 712-0107 736-0175 15 16 17 12894 725-0533 710-0207 18 19 745-0176 736-0175 20 21 22 712-0107 710-0672 736-0105 23 750-0445 24 25 26 27 28 29 30 73'1-0475 745-0175 710-2205 06847 712-0296 06831 736-0175 31 32 33 712-0107 712-0107 736-0175 34 713-0122 35 713-0247 36 37 38 39 736-01 19 712-0267 710-0378 732-0157 40 41 42 710-0180 710-0117 712-0306 ' i 43 v 44 7i 4-0507 736-0185 45 756-0194 DESCRIPTION I Seat Ass'y.-Biack Seat Ass'y . - Burgundy Bench Seat Ass'y. Hex Scr. 1/4-20 x .50" Lg. • Carrier Hex Scr. 1/4-20 x .50" Lg. * Shock Absorber Cover Ass'y. Compression Spring .88" O.D. x 5.65" Lg . Telescopic Bushing 1.10" O.D. Telescope Boot Telescope Tube Binder Bolt 5/16-24 x 1.75" Lg. Spec. Rear Fender Snap Bushing Hex Cent. L-Nut 1 /4-20 Thd. L-Wash .. 270" I.D. x .51" O.D. x .030 Cable Clip ' Taillight Hex Mach. Tapp Scr. 1/4-20 x 1 .00" Lg . * License Plate Bracket L-Wash .. 270" I. D. x .51" O.D. X .030 Hex Cent. L-Nut 1 /4-20 Thd . Hex Scr. 3/8-24 x 1.25" Lg. Beii.-Wash . .400 I. D. x .88 O.D. X .060 Sp lit Tubing Spacer .395 x .50 X .50 Grommet Shock Absorber Ass'y. Hex Scr. M12 x 1.5 x 170 Chai n Adjuster Hex Cent. L-Nut 3/8-24 Thd . Rear Fork Ass'y. L-Wash . . 270" I.D. x .51" O.D. x .030 Hex Cent. L-N ut 1/4-20 Thd. Hex Cent. L-Nut 1/4-20 Thd. l -Wash .. 270" I. D. x .51 " O.D. x .030 #48 Master Link 1/2" Pitch Type II Freewheel-Sprocket 18 Teeth L-Wash. 5/16" Scr. * Hex Nut 5/16-18 Thd. • Hex Scr. 5/ 16-18 x 2.50" Lg . * Extens ion Spring .50 O.D. x 3.25" Lg . Hex Scr. 3/8-24 x .75" Lg. * Hex Scr. 3/8-24 x 1.00" Lg. Hex Top L-Jam Nut 3/8-24 Thd. Cotter Pin 3/32 x .75" Lg . FI-Wash . .406" I.D. x .74" O.D. x .063 Idler Pulley 1.50 0 . D. x .378 I. D. REF. NO. PART NO. 46 47 06896 736-0105 48 49 50 712-0296 712-0158 741-0249 51 52 710-0378 750-0347 53 741 -0249 54 736-0187 '\ 55 56 57 738-0419 71 0-0758 736-0309 58 736-0290 59 724-0156 60 61 62 751-0214 751 -0237 717-0389 63 64 65 66 754-0235 736-0119 712-0267 732-0433 67 68 69 70 71 72 73 74 75 76 06835 736-0119 752-0691 751-0251 736-0329 712-0107 712-0296 736-0105 738-0141 732-0362 77 78 06878 738-0420 79 80 81 82 710-0620 06861 712-0107 745-0165 83 84 745-0174 751-0249 85 713-0241 86 ' 751-011 5 87 88 89 90 21 723-0348 751-0248 06863 06862 06906 712-0213 DESCRIPTION Chain Id ler Brkt. Ass'y. Beii. -Wash .. 400 I. D. x .88 O. D. x .060 Hex L-Nut 3/8-24 Thd. Hex Cent. L- Nut 5/1 6-18 Thd. Flange Brg ..630" O.D. Plastic Hex Scr. 5/16-18 x 2.50" Lg. * Rear Fork Spacer .62" O. D. x .381.D. X 2.8 Flange Brg .. 630" O.D.Plastic FI-Wash . . 640" I. D. x 1 .25" O.D. x .060 Hd n. Pedal Shaft Socket Hd. 3/8-24 x 4.00" Lg. • FI-Wash . .71" I. D. x 1.1 7" O.D. x .036 Spec. FI-Wash . . 640" I. D. x 1.00" O.D. x .067 Hdn. Pedal (Set of Two) R.H. and L.H. Pedal Crank Cotter Pedal Crank-L. H . 7.5" Dia. Pull ey with 11 Toot h Sprocket V-Belt 1/2" x 35" Lg . L-Wash. 5/16" Scr. · Hex Nut 5/16-18 Thd.* Extension Spring .50" O. D. x 2.75" Lg. K ickstand Ass'y . L-Wash. 5/16" Scr. * So lo -Eogine Rubber Engine Bush ing L-Wash. 1 / 4" Scr. * Hex Cent. L-Nut 1 /4-20 Thd. Hex Cent. L-N ut 3/B-24 Thd. Bell-Wash . 3/8" I. D. Sh ld. Scr.. 437" Dia. x .350 Extension Spring .75" 0. D. x 8.00" Lg . Engine Brkt. Shld. Scr .. 312" Dia. x 4.03'' Lg. Hex Scr. 3/8-24 x 4.50" Lg. * Cable Cover Hex Cent. L-N ut 1/4-20 Thd. Steering Lock with Keys (Optional) Gas Cap Ass'y . Pedal Crank w I Sprocket 30 Teeth #48 Chain 1/2" Pitch x 87 Link Gas Line .18" I. D. x .31" O.D. x13 Hose Clamp Gas Valve M12 !< 1 Frame Ass'y. Frame Ass'y . w/o Shocks or Fork Lock Frame Ass'y. w/o Fork Lock ; Binder Nut 5/16-24 Thd. '· PA RTS LIST FOR MAIN FRAM E REF. NO. PART NO . 91 92 93 94 751-0252 30102 06877 736-0270 95 710-0653 96 97 98 99 06876 749-0310 710-0376 710-0597 100 750-0348 101 738-0421 102 736-0264 103 104 736-01 19 736-0175 105 712-0107 DESCRIPTION Tan k Vent B lock Seat Post .81 Oia. Step Plate- L.H. Bei i. -W ash . . 265" 1. 0 . x .750" 0. 0 . X .062 Hex Wash . SF-Tap Scr. 1/ 4-20 X .38" Lg . Step Plate-R. H. Sw ing Arm Brace (Optional) Hex Scr. 5 / 16-1 8 x 1.00" Lg. * Hex Scr. 1 / 4-20 x 1 .00" Lg . • (Insi de Taill ig ht} Spacer .62" 0 . 0. x .38" 1. 0. x 3.84" Lg . Shld . Scr.. 312" Dia. x 2.45" Lg. Bel l-Wash . .330" J.D. x .630" O. D. L-Wash. 5/16" Scr. • L-Wash . . 270" J. D. x .51" I. D. Hex Cent . L-Nut 1/4" Thd . *Commo n Hard ware may be purchased locally. Importan t : Do not order by Reference Number (Ref. No .) . 22 --"- ... \.,...-'"''\; 717-0411 717-0410 '717-0409 ) Torque Converter 20M. P.H. To roue Converter 25M .P.H. Torque Converter 30 M.P. H. ' PARTS LIST FOR TORQUE CONVERTER REF. NO. ..• PART NO. REF. NO. DESCRIPTION 1 712-0302 2 732-0367 3_ 06879 4 t 732-0349 " U"- Nut M5 .Spring Wire Cl ip Clutc'flli.Hs Ass'y. . "Compression Spring 1 .18 . ·~· O.D. X .90 I.D. X .83 5 _.06881 . :: · Spring Plate, ~-· 748-0265:'''' , . , -;T orque Converter-Weight .7:' 732-0348 · Extension Spring .34" 0 . D. x Lg. 8 06885 Pul ley- Hub Ass'y. 9 741-0224 Needle Brg. 1.125" I. D. x 1.38" O. D. X .37 10 748-0268 Flange Bush i ng (For 20m.p.h.) 748-0267 Flange Bushing (For 25m.p.h.) 748-0266 Flange Bushing (For 30 m.p.h.) 11 732-0350 Telescope Spring 1.38" 0 . D. X .941.0. X 1.00" Lg . 12 748-0262 Pull ey Half Ass'y . 13 731 -0472 Shut-off Block 14 712-2203 Hex Ins. L-Nut M4 15 732-0365 Leaf Spring Ass'y . 16 710-2202 Hex Scr. M4 x 12 17 SL-0054219 Seal 18 735-0194 Rubber Sleeve PART NO. 19 713-0248 20 736-0290 21 710-2203 22 23 24 25 732-0364 756-0321 712-2203 741-0282 26 27 736-0309 28 736-0187 29 30 754-0235 715-0142 ·31 736-0308 32 33 71 2-2200 736-0931 34 35 36 736-0722 710-2200 751-0250 SL-005421~ ~-~ 'l 23 DESCRIPTION Sprocket Hub 11-Teet h x .50" Pitch FI-Wash .. 640 I. D. x 1.00" O.D. X .067 Hdn . Oval Counter Sunk Scr. M4 x 20 Spring Plate 7.5" Dia. Pulley Hex Ins. L-Nut M4 Needle Brg. 161.D. x 22 O.D. x 14 Seal FI-Wash . . 71" I. D. x 1 .17" O.D. x .036 Spec. FI-Wash .. 640" I.D. x 1.00" O.D. X .06 Hdn. "V"-Belt 1/2" x 35" Lg . Spring Pin Rol11 /8" Dia. x .50" Lg. Beii. -"Wash . .430" I. D. x .90" 0 . 0. X .030 Hex Jam Nut M10 x 1 FI-Wash . .203 1.D. x .41 0.0. x .040 L-Wash. #10 Hex Scr. M5 x 18 Clutc h Spri.ng Lever :e;1~~t~~- ~~~~:..z ~· ;l~ce~"' e-~ ~~ ·~fG -~1(o'J / --. -1 PARTS LIST FOR FRONT WHEEL ASSEMBLY COMPLETE 734-0950 REF. NO. PART NO. 1 734-0952 2 3 4 5 6 7 9 10 11 12 734-0774 734-0775 734-0776 734-0955 755-0220 755-0183 732-0361 711-0692 06917 712-2003 736-0192 13 14 16 17 18 710-2204 736-0329 746-0344 06912 750-0436 19 20 761-0173 741-0290 21 750-0429 8 22 734-0958 23 24 25 745-0171 712-2204 1 750-0277 DESCRIPTION Front Wheel Ass'y. Less Tire and Tube Tire Only 21.0 x 2.25 Inner Tube Only 21 .0 x 2.25 Rim Band Rim Only 1 .35 x 17 Spoke 105 Dia. x 7 .28" Lg. Spoke Nipple Extension Spring Brake Cam Brake Lever Hex Nu t M6 FI-Wash .. 531 I. D. x .93 O.D. X .090 Hex Scr. M12 x 1.5 x 150 L-Wash. 1/4" Scr. Brake Cable 38.9" Lg . Brake Arm Ass'y. -Front Spacer .480 I. D. x .81 O.D. x .626 Lg . Brake Shoe Camp. 105mm Ball Bearing 12 I. D. x 28 0 . D. x8 Spacer .5051.D. x .. 63 O.D. x 2.385 Lg. 1 05mm Front Cast Hub Ass'y. Speedometer Gear Box (Optional) Hex Jam Ins. L- Nut Spacer 24 ZDW-57008A ZDW-57061A ZDW-57062A _w - -1 ... II' PARTS LIST FOR REAR WH EEL ASSEMBLY COMPLETE 734-0951 REF. 2 - PART NO . DESCRIPTION 1 734-0953 2 3 4 5 6 7 8 9 10 734-0774 734-0775 734-0776 734-0955 755-0220 755-0183 710-2205 06847 750-0277 11 741-0290 12 750-0430 13 14 15 16 17 18 19 20 21 23 24 25 26 27 734-0959 713-0246 06921 710-2201 732-0361 761-01 73 711-0692 06913 06917 736-0329 712-2003 712-2204 746-0345 750-0436 28 29 713-0252 713-0242 Rear Wheel Ass'y . Less Tire and Tube Tire Onl y 21 .0 x 2.25 Inner Tube 21 .0 x 2.25 Ri m Band Rim Onl y 1 .35 X 17 Spoke105 Dia. x 7.28" Lg. Spoke Nipple 105 Dia. Hex S cr. M12 x 1.5 x 170 Chain Adj uster Spacer .51 o I. D. x .68.0. D. x .44" Lg . Ball B earing 12 1.D. x 28 0 . 0. x8 Spacer .505 1.0. x .63 O.D. x 3.173" Lg . 105 Dia. Rear Cast Hub Ass'y. Sprocket 57 Teeth .50 Pitch Screw Lock Strip Hex Self-Tap Scr. M6 x 20 Extension Spring Brake Shoe Com p. 105mm Brake Cam B.rake Arm Ass'y.-Rear Brake Lever L-Wash. 1 / 4" Scr. Hex N ut M6 Hex Jam Ins. L-Nut Brake Cable 64.8'\ Lg . Spacer .480 I. D. x .81 O.D. x .626" Lg. #415 S Mast er Link #415 S Chai n .50 Pitch 97 Links NO. I ;' j 25 ZDW-57008A 5 3 6 7 \ l zow..s7061A zow... s7062A 8 'I I I I / I I ; I / ./ JI I /' 74---~1 / ·.~, ' / . 1 ' /I : ~/ PARTS LIST FOR CONTROLS REF. NO. 1 2 3 4 PART NO. 5 746-0284 746-0286 MA-270.51-03.1 SZ 746-0349 746-0347 6 746-0348 7 8 746-0286 746-0285 9 MA-HL3-1·1-1 10 11 12 13 14 15 16 746-0345 746-0288 MA-13.1-Z3.2SZ MA-21 0.1-03.7TP 746-0344 746-0346 MA-270.1-03. 7TP I I DESCRIPTION I ~ Throttle Control Camp. Nipple Holder Choke Lever Inner Cable 425 ThrottleCable42x3.18" , Ext. Choh:e Cable 42 x 2.0" I Ext. Nippier Holder Brake Lever Control Comp. Truss Mach. Scr. M6 x15 Brake Cable 64.8 Dummy Grip Compression Lever Brake Lever Brake Cable 38.9 Starter Cable 37-5.5 Ext. Brake Lever 1 1 I I I ----·-------·-----~--· 26 6 1 8 1 33 5------~ "15 -----=""' ~ 9 \---21 o------22 ~23 PARTS LIST FOR ENGINE CRA N KCASE PART NO. REF. NO. 1 2 3 4 5 6 7 8 9 11 15 17 21 22 23 26 27 28 29 30 31 32 33 SL-2011570 SL-2011572 SL- 0042208 SL-0010161 SL-0020102 SL-0054203 SL-0066217 I SL-0062112 SL-2061334 SL-00341 07 SL-0020169 SL-2045460 SL-2045455 SL-0015158 SL-00341 03 SL-00201 01 SL-0031292 SL-2012448 SL-2061284 SL-2074525 SL-2042289 SL-2063163 SL-0015226 SL-0054128 I DESCRIPTION I Crankcase- R. H. Cran kcase - L. H. Cran kcase Pi n F.H. Screw M6 x 50 Hex Nut M6 Crankshaft Seal 26 x 35 x 7 Ignit ion Cable Grommet "0"-Ring Crankcase Gasket Spring Washer 86 Hex Nut M6 Cover- Clutch Cover-Ignit ion Stud Screw M5 x 15 Spring Washer 85 Hex Nut M5 Washer Carburetor Flange Carburetor Flange Gasket Reed Valve Housing Reed Valve Pos itioner Stud Screw Crankshaft Seal 15 x 35 x 7 27 31 @::. 19 32 20 ' © 18 ' 21 12 11 6]1308 ' ·. i lcr~/~y- 1,~,~~~ 29 15 16 - ---17- -"" ··~ ~g I I 10 -® .@ 14 27 28 PARTS LIST FOR CRANKSHAFT -PISTON-CYLINDER REF. NO. PART NO . 1 2 3 SL-0050102 SL-2200674 SL-0031375 6 8 9 10 11 12 "13 14 15 16 17 18 19 20 21 24 SL-00751 01 SL-0030144 SL-0020161 SL-0034115 SL-2200593 SL-2048227 SL-2031238 SL-0055144 SL-0015201 SL-00301 00 SL-0028100 SL-2200684 SL-2000685 SL-2061337 SL-2061346 736-0308 25 26 27 28 29 30 31 32 712-2200 SL-0052186 SL-0061255 SL-001 0266 SL-0062159 SL-00551 06 SL-0016126 SL-0061 210 DESCRIPTION Ball Bearin g 15 x 35 x 11 Crankshaft Spaci ng Washer 15.3 x 22 x0.5 Woodru ff Key 3 x 3.7 Washer8.4 Hex N ut M8LH Thd . Crown Washer 8 Piston Complete Piston Ring Piston Pin 10 x 6 x 32 Ci rcli p A10 St ud Screw Washer 6.4 Hex Nut M6 Thermae Cyl inder Comp. Cyli nder Head Cy li nder Head Gasket Cylinder Foot Gasket Beii. -Wash . .430 1.0, x .90 0.0. X .030 Hex Jam N ut M10 x 1 Needle Bearing 10 x 14 x 3 Seal 5 x 9 x 1 F. H. Screw M5 x 15 " 0 "- Ring 101 .27 X 2,62 Snap Ring 35 l.ocki ng Screw M1 0 x 1 Seal10 x 14 28 .. I I 18 19 i I 3 2 - PARTS LIST FOR CARBURETOR SL 2300341 REF. NO. 1 2 3 4 5 6 7 PART NO. SL-0064302 SL-2074597 SL-2500328 SL-0066132 SL-0510658 SL-0510657 SL-0510115 8 SL-051 0218 9 SL-051 0132 10 SL-0510460 11 SL-051 0188 12 SL-051 0216 13 SL-051 0461 14 SL-051 0462 15 SL-0510463 DESCRIPTION Vinyl Tubing 14 X 2 X 178 Intake Si lencer Air Fi lter Insert Intake Silencer Clamp Float Inlet Needle Bowl Gasket Main Jet Size 58 Main Jet Seat Fuel Line Nipple Gasket Adj usting Screw Spring Choke 29 REF. NO. PART NO. DESCRIPTION 16 17 18 19 20 21 22 23 24 25 26 27 28 29 SL-0510464 SL-051 0465 SL-051 0466 SL-0510467 SL-0510468 SL-0510469 SL-0510470 SL-0510471 SL-0510472 SL-0510473 SL-051 0185 SL-05101 27 SL-0510189 SL-051 0458 Stud Safety Washer Torsion Spring Screw Carburet or Slide Meteri ng Needle Needle Holder Washer Slid e Spring Cover Cable Adjuster Nut Float Hing Pin Clampi ng Screw Jf, PARTS LIST FOR MUFFLER SL.2500371 REF. NO PART NO. 1 2 3 5 6 7 SL-2061316 SL-00301 00 SL-2035854 SL-0062171 SL-2035859 SL-0018191 SL-0010122 SL-003411 4 SL-001 8191 SL-0061 255 8 9 10 11 DESCRIPTION Muffler Gasket Washer- Flat 6.4 Dia. Tuning Tube " 0"-Ring 25 x 3 Exhaust Pipe St ar Hd. Scr. M5 x 20 Allen Hd. Scr . M6 x 45 L-Wash. A6 Star Hd . Scr. M5 x 20 seal 5 x 9 x· 1 · REF. NO. PART NO. 12 13 14 15 16 17 18 19 20 SL-2011533 SL-2035856 SL-2042497 SL-0060122 SL-201 1534 SL-2500372 SL-00281 00 SL-00301 00 SL-001 0349 I 30 DESCRIPTION Lower Muffler Hous ing Inner Tubing Mu ff ler Screen Damper Upper Muffler Housing Mainfold Hex Nut M6 Flat Washer 6.4 Dia. Al len Hd. Scr. M6 x 20 10 I 19 13 PARTS LIST FOR IGNITION SYSTEM REF. NO. PART NO. 1 2 3 4. 6 7 8 9 10 11 12 SL-23001 03 SL-0084100 SL-0084203 - SL-2300302 SL-0520148 SL-0520149 SL-0520151 SL-0520150 SL-0520146 SL-0520147 DESCRIPTION Spark Plug W225 Spark Plug Connector Protective Cap Ignit ion Cable 7 x 355mm Ignition Coil , Outer Ignition Coil, Inner Lighting Coil Ill Lighting Coi l II Lighting Coi l I Breaker Point Condenser 31 REF . NO. PART NO. 13 SL-2300395 14 15 SL-001 0293 710-0467 16 17 18 19 20 21 ' 736-0722 712-0121 SL-0034156 SL-0030101 SL-001 0119 SL-0010268 ~~ DESCRIPTION Ignition Ass'y . Comp. 6V/376 Watt F.H. Scr. AM4 x 16 Truss Mach. Scr. #10-24 x 1.00" Lg. • L-Wash. #10 Scr. • Hex Nut #1 0-24 Thd. • Spring Washer 4 Washer 4.3 F.H . Screw M4 x 30 F. H. Screw M4 x 30 mmm SERVICE NATIONWIDE HOW TO OBTAIN REPLACEMENT PARTS AND SERVICE The merchandise you have purchased from us has been carefu lly engineered and manufactured under Wards rigid quality standards and should give you sat isfactory and dependable operation. However, like all mechanical merchandise, it may occasionally .require adjustment or m·ainte~ance. Should you ever need technical assistance or replacement parts, please contact or write your nearest Wards Retail Store, Service Center, Catalog Store or Catalog House. · Provide the following: 1. Model, serial num.ber and all of the other data shown on the model plates on the MOPED and the engine. 2. The date and the Wards branch from which you purchased your merchandi se. 3. State briefly the trouble you are ha~ing. 4. When requesting replac ement parts, be sure to give the part number and the name of the part as shown in the parts list. If you order by mail , you wi ll pay the transportation charges from the shipping point. FORM ·NO. p1M~208B *. (2179) , '' · ·;·, . PRINTED IN U.S. A . PART NO. 770-8839
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