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Instructions for Maintenance of Speedway Engine JAWA 250-10-006
The speedway engine JAWA type 250-10-006 is intended for junior speedway. Also for the adult
long and grass track racing events the engine can be used . The tuning of our engines for higher engine
speed is to the detriment of their service life interval and not allowed in junior speedway class. The
engine fits into standard JRM speedway chassi, only exhaust pipe diameter is smaller.
Technical data:
Bore/stroke: 77,00 / 53,6 mm
Capacity: 249,59 cm3
Maximum power output: 28-30 kW (38-41 bhp) at 10200 rpm
Max. rpm : 12 000rpm
Compression ratio: 14 : 1
Ignition: electronic Selettra
Ignition Advance: 30° BTDC (adjustable 25°-35°)
Measured at valve lift of 1 mm and at valve clearances inlet 0,1mm / exhaust 0,15mm (cold engine).
Lubrication of engine
The circulation-system lubrication is used. Oil is sucked through rough filter into pump and squeeze
into crankshaft (connecting rod big-end bearing lubrication). The rough oil filter must be check after first
running of new engine, and often clearing of this filter is recommended to avoid engine seizing. From
crankshaft space is oil returned to oil tank through reed valve. Oil filling is recommended to be replaced
after five or six heats.
Dismantling, assembly, adjustment and service life of engine
Cylinder head and cylinder
Minimum thrust of valve springs when assembled has to be 300 N - this thrust ensure maximum engine
speed 12000 rpm. The valve springs are checked as follows: after dismantling of rocker arms the valve is
leant over suitable support against the plate of a balance and during the pressure of the head towards the
balance, the values in kg are read just in the moment when the valve starts opening. This value may not
drop below 30 kg (300N). If the value is lower the valve springs must be dismantled and check for free
length, if the free length is not under 39 mm (valid for springs 889-13-163), then springs may be
underlaid but the minimum clearance 1 mm between spring threads at the complete valve lift must be
observed.
- Width of intake seats 1,0-1,2 mm, round off the edges of valves and valve seats in the head.
- Rocker arm roller must run freely without grabbing
- Axial clearance of camshaft 0,2 - 0,4 mm
- Replace the valve upper plates approximately after 30 races
- Replace the camshaft drive chain approximately after 25 races
-Combustion pressure is sealet by silicon ¨O¨ ring .
-Please replace the O ring during every engine overhaul.
-Compression ratio is adjusted by steel plates of different thickness under cylinder.
Crank mechanism
Repair works of crank mechanism are recommended to be made in specialized repair shops. The crank
mechanism is pressed on cylindrical surfaces. Before pressing the interference size of pressed diameters
has to be checked. The flywheels are forged together with main pin like one piece, the interference of
crank pin at 0,11/0,13 mm. The crank mechanism can be pressed three times without using abnormal
parts. The crank pin can be ordered in an abnormal modification with greater pin diameter for pressing by
0,025 mm. Axial clearance of crank mechanism in crankcase is 0,5-0,7 mm. Axial clearance of
connecting rod in assembled crank mechanism should be 0,4-0,6 mm.
The balancing of crank mechanism for horizontal engine has to be 52 % of balancing masses.
- Clearance of gudgeon pin in piston must be 0,007-0,017 mm
- Clearance in piston ring lock 0,30 - 0,35 mm
- Please use the correct piston size for the cylinders bore according the table.
For safety reasons replace the big end connecting rod bearing and piston after 15 races. During this the
checking of connecting rod dimensions is recommended, the big end diameter should be 42,00/42,008mm
(min/max), the radial clearance between crank pin and big end should be 0,037/0,052mm.
The clearance between piston pin and small end should be for
connecting rod 881-12-110: 0,02-0,04 mm (143 mm length)
Assembly of crank mechanism
Before assembly all parts must be cleaned. The crank pin must be oriented according the oil hole in
right flywheel During pressing the holes (pins) should be slightly oiled to prevent pressed surfaces from
seizing. After pressing balancing is necessary. Measurements are made in points and the run-out is measured
5 mm from flywheel faces and it should not exceed 0,03 mm. The highest value of run-out must be at the end
of crank pin.
The shaft of ignition rotor is carried separately in two bearings and is connected with the crankshaft
by a clutch. When dismantling the ignition the proper throwing of the shaft in the small valve gear during the
reassembly must be observed.
4 5
6
3 7
20
16 9 10 12 13 8
11 14
17 19 18 22 21
24 26
25 27
250 – 01
250-01
Výfuk a řetězy
Exhaust and chains
Auspuff und Kette
3 7
4 8
15 9
13 11
16 14
12
17 19 26 36
24
21 22
25 23 20
31 18 37
28 32 34 35
44
29 33 46 43 42 41 40 39 38
45
27
30
47 48 49 52 54
53
51 55
56 50
250 – 11
250-11
Motorová skříň
Crankcase
Motorgehäuse
3 7
4 8
15 9
13 11
16 14
12
17 19 26 36
24
21 22
25 23 20
31 18 37
28 32 34 35
44
29 33 46 43 42 41 40 39 38
45
27
30
47 48 49 52 54
53
51 55
56 50
250 – 11
250-11
48 875-11-514 2 Planžeta Plate Platte
49 875-11-515 2 Opěra planžety Stop of the plate Stütze
50 309 543 210 512 2 Šroub M5x12 ČSN 021143.59 Screw M5x12 Schraube M5x12
51 311 214 023 051 3 Pružná podložka d 5.1 ČSN 021740.09 Spring washer d 5.1 Federscheibe 5.1
52 889-11-516 2 Kolík D4x16 ČSN 022150.2 Pin D4x16 Stift 4x16
53 875-11-061 1 Víčko Lower Deckel
54 888-15-025 1 Šroub M20x1.5 ČSN 021143.59 Screw M20x1.5 Schraube M20x1.5
55 888-15-026 1 Podložka Washer Scheibe
56 273 111 016 012 2 „O“ kroužek 16x12 Rubber ring 16x2 Gummiring 16x2
1
3 2
10 (30) 13 14
5 (6) 11
7
12
8 (27,28,29)
9
4 19 15 16
25
22
17
26 20 21
23 24
18
250 – 12
250-12
Klikové ústrojí úplné
Crankshaft mechan.
Kurbelgetriebe
62 63 61
7 64
10 (70) 11 (71)
6
4
12 5
13 14 (72) 39
43
17 37
8 8
18 36
42
22 19 9
9 44 40
21 15 16 46 41
45 65
38
20
50
25 48
23 32 34
49
27 47
60
33
28 26
58
24 59
29
31 35 57
30
52
51 56
53 54 55 66 250 – 13
250-13
Válec s hlavou
Cylinder with head
Zylinder mit Kopf
62 63 61
7 64
10 (70) 11 (71)
6
4
12 5
13 14 (72) 39
43
17 37
8 8
18 36
42
22 19 9
9 44 40
21 15 16 46 41
45 65
38
20
50
25 48
23 32 34
49
27 47
60
33
28 26
58
24 59
29
31 35 57
30
52
51 56
53 54 55 66 250 – 13
250-13
48 311 210 222 053 4 Podložka B 5.3 ČSN 021702.15 Washer B5.3 Scheibe B5.3
49 309 411 080 020 1 ŠroubM8x20 DIN 933 Screw M8x20 Schraube M8x20
50 884-13-144 1 Podložka d 8.2 Washer d 8.2 Scheibe d 8.2
51 889-13-161 1 Víko hlavy Cover of the head Ventildeckel
52 889-13-166 1 Těsnění Gasket Dichtung
53 898-13-166 1 Šroub oddychu Breather screw Lüftungsschraube
54 898-13-169 1 Přípojka Connection Anschluß
55 898-13-171 3 Těsnění Gasket Dichtung
56 309 543 210 624 4 Šroub M6x40 ČSN 021143.59 Screw M6x40 Schraube M6x40
57 889-13-118 1 Víčko Lid Deckel
58 889-13-139 1 Sací hrdlo pryžové d 35x29 Intake branch gum. Einlassflansch gummi
59 309 543 210 615 4 Šroub M6x18 ČSN 021143.59 Screw M6x18 Schraube M6x18
60 273 111 014 399 1 "O"kroužek 99.5x3 VMQ Rubber ring 99.5x3 Gummiring 99.5x3
61 870-13-174 2 Cetrážní trubička Dowell pin Centrierrohr
62 889-13-169 4 Kroužek Ring Ring
63 889-13-168 4 Matice hlavy Nut of the head Mutter des Zylinderkopfes
64 624-13-014 1 Podložka válce d 107 Washer d 107 Scheibe d 107
65 898-13-172 1 Hadice 13/18 - 600mm Tubing 13/18 -600mm Schlauf 13/18 - 600mm
66 893-13-152 1 Objímka TORRO 12 -29/9 - C6 W 1 Sleeve 12-29/9 Muffe TORRO 12-29/9
4 5 7
9
6
889 – 15
889-15
Mazání
Lubrication
Schmierung
(3)
7 11
12 13 14 15 16 17
22 21 20 19 18
25 23 24
889 – 19
889-19
Ignition
Zündung