JAWA 350 Manual (638, 639 and 640)

DILENSKA PRIRUCKA WORKSHOP MANUAL MANUEL DE MONTAGE MONTAGEHANDBUCH MANUAL DE MONTAJE JAWA 350/638 639 640 JAWA ZS © JAWA S.P. TYNEC nad SAZAVOU MADE IN CZECHOSLOVAKIA 1992 aaMontéin{ pf frutka, kterou Vén ptedklédime, je uréena opravndm a a4 usnadnit pr: opray motocyklu Java Popisy manté2i jsou vypracovény ze pfedpokladu pauziti specidlni sady mantaznthe nétads veskerd informace, vyobrazens, nvacy a technick4 data, které jsou y tamto titulu abeazena, jsou podlozena nejnovejéimi poznatky z vyroby. JAVA s.p. si’ vyhrazuje privo provad8t zminy na vjradku bez pradenozina upezornéni. K oznéneng teehte eventudlnsch men, pEipadné odchylek pro urolta te ritoria, bude vydan dodatek. Tato montéeni pfiracka ani 2écny jejf dil, nesmi byt bez pisenného povoleni dle reprodukovsne, The purpose of this Manual, intended primarily for specielizet JAVA repair shope, is to facilitate all jobs connected with repaire of JAWA 350 moter cycles. All the described disnant ling, refitting and adjusting procedures have been elaborated uncer the assumption thet the Te- Commended toole and spacil Jigo and fixtures will be used for them. All information, 11lustre tions, instructions and technical data contained in this Manuel sre based on the latest know- ledge’ gained in anc during nanufacture. The JAWA National corporstion reserves the Tight to chan. ge its products any time without orevious notice. Any changes and or deviations from the standard version for cetain territories will be published in the form cf supplements to this Manual. It is hot permitted to reproduce this Workshop Manual or its parts in eny form what s0 ever without written consent Le présent Menuel que nous vous remettons est destiné surtout aux ateliers de réparation et doit feciliter 1a réalisation de tous les traveux de réparation sur.les motocyelettes JAW. Les des~ Griptions des travaux de montage conptent avec 1 utilisation d'un jeu J ovtillages spéciaus Toutes les informations, illustrations, instructions et données techniques contenues dane cet publication sont besées sur les derniefes connaiseances acquises pendant la sonstzuction des \ entreprise nationale JAWA se réserve le droit de réaliser sans préavis de s modifica tion et écarts dventucla seront notifiés dans un additit. Toute reproduction do present manuel ou dune de ses parties réalisée sans accord écrit préalable est interdite Dieses WERKSTATT-HANOBUCH ist vor allem fr ReparaturwerkstStten bestimnt und soll die Avs~ fOhcung aller Instandsetzungsarbeiten an JAWA-Motorrddern ecLelchtern. Die Beschreibung der AT~ beitapinge wurde unter der Voraussetzung der Verwendung von Spezialmantagewerkzoug ausqeatbei- tet. Alle in diesem Werkstatt-Hanbuch enthaltennen Informationen, Atbildungen, Weisungen und technischen Parameter haben ihre Basis in den neuesten Erkenntaigsen der Produktion. Die JAMA. Werke behalten sich des fecht vor, ohne vorherige Ankindigung Anderungen an ihren fezevgnissen verzunchmen. DLese oventuellen Anderungon bzw. Abweichungen fOr bestinnte Teritorien werden 10 Nachtrligen bekanntgegeben. Veder dieses Werkstatt-Handoush noch eines seiner Teile dart onne vorherige scheiftilene Zustimaung des Merstellers nachgestuckt oder reproduziert werden te Manual de monteje ol qual ce dostins ante taio a loo Noe complacomos on prosentar a talleres de reparaciones y su finalidad es faciliter la realizacion de todas las reparaciones de jactadas suponiendose 1a utiliza~ 1a motocicleta JAA, Las escripclones de Los montejes estan ri cidn del surtido especial de dtiles de nontaje. Todas las informaciones, los grabados, las instrucciones y los datos técnicos contenidos enel presente Manual se basan en los conécinientos mds recientes de 1a praduccions. La empress nacionel JAWA c» raserva el derecho do efectuar mo Jificaciones del productc sin aviso previo. Los canbios 0 las desviacicnes vigentes para ciertos Be aviserén en forma de un suplements al presente Manual. Se prohibe le repreduccian de cate Ma nual de Montaje, resp. de alguna parte del mismo, sin 1a autorizacion respective hecha por es:a ntovat oddBlen’ dodané © souhlas{ s dokl 3. vyimut{ akunulatorw, nabitt -2formovéni, montaé 4, Kontrola hladiny oleje v lové sk¥ini - doplntnt 5, zkontrolovat vSechny funkce el. spotiebitd 6. Zé&kladni seffzen{ svBtlonetu /viz str. 50 ndvodu x obsluze/ a skldpéns evtiometu 7, Seffzent predstinu 8, Serizeni spodky 9, Gekteoni brad / krok brady, cdveduinit v pEfpadé nutnosti pledaf brzai/, event. seffdit vali lanka sp{naée STOP 10. Naplnéni stroje min. 11 benzinu ~ snési nastartovat tf notoru ser Sh, Dotdhnout matice piirub vYfukovyeh kolen a hlav vétct t volno! 12, Kentrola Sroubovfch spojt - dotazent 13. zékladn{ pougent o obsiuze motocytiu a pfedént note: 120 minut ADVANCE ‘ALE, SERVICE 1. Unpack the motorcycle, free it from the presexvation grease, assemble the separately Aclivered unite ané parts of accessories /control of completeness/. Verify (f the numbers of the frame and the motor are o: uments. Take out the accumulator, charging - forming, assembly. control of ofl level in the gear box ~ refilling. Control all the functions of electrical appliances. Basic adjustment of the headlight /see the page 50 of t! verification of the hea: operating instructions/ and Light tiling. Adjustment of advanced ignith 8, Adjustment of coupling Adjustment of brakes /idle runnin in case of necessity dearate the front brake/ or adjust the clearance of the s cable. : 10. Filling of the machine with min. 1 liter petrol - lubricated petrol 1:33 - 11, Adjust the idle running after having warmed the machine. Retighten the nuts of the exhaust elbows and cylinder head flanges. ” 12, Control of bolted connections 13. Bas: le to the instructions about the motorcycle attendance and hand over the motor: 120 minutes 1. Déheller 1a nots, aébarrasser Les moyens de préservation, assenbler les ensenb! les parts aa 2. Vérifier si le numéro du chfssis ct du moteur est conforme aux documents , assenblage set cessoires Livrés séparément /contrOlez si la Livraison est compltte/. - 3. Enlavenent de 1’accumilateur, chargement - fornat txBle du niveau @“huile dans La bBite de vitesse - remise & niveau L 5. Vérifier toutes les fonctions des appareils électriques Regiage de pase de 1e phare /voir 1 page 50 de: ions de service/ et vérification nt de 1a phare b8. Réalace 9. Réslage des freins /fonctiornenent au pas de frein, déaérer le frein avant en cas de ventuellenont régler le jeu du cfble de 1“interrupteur stor. e - nélange de 1 0. Renplissage de 1a machine par 1 Litre d”esse1 ~ 11. Apres avoir échauffé le moteur, régler la marche A vide. Resserrer les écrous des flanges “échappenent et des culasses: 2 des assemblages boulonnds - resserrage _- 13. Instructions de base de service de 1a moto et renize de 1a moto au client 120 minutes 1. Das Motorrad auspacken, dekonservieren, dis separat gelieferten Gruppen und tubshérteile montieren. /Vollstindigkeitskontrolle/. 2.0 3. Ausbau des Akhumulatora, Datterieaufladu! srptlifen, ob die Wummer des Fahnens und des Motors mit der Dokumentation dbereinstimmen. Jebekasten ~ Nachfiil1en 5. Alle Funktionen der elektrischen Verbraucher iberpriifen. 6. Grundoin stellung des Scheinwerfers /siehe Seite 50 der Betriebsanleitung/ und Uberpriifung der Funktionalitit der Scheinwerferschwonkung. 7. Einstellung der Vorsindung. 8. stellune der Kupplung. 9. EsasteLlung der Brense /Brensscnritt, falls nitig aie vorderbremse entliften/, event. das spiel der Schelterlitze STOP einstellen. n Ellen = Miechung 1:23 - etarten 11. nach griicmang des Motors den Leerlauf einstellen. Die Mattern der Planschen der Auspuff- krimmern und der Zylinderkdpfe nachziehen 2. Koatralle der SchrauBeaverbindungen - Nachzichen. 13. Grundanleitung fiber die pedienung des otorrads und Ubergabe des Motorrades dem Kunden. 120 Minuter WVICTO PREVIO & NTA artes de loz accesorios + Desembalar 1a motocicleta, desconservar, montar los conjuntos y suninstrados por separado /control de 1a integridad/ 2. Controlar de si concuerdan los ntineros del cuadro y del motor con los documentos. Extraer el acumulador, cargar - formarlo, montarlo 4. controler el nivel de 1a carga de acei en la caja de velocidades ~ complementarla en = Controlar el funefonamiento de los consumidores eléctricos — 6. Ajuste bésico del faro /véase pég. 50 de las Instrucciones de Servicio/ y con funcionaniente de la inelinacién del mismo. + Ajuste del avance de encendido. ~ 8. Ajuste del embrague. « Ajuste de los frenos /paso del freno, desairear en cuanto sea necasaric @1 freno delantero/, resp, ajustar 1a holgura del cable del interruptor stor = 10. Lenar Je néguina por lo menos con 1 litre de gagolina ~ mezcla de 1:33 = y arrancaria 11. Después de calentarse el motor ajustar 1a marcha en ralent{. Apretar a fondo las tuercas de la bridas de los codos de escape y de las culatas de cilindros ontrolar resp. apretar a fondo los tornillos de unidn Instruir al cliente en lo que se refiere al servicio bisico de la motocicieta y entregdrscla.TECHNICAL DATA DIMENSIONS OF THE MOTORCYCLE MASS ARD LORD ENGINE ‘cARBUREPTOR cuore GBARBOX FRAME SUSPENSION Ist gear rind gear 31rd gear Ivth gear Length 2100 = 30 mm width 780 £15 mm Height 1160 ? 30 nm Clearance neaght 120 + 10 mn Weight of sadaie ez0 15 m Axle hase 2370 t 25 ma Minimum turn radius 28 toan Proper mass 149 23 kg Running mass 162 2 3 kg Overall mass 342 akg Payload 180 kg Number of seats /persons/ 2 a Trailer mass 90 kg overall Sidecar mass 172 kg overall category two-stroke, ignition, air cool: Number of cylinders 2 cylinder capacity 343,5 com Bore 58 mn Piston stroke 65 mm Advance of ignition delay 2,5 + 0,3 mm = 0,2 mm Conpression ratio 98 40,7, = 0.3 Maximum revs. 5750 min > Maximum engine output 17 kW ~ 108/5250 min“) £35 Maximum torque 32 Nm - 68/4750 min > 45 class JIROV 2928 CE - horizontal, slide type Type maltiple - plate type in of] bath Characterization # 146 mm - 8 active surfaces ‘Type mechanical with gears, double shaft Nunber of gears 4 control by foot lever overal ratio: climbing capacity with full load: 2: 14,50 as 1s 8,60 208 1: 6,10 aa 1: 4,96 9.58 Primary ch 2x 9,525 14,77 66 Links Secondary chain 1x 12,7 * 7,75 128 Links type tubular, double, closed Front suspension telescopic fork with steel spiral springs Stroke 180 mm ~ wheel axle 134 mm paRIMS evRes: ARAKES: FUEL AND LUBRICANTS Rear suspension Stroke Front shock absorber type Rear shock sbsorber Type Front wheel Dimensions Rear wheel Dimensions Prone ~ dimension Front EGC - FAIR Dimension Rear ee. 14 Dimension ovepat Rattery Headlamp Dip switch Direction indicators” ‘rail Lamp swinging fork with spiral springs 80 nm ~ wheel axle 90 mm hydraulic telescopic in rork’s arms hydraulic telescopic in the suspension unite steel, deepened profile 2/15 Bx 18" steel, deepened profile 2.15 Bx 18" 3,25 x 18" 3,50 x 18" nydeavlie, dine type, controlled by hand lever 265 mm nechanicel, brake shoe type, foot lever controlled 6 160 mm chree phases, synchronous 12 V, 210 Vay /14 v/ 15 a/ lead type 12 -V, 5 An asymmetrical, rectangular, adjustable 12 ¥ ~ 45/40 W Ba 204 v- 4WwRags sliding type lever type group type Direction indicators location - headlamp bracke:, rear franc Fvel tank capacity Gearbox - 011 charge Suspension ~ o11 charce 17 am3, 2,8 am? energency reserve + 0,2 am? front: 200 on: rear 47 en? to each absorber, 3 to each arm parmanent chargeee LA PA Sos SEZNAM SCAVISNINO NARADL PRO TYP 638, 639, 640 LIST OF REPATR TOOLS FOR MODEL 638, 639, 640 LISTE DES QUTILIAGES MONTAGES POUR LE TYPE 638, 539, 680 KUNDEMDIENST-WERKZEUG FUR JAWA TYP 638, 639, 640 LISTA DE UTELES DE SERVICIO PARA EL TIPO 638, 637, 640 Pol.| _oznac. wr. €fslo ks Pojmenovéni Description Tten| Type Serial No Quan |i. | desig. tity L Z - 1 sue | 9.71.51559.0 a Marka piedetinu Feoler gauge for ignition advance adjustaent 2 s-18 | 9.71.51568.4 1 Stahovék rotory Drag, alternator arna- alternstoru ture’ /rotor/ 3 9.71.51589.4 1 PEidrsovae 24padek | Pawl retsiner 4 9.71,515590.4 1 Vyrazeé centréinich | Drift, centring bushes pouzcer a: 9.71.51577.4 1 vyrazet lozisek Drift for driving out bearings 6. | ser2 | 9.m.51576.0 iz Narazet tésnictho Orift for driving home krou2ku sealing rings a. | sa | 16-19758-4 1 Trubkovy k1fé hlavy | Tubular spanner, ste- rizent ring ead € s-0s | 9.71.52240.4 1 Stahové primér. Drag, primary sprocket Fet. kole removing s 5-86 | 9.71.52253.4 1 Wyrazet pist. tepu | orift dia ao, | s-87 | 9,71.52252.4 1 Vylisoveet kolik Mandrel for gudgeon pin piot. cepu 8 16 pressing dia. 16 in and out ui. | s-sa | 9.71.52251.4 2 Viozka do horniho Auxiliary bush, connec oka ojnice Hng-rod’ snail’ end Item Outillage ov montage Bezeichnung Denomnscién Now = 1. | Indicateur ce 1“avance Vorzundungsmesschraube Calibrador del avance de 3'1allumage encendido 2. | extracteur cu rotor de Alternator-Abziehvor- Extractor del rotor de 1a alternateur richtung altersador Serre-ciliquets Klinkennalterplatte Sostenedor de trinquetes 4. | exteacteur ces dovities Zentriechtisen-Austceib- | Expulsor de bujes centra~ de centrage dorn dores Extracteur des rovlenents Lager-Austreibdorn Expulsor de cojinetes 6. | Oytit a poser les bagues Dichtrin-Eintreibdorn Dispositivo para montar a d'étancnel te fuerza el enille obturador 7. | C16 tubvieize pour tete Lonkungskoaf-SteckschiU- | Liave tubular de 1s cabeza de direction ssel de la direccicn 8. | Extracteur du pignon Primtrkettenrad-Abzieh- | Dispositivo para quitar la a chaine primaire vorrientung rudea de cadena prinaria 9. | txtracteur 1’axe ou pis Leger Austretbdern Expulsor ol gorron ton de émbolo 10, | Wandrin a chasser 1 axe Kolbenbolzen-Austreib- Espiga pare expulsar a pre- ae piston, cian. 16 Gorn B16 sign el gorren de énbolo aie 11. | Bague pour pies de bielle EinsatzstUck tr gros- Canisa pare el ojo de 1a ses Plevelsuge biela Os >~ JAWA, Zopol. | oznac. | vyr. eisio| ks Tten | type | Serial No. | guan- Podmenavéni Description No. | cesig. tity az. | s- 90 |2e-ae-763 | 1 Rozlisovaé motor. Jig with bolts for skPiné se Srouby seperating crankcase haves as. | 5-91 | 2e-86-764 | 1 Zajistovact lanele fuxiliary clutch plate sposhy as. | 5-92 |20-0e-76s | 2 Norated nritt 1s. | 5-93 |2e-ac-766 | 1 Vytanavas ramone Fork leg extractor vidlice ae. | s- 90 |2e-a6-818 | 2 Zajistovat primée- Prinerchainadapter iho pFevodu Ttem . a Dutillage ou montege Bezeichnung Denominacisn 12. Dutil a éésessembler Notargehtuse-aurtre- Dispositive para sbrir le carter moteur avec ibvorrichtung mit a presién el cétter del vis Schrauben nator con tornillos wb. Disque do helcage de Kupplungssicherungs- Plato de seguridad del 1 enbrayege Lamelle embrague 1a Enfoncoir Auftreiver Dispositive para nontar 2 golpe 1s Extracteur des bres de Redgabelarn-Abzieh- Exteactor del brazo de fourche vorrichtung la horquille 16. Tmmabilisetion par tren Primirkettenadapter Asegurador de 1a transmission primaire smision primariaror. [oznac. | vyr. ersio | ks Pojmenavani Description | Trem | Type Seriel No Quan= No. | desing tity 11. | - 201 | 9.96.55607.5 ] a Paka Lever ae. |s- 203 | 2a-a6-767 1 kieste Pliers” as. |s- 209 | ze-a6-725-2 | a Lisovact ptipravek Pressing jig vo. prislusenstys with accessories” Ttem No, | Outitiage ou montege Bezeichnung Denoninacién a7. | Levaee Hebel Pelanca ie. | Pince Zange Aliestes 1s. | Presse avec Precevorsicntung Dispesitivo pare monter U accessories mit Zubohbr 9 presién ineluyanda los acceroriosTabulka doperucenjch maziv pro motocykl JAWA 350 typ 640 List af Lubricants Reconmended for JANA 350/680 Motor Cycles Apercu des lubrifiants commandés pour notacyclette DAWA 350 type 640 EmptBhlene Schniermittel flr Motorrad JAVA 350 Tya 640 Tabls de lubricantes recomendados pare 1a motocicleta JANA 350 del tipo 640 SER 4 aa-rr 90 8 OA-M2T Super © motor, ole3 SAC 30-40 D T-A 00 E PH-nKe F PH-AK2 6 A ao BP casTROL SHELL OBL A Gearoil 60 EP Castrol sT 90 Shell Spirex EP 90 6X 80 SAE 80 8 BP Two Stroke Oil Castrol 11 Shell Super Mobil Mix Two Atrone 012 Two Strok Super 6 BP Ghack-Absorber Gil Stosadiim petr8l Shell Oenax A Mobil OTE L3 J Forkost / JHLP/ 0 Enerarease A Castrol Grease CL Mitilus Grease A Mobilorease No.2 E Energrease L2 Castrolesse LH? Shell Retinax A Mabilgrease MP F BP Fliesctett NO Castrol Grease Shell Retinax AM {Mobi 1grease or Energreese L 21- —Castral Chain Special Lube Ket ten-spray Nobiltac 81/ M2T 1:40 CASTROL TT 1:50 (Iga /US/= 1,3 Ul. oz. )LEGENDA Poutiti oleia A/ ptevodové sktin, copy pétex brzdy @ spuihy, Eepy vahader prerusovate, K1ice vezd, cepy stojénka, Lanke bovdens, plst ptorutovate B/ mazni motoru C/ afedni teleskopickd vidlice 3/ ototnd rukojet plynu , zadni kyvnd vidlice lofiska zadniho fetéz. kola, vatka poloautonatického vypinaée spojky, Lo2iska Kol nazani lozisek sekundérni tetez Use of oils A/ Gearbox, Brake lever pins, clutch lever pins, breeker rocker pins, breke cams, stand pins, bowden cables, breaker felt 8/ engine Lubrication C/ telescopis front fork D/ accelerator twist grip, swinging rear fork E/ cear sprocket bearings, semiautomatic clutch disengaging device cam, wheel bearinss F/ secondary chain Bentitzung des Gls A/ Gateiebekasten, Grams und Kupplungshebeltolzen, Unterbrecherhebelbolzen, Bresnacken, Stn dervolzen, BoudenzBae, Unterbrechernockenfilz 8/ Motorschmierung C/ teleskopische \ordergabel 0/ Gasdrengriff, Kinterrad-Schwinggabel / Lager des hinteren Kettenrades, Nocke der halbeutomatischen Kupplungsausschal tungs-vorrichtung, Radlager F/ SekundSrkette Utilisation @tuiles A/ doite de vitesses, axes de leviers de frein et d’enbrayage, axes de culbuteurs de rupteur, ca- nes de freins, axes de béquilles, cables de boxdens, feutre de rupteur 8/ graissage au moteur ¢/ fourche *é1éscopique avant 0/ poignée tournante des gaz, fourche arriare ' E/ roulements ce roue a chaine arriére, came de débrayage Semi-autonatique, roulesents de rouss F/ chaine secondaire Uso de aceites A/ Caja do velocidades, pornos do las palancas del freno y del embrague, pornos de les balencines del interruptor, laves de los frenos, pernos de los Soportes, cables houden, fieltre del inter- tuptor 8/ lubcicacién del motor C/ Horquilla telescépica delantera 0/ mango giratoric del acelerador, horquilla oscilante tresera [/ rodamientos de 1a catalina trasera, leva del sistena seni-automético de cesecoplemiento del embrague, rodanientos de 1as ruedas F/ cadena secundaria — 3 ) Fee eoTT isle fissile Die ee pete py ate [Kx [ke TK yyy Tk 3 5 2 Che hey pepe py : r [wpe] fem i TT 1k Tee hee ee we . w{_twy [mw Hi rte | pele tex ra cereCececerereK nv a K af |e }epeteys pets fe v v v eee le tel x elute fete te eye hope peep = lcale: [ied lwalig lel pete ty eee te Pe feb f ef e 1. transmission of1 2. cluten rburettor 4, €4itering clement of the air filter 5. steering head 6. rear euspension 7. secondary chain 8. wheels and rear suspension bearines 9. brakes ~ brake Lining 10. bowden cables LL. battery 12. alternator K ~ indSepenzable checking, cleaning, adjusting or eventualy replacement © - cleaning 5 ~ adjustment M ~ lubrication V ~ replacement D ~ decartonization + as necessary @2 = ovary 1000 tm #8@) every 2500 km = every 5000 km After running of: 25.000 ~ primary chain replacement 30,000 - checking of the condition of connecting rods bearings, checking, event. repla~ cement of bearings in the stetring head replacenent of shaft type gasket rings with the crankshaft as vell as wheel with ub, checking of wear of the cy Linger, eventually re-bere 50.000 = complete dismantling of the brakes system 13. point gap and ignition advance 14. spark pluge 45. front fork ~ oil exchange 16. wheels - spokes stretching 17. brake lever pins, joints, Stop switches, accelerator twist, grip, contact breaker cam lubricating felt, 18. exhaust silencer 19. piston, piston rings, transfer ports 20. brake plate 21. screws, nute and packings273521000917 le) f me. Fie ve | ol - ; ! W/é ! soa 63054AWA. ZO SeZnaM HLAvMicH LozrseK 4 TéaNfctoH KROUZKU LIST OF MATH REARTNES AND SEALING RINGS | OZNACENT POIMENDVANL ks uwIsteNt - Sia 994 Ga) 80D | TostsKo Jenlove Ina WW /iSx2m27 | 1 | nator - levé polovina 324 163.030 190 | toziske 6303 A 1 324 163059 566 | loziake 6505 A 1 324 594049 200 | tosiako jentove TNA aN /16x22012/| 1 | wotor 324 132 054 e020 | tozisko 3205 1 am 324 132 054 803 | toziake 3205 ¢ 3 1 =". 324 162 069 556 | loPiske 4206 2 | k1ikovy mechanismus 273 521 008 617 | teanici kroutek /30x52x10/ 1 | moter - pravé polovina 273 521 008 517 “us /30x52x8/ 1 sue Led 273 521 008 917 -t- 125x62x8/ 1 | moter - 1evé polovina 273 521 000 317 ote /8x1647/ 1 | ponun techonetry 326 914 010 452 | wudicke /6 6,35/ 1636] vypingnt spojky + nave rému s 324 163.020 100 | togicke 6302 A 2:2 | pfodnt © zodni kato if 324 162 050 100 | toziske 6205 A 1 | zadnt ptevoanse DESTONATION NANE OF PART qua. PosITiON 324 594 043 400 | neeore veering ena nn /15x72x12/ | 1 | engine 1-n. sige 324 163 030 100 | boaring No. 305 A 1 * 328 163 059 566 =" 60s A 1 es - 324 576 049 200 | needle beering INA BN /16x72x12/ | 1 | engine rh. side 324 752.054 800 | bearing No. 3205 1 ed 326 732'054 803 | bearing No. 5205 ¢ 3 1 a 324 162 069 546 | bearing No. 6206 2 | crankshaft mechanism 273 521 008 617 | shaft sealing ring /30x52x10/ 1 | engine rh. side 273 521 008 317 ae /3x52x8/ 1 oh Ld 273 521 006 917 abe 125x82x8/ 1 | engine 1.n. s1ue 273 521 000 317 sth /9x1647/ 1 | specdoneter erive 324 914 010 452 | boi /rectrevlating/ dia 6,35 1436| frame head and clutch release AM ier nechanism 324 163 020 100 | bearing No. 6302 A 2+2 | front and reer vheel 324 162 050 100 | bearing No. 6205 1 | rear-wneet sprocketTatoewt ptsto PISTON GRADING CLASSEMENT DES PISTONS KOLBENKLASSIFIZTERUNG CLASIFICACIGN GE LoS EwBoLOS Trident D2 Snading class + 0,000 Symbole = 0,020 Klasse clasiticactén Worndl a 3572 standaca a 31,982 tornai c sro Horna Hornat 1. tytrus A 58,222 -st Rebore 8 98,252 ~ére Rectit. c 98,202 EinsehLitt kectificac ; r OVAL 4 ~ [2 worue A 58,472 t -nd Redore 8 se,482 i_ jd ~ére Rectit. c 56.432 he Einschlitt oF Rectittcac. 2 rd Rebore ° 90,732 emo Roctit e 50,742 Finceniite Rectiticac . 4, Worus A 58,972 th Rebore 8 50,962 ~ére Rectit c 98,952 EinschLitt Rectiticac.ZO TRiveNt vitel CYLINDER GRADING CLASSEMENT DES CYLINDZES ZYLINDERKLASSF IZTERUNS CLACIFICACION Of LOS CILINoROS THaeni D1 + 0,01 Grading class | 9 2 + 0,01 symbole 03 + 0,02 Kasse Clasiticacién Normal x 38 Standard 8 53,01 Normal c 33,02 Normal Norma Lacsaale | ' 1. Worue A 53,25 | -st Rebore 8 58,26 | ~ére Rectif| c 98,27 DD, Einsehlitt Rectificae 1 2, vybrus A 58,50 I ost 54,91 \ -ére 5,52 G\D3 Einsehlitt Rectificac. il 13. wybrus A 58,75 | -st Rebore 8 38,76 ds were Rectit, c 58,77 | exnscniits Rectificas 4. vyorus -st Rebore -ére Rectif c 7 1POZNAM Tyrobce dodivé ndheadnt vélce vhradné v zdkladnich cozmérech /nornél/. V tabulce uvedené ddaje platt pro zhotoveni vybrusd. Vzhleden k tonu, Ze z vyrob- Aich dived’ Ice jen valmi obtizné provést v/brus v setinové toleranci, je mutné po provedens vjorusu promér otvoru vélce proméfit /aéfime ve vice mistech/. Na Poklade rjiatenyon modnot poustt pisi vnodreho tituenf. Vélee nutno na horn’ plo- Se pFeznaéit. Jak u novjch motord, tak u motord s vjbrusovymi vélci je pfipustnd montéz + lovéno a pravéno valce rhzného teidéni /nikoliv riznych vybrusovych stushi/. PRL vjbrusu, n'a Fozhrani svou tFid{cich skupin, mizene pout{t pist B nebo C. Pil B We ryeniejsr zaben, pri C moznost vzniku kicpénf pisty omerene ungprehFatého ao- Yoru. note: ‘The manufacturer delivers spare cylinders oxclusively with the basic /standard/ bore. The other dimensions given in the table are guides for cylinder reporing. Because 1t $1 very difficult to repore tne cylinders accurately within tolerance limits of hundredths of millinetres, it is necessary to check the bore Of the rebored cylinder by measaring it at several points, and to use a piston Of the grading corresponding to the meacured dimension. ‘The grading mark on the top face of the cylinder has to be chanced acordingly- In new engines as well as in engines with rebored cylinders, the right-hand and the left-hand cylinder may be of a éifferent grading class /but not of Afferent rebore grading/. Tn the ease of cylinders with relores in hetween two grading groups, it si possible to use a piston of the group "B" or "C*. with the Spr piston, the running-in is quicker, with the *C™ piston knocking is Likely to occur before the enjincheats up to its service temperature. NOTE: ‘Le fournisseur livre exclusivement des cylindves de rechange des cotes fondanentales /standard/. Les cotes indiquées dans le tableau répondent aux diferente rectifications.conme 11 est tres difficile d effecteur 1e réalésage evec une tolérance de quelques centitmes de millinbtre, i1 fast mesu- rer 1 alésate du cylindre & plusieurs endroits aprés 1a rectification. Utiliser Ala base deo réesltate des nesares 1c piston de 1a classe correspondante. Changer la marque sur la portée supérieure du cylindre. 11 est adnis de monter tant dans les noteurs newfs que dans les moteurs équipés de cylindres réalisés des cylinéres gauches et droits de diverses Glasses /non do diverses cotes réparation/, 2: le classerent des pistons ot des cylinéres est identioue. En cas de rectification & la limite de deux valeurs on peut utiliser un pistons ou Cc. Dans le premier cas le rodage est plus rapice et dans le second 1a possibilité du cognement dun moteur insuffisament chauffé est linitée. ANMERKUN Der Hersteller 1iefert Ersatzzylinder ausschiiessiich in den Grundaassen fMormal/. Die in der Tabelle angegebenen Daten gelten fir Einschliffe. da aus fertigungstechnischen Griinden Einschliffe nur sehr schwer in hundertstel Tole- ranger ausgefiinrt werden Kénnen, mass nach dem Einschleifen der Zylinderbohrungsdurch- messer nachgenessen werden /an nehreren Stellen vornehnen/. Auf der Grundlage der Nesswerte bind dann Kolen der geeigneten Sortierklasse zu verwenden, Die Zylinder sind an der Oberflache zu kennzeichnen. Wile bei fabrikneuen Notoren so ist auch het Motoren mit eingeschliffenen aylindern der Einbau des rechten und linken zylinders in unterschiedlicnen Bortierkiassen /nienale jedoch in verschiedenen Einschliffotufen/ moglich. Bein Einechlife im Grenzbereich 2veicr Sortiergruppen kann cin Kolben B oder C ein= Sebaut werden. Kolben B laufen schneller ein, bet Kolben C ist das mégiiche Kolberklopfen bei nicht durchaewarnten Motor’ beschrankt. Noma: "EL fabricante suministra los c4lingros de repuesto exclusivanente en les dimensiones bésicas /normal/. Los datos que se indican en la table estén vigentes para la confeceién de las rectificaciores. Considerando que por razones de produccién resulta ser aifficilfaine efectuar 1a rectificacion dentro de 1a Eolerancia de centésinos de nilfmetros, es preciso nedir el digmetro del oriz.cio del cilinaro después do la rectificacion /medinos en varios puntos/. En base a los valores comprobados utilizamos el émbolo de clasificacion conve~ niente. Cabe marcar los cilindros en su superficie superior. tanto en aotores nuevos, como tanbién en caso de motores con ciliniros rectificaios se ainite morta! lon cliindros isquierdo y derecho pertenecientes a Glferente clasificacién /no a diversis grados de rectificacson/. /fay que fantorer 1a clasificacion Ge los énbolos conforme a 1a clasificacién de, tos Gilindvos./ En cago da una rectificacion que ge encuentre en el Linite Je dos rupos de Clasificacion, podenos utilizar ‘el gmbolo BoC, En caso de By @ TrEhte es nde Fapido, sn’case de € quece reduoida 1a posibiligad de surai- miento det golpsteo ae] énbolo en caso del motor no calentado, GsTABULKA SESTAV LOZISEK PESTNECH CEPU LIST OF CUDGEON-PIN BEARINGS COULEURS DES ROULEMENTS DES AXES DE PISTON KOLBENBOLZENLAGERSATZE TABLA DE LOS CONQUNTOS DE COJINETES DE LOS GORRONES DE EMBOLO bleu 19,998+20,002 rot 1,99341,995 ojnice Pistai cep Jehlovy vélecek vane Connecting rod Gudgeon pin Needle roller Clearance Bielle Axe de piston Roulement @ aiguilles| Jeu Plevelstenge KoLbenbolzen Nadelrolle Spiel Bieta Gorrén de éabole Rodille de aguja Holgura servend modry red blue rouge 19,994+19,998 |bleu 15,994+15,997 1,99441,996 0,005+0,016 rot bleu 1,99341,995 0,007+0,018, roja azul cerveny nodré eet ae rouge 15,997#16,000 1,99841,996 0,006+0,017 0,008+0,019 rojo ite ‘nodey azul blue bleu 15,994+15,997 1,996+1,998 0,005+0,016 blau 1,995+1,997 0,007+0,018 azul cerveny red rouge 15,997616,000 1,996+1,998 0,006+0.017 bas | rot 1, 99541, 997 0,008+0,019 white 030 lane 20,002+20,006 [aogry weise tue! Bience bleu 15,994+15,997 1,998+2,000 0,005+0,018 blau 1,99741,999 0,007+0,018 azul eluta cerveny = yellow red jaune 20,006+20,010 rouge 15,997+16,000 1,99842,000 0,006+0, 917 gelb rot 1,997+1,999 9, 008+0,019 amarillateats $$$. (AWA 0: 1. KOTOR hlav valet 1. Le Demontd a non: a valet Pred denontaai je nutaé nejprve vymentovat pf frubu karburatora, které Je pro oba vales apoleting. Povolentim a vytosenim @ matié M 10 trubkovym kL{Cen Rlavy véled uvolnine a sejmeme, Motorem pootdéine tak, aby pfst vélee, ktery chcome demontovat, byl ve spedni /dolné/ dvrati. pote valec vyjmeme. Po demontd¥i vélei venikié otvory ochrénime ped vniknu- ffm neBistot. Montés provdaime opacnym zpiisohen. Pked demantss{ ofiatine dosedact plochy vélcd a notorové sk#ind. oBizt nou Pracovnt plochu vdice potfene olejen a nasadime na pist. PEL montd#i postupujene opatené, dbéne aby pistn{ kroutky byly sprévné usazeny v 2dmefch a nedodlo k Jedten poskozent, po hlay véle’ vlo¥ine /poure ¥ pEtpad’ pokozent/ nové teenént. Detazen{ matic evornshd hla provedene kELZové, momentovyn kien oilou 17,6 Nn. V pEfpadé domontaie hla véio8 a véleh pi moteru v rémi Je pot¥eba neiprve sejnout sedlo a néérZ, odpojit vyfukové kolena a edklopit Je, demontovat civky i s kabely a koncovkani. 1 ENGINE 1. 1. Disassembly and assembiy Of the cylinder Head and cylinger Prior to dissasenbly take out the carburettor flange, which is shared by both cylinders. Using the box spanaer loosen end undo the eignt M10 nuts to be able to loosen and remove che cylinder heads. Make the engine move until the piston of the cylinder to be disnounted gets at the botton dead centre. ‘Take out the cylinder. after having taken out the cylinder, cover the ensuing holes to evold drain et dirt. For assenbly proceed in the opposite Sequence. Clean the cylinder and engine housing seating surfaces before the assembly. coat the cleaned cylinder working surface with fit it on the Piston. Proceed at the assenbly witn caution, see that the Piston rings sit right in the Joints to avoid thelr danage. Fit fresh packing in the cylinder heads if the old one is damaged. Screw the head bolt nuts home crosswise using ‘the torque spanner and the force of 17.6 im. Tf the engine is mounted in the frame, take first out the seat and tank, separate the exhaust elbow and disconnect the coils plus cables and cable shoes.L. 1. Dénontage et montage de la culasse et des cylindres Avant le démontage 11 est nécessaire de aéposer avant tout La bride éu carburateae qui fest commine pour les deux cylindres. Desserrer et déposer 1a culasse en débloquant et aé- viseant les 6 éerous M 10.2 Laide de 1a clé tubulaire. Tourner le moteur de facon & ce que le piston au cylinare gue lon Séeize aénonter soit an point mort bas. Recirer ensuite le cylindre. apris Lvextraction des cylindres, obstruer les orifices pour enpécher leur encrassament. Effectuer le renontage ne procédant dans 1 “ordre inverse. Avant cette opération, nettoyer leo faces de contact aée cylin- ares et du carter moteur. duire d“huile le face ae tra~ vail du cylindre et assembler celui-ci avec le piston. Prenard des précautions pendant le mon- Veiller & ce que les seg- Eas tage ments de piston soient correcte4 ment placés dans leurs gorges et ne cvendonmagent pas. Intro- duire dans 1a culasse /seule- ment en cas de éétoroiration/ un nouveau joint. Resserrer les boulons de 1a culasse en pro- cédant en diagonate & 1“aide de La clé dynamonétrique & 17,5 mn, Pour déronter la culasse et les eylindves sens adposer le moteur du cadre, aabord la selle et le résorvoix] Aésassenbler les coudes des si- lencieux et les faire basculer, Aénonter les enroulements avec les cibles et les embouts. agpocer tout] 1. 1, Ausbau und Montage der gylinderkipte und zylinder Vor Ausbeu zuerat den ge~ meinsanen Vereaserfiansch beider aylinder entfernen. Acht M Lo-Muttern mit Hilfe eines Hiilsenschlissels und entfernen, zylinderképfe herabuehnen. Notor so umdrehen, dase sich der Kolben des auszu- bauenden zylinders in unterem ‘Totpuakt befindet. iylinder he- ate Den Lésen pie euren rausnennen. kage entstandenen 8ffnungen vor Verunreinigancen sehiitzen. vonta-| ge in ungekehrter Rethenfolge vornehnen. Vor Montage Sitefla- chen der 2ylinder sowie des Motorschrankes reinigen. Gerei- nigte Arbeitsflache des 2yLinder: mit Ol schmieren und auf Kolben aufsetzea. Bed Mortage vorsichtas verfahren und darauf achton, dass die Kolhenringe richtig in Schléssern sitzen, un deren Be- sch&diguag zu vermeiden. Im Fall einer eventuellen Beschidigung der Ringe 2ylinderkipfe mit neu- en Dichtungen verseten, Mattern ger zylinderkoptboizen mit Hilfe eines Drehmomentechlissels mit einer Keaft von 17,6 Nn tbors Krenz nacheiehen. Wena gylinderképfe und Zy- Linder aus einem in einem Rahmen befestigten Motor auszubauen sin¢ miissen zuerst der Sattel sowie der Behdlter entfernen werden. Weiter sind die suspuftkrimer abzukuppela und ebzulenken und ic Spulen cincehlieeeiion Kabol und Endstiicke abeubauen. 1. momo 1. 1, Desmontaje y montaje de las culatas de cilindros y de los cilindros Antes de proceder al desrontaje hice falta desnontar prinero 1a bride dat-cactareder que ex conin'pare =o. fahor ollinaroe. Por aflojar y desencrosear 8 tsercas H 10 con avuda Ge 1a Lave tabular aflojancs las culatas de etlindros y las quitanos. Hacenos aixar el motor de manera que el éabclo_ el cilindro que querenos desnontar ae encuentre en e1 punto merto Anfestor. 0 continacién extrannos 1 cllindrs. Deeputa doi domontaje de os chiindros protegenoe Los oritieios surgicos 1a penetracisn de isparezas. Para efectvar el montaje ~], Procedenos a 1a inversa. antes del nontaje Linpianos las superficies de asiento de 10s cilindros y de cérter, el nbtor. untanos 14 sapperti~ || efe de trabajo Limpiada del cilindye con aceite y montanos ol émbole. Pro- —;) cedenos con cautela para asentar los | aros de énbolo correctamente en los cierres e impedir su damnificacién. Bn caso de estar daiiada 1a junta en las culatas de eilindros 1a recambiano + por otra nueva, Apretendo las tuercas _ de los buiones de las culatas lo nace~ moe en crus apiicando cl par de aprie~ te de 17,6 mm y utiiizando La Lave torsionétrica. Cuando queremos desmontar las culatas de cilindros y los eilindros estando el motor montado en el cuadro hace falta guitar prinero el sillin y el tanque, separar 10s codos de escape y rebatirlos, desnontar las bebines y sue cables con torminales- iLe 2. Bkety ~ damon Pistn{ Sep je uloden v je~ hlovém lotisku bez klece. 2 téch- to dived nedoporutujeme demon tovat pisty bez specielniho néEadt. Behen demoataze by moklo do- Jet k vypadnutt aukteryeh je~ hel do motors a tim k tazkd mu poskozen{ motora, pF{padné by bylo nutne motor rozebrat a zapadlé jenly vyjmout. Dopo- ruujene tento postup: Po vyjmat{ valet /viz kap. 1. 1./ utésnime otvory do klikové skif- né.Sejmeme pistat krouzky @ vhodnymi klestémi vyjmene pojistky pfatnich SepS. De otvoru pfatu veuneme pomocnou vioziu $-B8 a do té zasuname vylisovact kolik § -87, kterf zatlatine 2% k opir. ploe kolfku. Pist 2 hornfho oka ojnice sejmeme a pomocac vlozkoa S-88, kterd 2tstala mezi jeniems v oku ojnice, sajistime vietns ‘obou piivodnich vymezovactoh kroufkt 28 Jehlami proti vypadnutt. Pked monté#{ pista se piesvéd- Bie, ¥e v hornfch okéch ojnic jeou viokeny vEecmy jehlové valetky /28 ks pro ojnici/ a vymezovaci kroutky. Uvnitt véleck® must byt vioeny pomo- ené vlodky $88, N @ horn£ oko ejnice nacazujone pict opatrn’, aby nedoSlo k vypadnut{ vynezo- vacich krouzkG a véletkt do prostoru notorové skEing. 2. BIGTON ~ Disansendly and Assenbly Since the piston pin is moun ted in the cageless needle bearing, use for dismounting of the piston special tools. There is a chance, that some nesdles may fal1 into the engine intecnals, which thing might renult in heavy damage to the engine and it would then be necessary to take the engine to pieces and look for the strayed needle, the following procedure is hence recommendable: Take Off the cylinders /see section 1.1./, Flug the crankease holes, remove the ploton ringe and using suitable pliers take off the piston pin locks. Fit the auxiliary insert s-83 in the piston opening and the press- out pin in the auxiliary insert. Push the pin as far as the pin support surface. Detach the piston from the piston rod top en and lock the auxiliary insert s-68 /nelé between the needles in the piston xod end/ and the two original take-up rings to avoid their falling out. Prior to proceeding te moun= ting of the pistons make sure that all needle rollers /23 units per connecting red/ and the take-up rings are fitted in the connecting rod top ends. The auxiliary inserts 8-88 must, be mounted inside the rollers. when fitting the piston fon the connecting rod top end, see that the take-up rings and rollers do not fall in the engine housing internals.BISTON - démontage, montage Lvaxe de piston est logé dans un roulenent & aiguilles Pour cette raison, 11 nest pas recommandé de aémonter sans cage. les pistons sane outils epéoiam. lors da dénontage, certainss aiguilles risquent de tomber dans le noteur et de 1endonmagar & tel point qu“il feudrait éven- ‘tuellement le désassembler pour en retirer les aiguilles. c est pourquoi, nous reconmanaoas de procéder conme suit: apeée avoir retiré les Ly, obstruer les orifices éu carter oylindres /voir chap. 1. de moteur. déposer les segments de piston et, & 1”aide d“une pince appropriée, retirer les anne~ aux de sireté des axes de piston. Introauire dans orifice au Piston 1a pikes auxiliaire 6-03 et dane celle-ci 1a cheville S-87 que Lon enfonce jusqu™® sa face a”eppui. Dénonter le piston de L ceil supéricar de 1a bielle et bloquer la pice auxiliaire $-83 qui est restée entre les aigui- Lies de 1“oeil, ainsi que les bagues de réglage derritre ces aiguilles, afin d“imnobiliser ensemble. avant de monter Les pistons, svassurer que dans les tftes des bielles troavent tous les roulements & aiguilles /28 par bielle/ et toutes les bagues de réglage. Les pitces auxiliatres 5-38 doivent Sere enmanchées dans Les roulonante. Prondre besucoup de précaution pour monter le piston sur la tite de bielle , afind a” éviter que les bagues de réglage et les roulements tombent dans le carter moteur. 1. 2. KOLBEN = Aushau und Montage ber Kolbenkolzen ist in einen kafiglosen Nedellager ge- lagert. Aus diesem Grunde wird enpfohlen, dic Kolben ausschlic— eelich mit Hilfe eines speztel- len Werkzeugs auszubauen. Wahrend des Aushaus kéanten die Nadeln in den Motor fallen und so dessen schwere Beschidi- gung verursachen, eventuell nilsste der Motor auseinander- genonmen werden, um die wadein herauszunehnen. Es wird folgen- dee vorfahren ompfchien: Wach tylinderaushau /siehe Rep. 1.1./8£fnungen im Kurbel- gehduse abaichten. Kolbenringe entfernen und mit einer entspre- chenden Zange Sicherungen der Kolbenbolzen nerausnebmen. HiLrsbucnse S88 in KoLpend=r~ ung hineinochicben, Haltestife 6-87 bie au dersan An Buchse: Stiitefliche elnetecken. von oberen Pleuelauge herabneh- men, Hilfsbucase S88, die zwischen den Nadeln im Pleuelauge geblieben ist, einschliesslich Kolben der beiden urspriinglichen Be~ grengungsringe ninter den NadeLn gegen llerazefallen aichern. Vor Kolbanmontage Gherpri- fen, ob in oberen Plevelaugen alle Nadelwaizen /28 stiick/Pleu~ el/ und Begrenzungeringe ein~ gelest sing. In den Walzen miissen sich die Hilfsbuchsen 8-88 Definden, Kolben vorsicntig auf das obere Pleuelauge auf- eeteen, um ein oventuell Fallen der Regrenzungsringe sowie der Walzen in den Raun des Notorschrankes 2u verneiden. 1. 2. EMBOLOS - desnontaje, montaje Bl gorrén de énbolo est4 alojado en el cojinete de agujas sin jaula. Por este razdn no recomendanos aesnon~ ter los émbolos ein cl stil especial para este Fin. En el curso del desnontaie podrian caerse algunas agujas en el motor dando origen a una dannificacién seria del nisno, resp. serfa necesario desensanblar el motor y sacar las Recomendamos €l procedimiento siguzente: agujas. Después de extracr los cilindros Jvor capitulo 1. 1./ obturanes los orificios conducentes a la caja de manivela. Quitams los aros de émbolo y utulizando pinzas convenientes extraemos los seguros de los gorrones de énbolo. En el agujero dei énbolo introducimos la camisa auxiliar 8-88 yen la misma introducimos 1a espiga para expulear a preeién £-87 presto~ ndndola hasta la superficie de apoyo de 1a misma. Quitams el énbolo del ojo superior de 1a biela y valiéndonos de 1a camisa auxiliar S-88 que perma necié entre las agujes en el ojo de 1a biela le aseguranos, incluyendo anbos anillos de conpensacicn originales detrés de les agujas, para que no se eaiga afuera. Antes de moatar los émbolos aos cercioranos de si s2 encuentran ea les ojos superiores de las bielas tedos lee rodillos de aguia /28 pes por biela/ y los aros de ajuste. dentro” de los rodillos tienen que estar intro aucicas las camisas auxiliares S-38. Montemo: al ojo superior de le biels con cautela el éabelo velande por que no se caigan los anillos ae ajuste y los rodillos en el espacio del cérter del motor.must nit oznatent L nebo P Islev¥ P-pravi/ pro ten,kterf ovat doptedu —\ vyfukovym kandiim, K zatlatent pfstnich Seph poutijene opst vyli- sovactho kolfku S-87. Pri nontazi Je mtno dbét, aby odlenovact otvory pist. Gepa smérovaly k valec a Bipka musi sn vnej8£ strand motoru. Piotat copy sejistine pojiztkani. P¥ed nontaé etme, 2da maj{ odpovidajicl taint, novich pisti se pieevid~ ti. A/B nebo ¢ vzhledom k jedntlivyn vélcim. Abychom méli jistotu, %e pfst ve vélei nen{ vyosen provedeme pred Lmontaii pistnich krouzkt kontrolu: Na pisty bez krougkt nasadime proza~ timné vélee a otdtenin K1ikového “mechanism startovact pikou 2kontro~ lajene, 2éa na pist v horni Wvrata aa ob’ strany stejnou vali. Vv pEipadé, Ze Metstivé atdle piiticlaut k jeéné etrant vélce @ 4 pEL odtlatent se vract na tuté® stranu, je tkeba vélce vyinout a ojaici s pistem opatmé pEihnout na fopatnou stranu. Tento kon se nazyvé Ghlovént ojnice. U spréyné vyuhlované Ojnice must aft pist bohem kontroly “stejnou voli na obé strany. JAWA, Zo with the Letters 1 /for the left side/ ar P /for the right side/ for the corresponding cylinder and the arrow must, be oriented forwards to the exhaust ports. Use the press~ oat pin S-87 to push tne piston pins. See that the Lightening holes of the piston pine are orineted towards the engine outside. Lock the piston pins with lecks. when mounting the fresh pistons, see that their identification marks, i.e. Ay B or Cy correspond to the specific cylinders. Make the following check before mounting the piston rings to be sare that the piston in the cylinder is not off the axis: fit the piston /without rings/ provisionally on the piston and turn the crank mechanism with the starting lever to see that the piston has identi~ eal play on each side when it io in the top dead ond postion. If it leans permanently: against one side and, when pushed off, returns to take the original position, take the cylinder out and bend with caution the connecting rod with piston to the other side. This act is called connecting rod angle adjusting. The truly adjusted conrecting road must have the identical play on each side.he piston doit avoir 1a aési gration L ou P /L-gauche, P-arost, correspondante as eylindre ot 1a Eleche doit etre orientée vers Lvavant en direction des canaux dvechappement. Pour enfoncer les axes de piston utiliser de nouveau 1a cheville $-87. Veiller lors du montage A ce que les évidenents des axes ae piston soient orientés vers le face extérioure du moteur. Blequor les axes de pistons par des anneaux de sreté. Avant de monter| de nouveau pistons s‘assurer qu’ils ont bien 1a classe a, B ou © correspondante aux cylindres.| Pour avoir la certitude que le piston nvest pas aesaxé cans le cylindre, effectuer un controle des segments da pistons evant le montage: Monter proviséirenent les cylindres sur ‘les pistons sans segments et feire tourner & 1 “aide| du levier 1 embiellage et, ce faisant, vérifier si le piston au point mort haut 4 le mime jeu ces doux oBtex. 6741 se colle consta~ ment sur an o&té du eylindre ot S741 revient nfme en le repou- ssant vers ce m@ne coté, retirer le cylinare et plier avec précau~ tion la bielle avec le piston de L’autre obté. cette opération est la mise & angle droit de 1a bielle. si La pielie est ainsi convenabiement adaptée, le piston doit avoir pendant le contréle, Le méne jeu de chaque cfts JAWA. oS an Kolben miissen sich die Narkierungen & /~ 1inker zylan~ der/ und & /reehter iyLinder/ befinden, wobet dex Pfeil in Richtung nach vorne 2u den Rasblasekaniilen zeigt. Kolben- bolzen wieder mit Haltestife S-87 hineindriicken, nei dex Montage ist darauf zu achten, dass die Entlastungslécher dex Rolbenbolzen zur dusseren Motor~ seite gerientet sind. Kolbenbol- zon mit Sicherungen sboichern. Bei neven Kolben ist vor deren Montage zu tiberprugen, ob sie cine erntsprechende sortierung 7A, B oder C/ in Bezug aut einzeine tylinder aufweisen. Un sicher zu sein, dass der xolpen am aylinder nicht desa- xiert ist, wird vor der montage Jder Kolbonringe felgeade Kontre- Me vorgerommen: Auf Kolpen ohne Ringe tylinder provisorisch aufsetzen. Kurbelgstriebe mittels Anlassne- pels umdrehen und so iberpriifen, Job der xolpen in operen Totpunkt loetaseitig giaecnes spiel auf- Jweist. ralis der Kolben immer an Joiner 2ylindereeite geproset int jund auch nach dessen Abaciicken zuriick in diese stellung kommt, sind die 2ylinder herauszunehnen jund der Plevel wit den Kolben Inissen vorsichtig in entgegen- Jsesetzte Richtung abgebogen jweraen. pieses verranren wird [pieucl -winkel-Reyelung gennant. Jsei cinem Plesel mit richtig jerecelten Winkel mss der xolben| jéhrend der Kontrolle ein glei~ hes Spiel in beiden Bichtungen wufweisen. EL Enbolo tiene que Llevar 1a cesignacion L oP /L ~ izquierdo, # - derecno/ para tal 0 cual eilindro y la fleche tiene que estar orientada para adelante hacia lor canales ao escape. Para montar 2 presidn los gorrones de émbolo utilizanos otra ver la espiga para expulsar a presién S-87. Efectuando el nontaje aseguranos gue los orificios de alivio de los gorrones de émbolo estén orientados hacia e1 lado exterior cel motor. Aseguranos los gorrones de émbole mediante seguros. Antes de montar Eabolos nuevos nos cereioranos de si tienen 1a clasificacisn respectiva, © sea 2,B 0 C respacto de los distintos cilindros. Para estar seguros de que — el énbolo no esta desalineado en el cilondro efectuamos este control antes de montar los aros de énbolo: = Sobre les éabolos gin ares nontamos proviscriamonte los eilindyos y haci~ endo girar el mecanieno de manivela con ayuda de la palanea de arranqve lamos de si el énbolo tiene 1a Jmismo holgura hacia anbos Lados en el punto mierto superior, En caso de Jpermanecer el mismo adherido siempre Ja un lado ger cazinare y de volver, Jacopaés de separade del mismo a presién, Jai mismo lado, hace falta extraer loo Jcilindros y doblar 1a biela con énbolo Jcon precuacién hacia el lado opuesto. festa operacién se Ilana *angualacién" Jac 1a biela". en cago de 1a biela correc~ fcemente angulada el émbolo tiene que — Jostentar 1a misma toleura hacia ambos jrzaos.1. 3, BRIMARNE PREVOD - spojka ~ demonta® pozog: Provadi se po vypustént oleje z prevodové sk#iné. Sejmeme startovact pfku /pFedem 31 posters: me do startovecs pelohy/ a vy- Broubujene Srouby upeviuifet levé viko notoru. Po sejnutt vika vyéroubujeme 5 Sroubl M6 a vyimene pFftlatné pruziny, Poté ze spojkovéa0 koe vysunene vniteni unageé is laxelaml, odjistine poJistnou podiozku 2 pomocs pei- ~ pravku § 91 trubkovim kitten &. 19 povolime matics upevituj ses ko8 na hlavas hEideli a sejneme — uneBet. Pomoct pifpravku s 98 a k1iSe &, 27 povolime maticd pri- marniho kola. Stahovékem § -35 stahneme priméen{ kolo a soutasné se spojkovym koSen a fetéizem sejmene 2 hreae1a, ~ ve wéesind pEipadi je mond sejmavt spojkovy ko= hes statent primdrnfho Fetézového koletka tak, 1 #e nbkolikrét posuneme spojkovyin ko¥iem na hlavnf hF{deli, Sin? se ndm podakt povysunout rozpérku spojkovéto kela, Povysunutou cozpérku zachytime a vytahnene. Pots Ize kos vyndat. 1. 3. PRIMARY GEAR ~ clutch Disassembly CAUTION Drain first the oi1 from the gearbox. Take off the star- an the starting position/ and undo the Ung lever /seet it fir: bolts holding the left-hand engine cover. Take off the cover, undo the five M ¢ bolts and take off the compression springs. Remove the carrier with disks from the clutch cage, release ‘the lock washer and using § 91 34g loosen with the No. 19 socket spanner the nut which holds the cage on the mainshaft and remove the carrier. Using the S 94 jig and No. 27 spanner loosen the primary gear mut. Using 5-85 puller renove the primary gear plus clutch cage and chain form the shafts. In most of the cases you may renove the clutch cage without having to strip the primary chata wheel, vhile noving a few times the clutch cage on the mainshaft and releasing thus the clutch gear spacer. Grip the released spacer and pull it out and renove the cage.. TRANSMISSION PRIMALRE = enprayage - demontage noma: Effectuer ces opérations aprés la vidange ¢e 1 “huile de la bofte de vitesses. Dénonter la tige d“ambrayace /1“orienter dvabord en position de aébrayage/ et dévieser les vis de fixation du couvercle gaucne aprts la dépose du couvercle, ae carter. aéviewer lee 5 vie M6 at retirer les ressorts de retenue. Retirer ensuite du boitier dembrayage Je sélecteur interne avec les disques, débloquer 12 cale de gé~ curité et, & 1“aide du nontage s-9 et la clé tubulaire n° 19, desserrer 1“ecrou de fixation au bottier sar Lverbre principal, pais aé- poser l’entrafneur. Desserror Lécrou de La rove prinaire & Laide du montage 8-84 et de la elé n° 27, Extraize la roue prinaire au moyen de 1”extracteur S-85 et retirer des arbres simultané- ment le poitier a’enbrayage et la chatne. Dane 1a plupart des cas, on peut retirer le boitier d“embraya~ ge sans extraire 1a roue primaire & chatne en poussant plusieurs fois le bottier a’embrayage sur Lvarbre principal, afin de faire sortir 1“entretoise ae 1a roue avembrayage. Saisir et retirer 1” entretoice, aprée quoi le bottier peut @tre extrait. PRIMARGETRIEBE Kuppiung-Demontage lAcumuxe. Erfolgt erst nach Olablass Jaus Getrichegenduse. Aniasshebel zuerst in Startstellung umdrehen luna dann abheben, Schrauen zur lnefestigung des linken Motorde- Deckel nerapnenmen, tint m6 ~ schraupen lckels herausschrauben. Jsczauschrauber und Anpressfedern Jnerausnehmen. Tnneren Mitnehmer leinschiseselich Lamelien aus Jkuppiungskorb herauschieten, si- lcnerungsblech entsichern. Mit lfe der Vorrichtung § 91 so~ de des Hiilsenschliissels Nr. 19 gutter zur Befestigung des Forbes ut der Hauptwelle 18sen und tnehmer herebnohmen. Primierad- steer mit Hilfe der Vorrichtung js 94 und des Schiiissels mr. 27 sen. Prinirrad mit abzieher ~ 85 herabzienen und mit ‘upplungskorb und Kette von Weller rabnetmen . Neistenfalls kann der Kupp~ fungakorb herabgenonmen werden, ned dae Primirkettenrad herab- zuzichen. Es wird verfahren wie leoigt: Kupplungskorb mehrmals auf Jusuptwelle verschieben, so dass Jaie spreize des Kupplungsrads jerausgescnoben wird. spreize Denn kann auch \erausnehmen. ze Korb hersuegenommen worden 1, 3. SRANSMISION PRIMARTA = enbrague - desmontaje ATENCION: Se realiza después de evacuado el aceite de 1a caja de cambio. Quitamos 1a palanca de arranque /primero la giramos a la posiciéa de arranque/ y desenroscamos los tornillos que sujetan 1a tapa izquierda el notor. Despues de quitar 1a tapa desenroscemos 5 tornilies x6 y extraomos lor mialles de prosisn. A continuacién desplazanos el arrastra~ dor interior con laminillas del cesto de enbrague, desaseguranos 1a arandela de seguridad y valiéndonos del dispositivo § 91 aflojamos con 1a Llave— tubular no. 19 la tuerea que sujeta el cesto sobre el érbol principal quitames ¢1 arrasteador. Con ayuda dol 27 afiojanos 1a tuerca de la rueda primariz [Con el extractor $-85 quitamos esta jMutina y al nisno tiempo quitamos con Ja rueda prinaria el cesto de enbrague Aizpositive § 94 y de la lave no y la cadena de los ejes. zn le mayorfa de 10s casos puede jguitarse 1 cesto de ombrague sin 1 1 Jqaitar 1a rueda de cadena prinaria Jae tal modo que desplazamos ¢1 cesto Jae enbrague varias veces sobre el Jézbol principal con lo que logranos Jaesplazar un poco la piezza distancia~ Jdora de 1a rueda de enbrague. Agarramos lia pieza cistanciagora cesplazada y 1a Jsacomos afuera. A continuaciéa puede xernerse el cesto sin problens1.3.1. moe TAR ~ na Gisty suchy kuzeL Klikového hE{dele nasadime pri~ dent Fetezové kolo a na hlavai Fidel prevodovxy nasuneme pod losku, rospSeku /pied nontsaé roméEime hézivast ée1 rezpie~ v/a prozatinné Fetézové kolo spojky. Ocelowym pravitken pEi~ ofenfm « bokiim kel v nist ozu~ Lent se pfesvédéine, zda obé Kola jsou v jedné roviné, povo~ end tolerance vyosent - 0,5 mm, bi je dbiezité pro #ivotnost ‘Peimdmntho Fetéeu a pro hlut- most prindratho pFeveds. PE fpad- # sichylky se odstrané vypodio- Yeni tetézového kola spojty oce- lovymi pod1ozkami vhedné tloa~ Sky vloienfmi na hlavnt hEféel mezi loZisko a podlozku. Po kontrole rovnopeznosti. spejkové vio epét sejmame, Ped monté~ ww xtartovacths uetroj{ piekon— trolujeme stay téanfetho kroz \ hEidele, Nanontujene starto- Lick Wstrojf, pEi Send hridel poototime do polohy startovant. indrnf ¥etéz nasadime na ozubend Lila a soutasné je nasadine na kuzel Klikového hifdele a na hlavas fol. Na hlavné nE{del nasedine <_AeEne undtet epojky 2 nacazc- nym pryZovym "Oo" kroazkem a nepo- Benoa zajistovact podlozkou. | abet upevnime matics a pod- Jozku zajistime. potéhneme me~ tek primérntho Fetézového ke~ na klikovém hEideli. PES GEchto pracich pouzsjeme pt ip ravku 5-91, 2.3. 4. ASsENERY fit the primary chain gear on the clean dry crankshaft taper and the vasher and spacer /test the run-cut rate of the spacer faces before the assembly/ on the mainshart. Place a steel ruler on the gear flank against the gears to make sure that both gears are aligned /tho admi— ssible to The true alignment is important for the primary chain life expectancy and the primary gear noise rate. 70 eliminate the deviations, if any, of the clutch chain gear fit steel skimp of adequate thickness on the mainshart between the bearing and the washer. Test the parallelity and take ance is of 0,5 mn/ off the clutch goar again. Before mounting the starting gear check the condition of the shaft seal ring Mount the starting gear /nove for the purpose to bee the shaft in the starting position/. Fit the pranary chain on the chain gear, crankshaft taper and crankshaft. Fit the ianer clutch carrier /with fitted on rubber O-ring and undamaged lock washer/ fon the mainshatt. Pix the carrier with nut and lock the washer. Screw hone the primary chain gear nut on the crankshaft. Use for the job the s-91 jig.2. 3. 1. Mowmace 0,3 Aprés avoir de monter le mécanisme de démarrage| contrOler 1“état de la bague a”étanchéité de 1 “arbre. Monter le mécanisme de démarrage tout en raisant routner 1 “arbre A la poeition do aémarvaye. Monter 1a chaine primaire cur les rouse et| aluster simultanément celles-ci sur] le cone du villebrequin et sur Lvarbre primeire. ajuster sur 1 ar-| bre primaire 1“entraineur interne de 1“enbrayage avec’ un anneau élastique et une. rondelle-arrétoir en bon état, moyen de 1"écrou et bloquer 1a Fixer lentratneur au rondelle, Serrer 1"écroude 1a rove primaire A chatne aur le vilebrequin. Pour ces opérations on utilise le montage S-91. teas 1, Auf sauberen und treckenen Kurbelwel lenkegel Primarkettenrad aufsetzen. Auf Hauptwelle unterlage, Spreize /vor Nontage Stirnflichen der Spreize auf Schlag priifen /und provisorich auch Kupplungskettenrad aufziehen Verzannten Radersejten stahl- Lineal bestegen und Gleichach— sigkeit der Rider tinerpriifen, Brlaubto Desaxierungatolerans = 0,5 mm Die Toleranzeinhaltung det wich tig in Bezug auf die tabensdauer der Primiirkette sowie auf das Gerdusch des Prindrgetriebes. Bventuelle Abveichuagen mit Hilfe von Einlagen entsprechender| Stiirke zwischen Rad und Unterlage| auf Hauptwelle korrigierea. Nach Sleichachsigkeitskontrolle Kupplungsrad wieder nerabzienen. Zuctand doe Wellen-pichtrings liberpriifen. Welle auf start einstellen uné Startmechanismus montieren. Zahnréder mit Pr: kette versehen und auf Kurbel- Wellenkegel sowie auf Hauptwelle aufsetzen. Haputvelle nit inneres Kupplungsmitnehmer nit Gunmi-o-sing una undeschiiaigtem Sicherungsblech versehen, Mitnehmer mit Mutter befestigon und Unterlage sichern. mutter desl Primirkettesrades auf kurbelwelie| nachziehen. Bei cbengenanaten Verfahren Vorrichtung $-91 vezwenden. Bes ae Sobre #1 core limpic seco Mounage Jaet sigieiial catenos 1a rueda de leadena primia y sobre el rbot principal de 1a caja de cambio Jcorrenos 1a arande1a, JAistanciadora /antes del nontaje edims o1 banboleo de los Ja pieza frentes de esta vltima/ y provi- soriamente 1a rueda de cadena Jae1 embrague. con 1a regia Jac acero arrinade « los flancos Jac las ruedae_ en ol lugar del Jdentado nos carcioramos de ef ine laos ruedas estan en el mismo plano /tolerancia permitida de Jdesalineamiento ~ 0,5 mm/ 1o que Jes importante para la vida iti Jae 1a cadena primaria y para la ruidosidad de 1a transmisién prameria tuales se supsanan metisncose Las desviaciones even Jarendelas de acero debajo de 1a rueda de cadena del embraguo sobre el érbol principal Jaran- delas de espesor conveniente/ entre el cojinete y 1a arandela. Después de controlar el parale- Lismo quitanos 1a rueda de embrague. Antes de nontar el mecanismo de arranque controlamos fel estado del anillo obturador dei arbol. montanes eL necanismo de arrangue y al misno tiempo giramoe €1 4rbol a la posicién de arrangue.Collocamos 1a cadena peimaria sobre las ruedas den- tadas y simulténeamente sontanos Jostas Wltimas sobre el cono del sigicial y sobre el érbol principal. Sobre el érbol principal lcorremos el arrastrador interior Jaet embrague con e1 anitic ae Jgoma en "0" montade y con la Jarrandela de seguridad no dakads Sujetanos el arrastrador con ayuda de 1a tuerca y aseguranos la arandela. Apretamos a fondo 1a jerca de 1a rueda de cadena pri nairia sobre el cigiiehal. mnpleanos el dispositivo S-91 para realizar estas operaciones,1.4. SROSEA~ monday be hiavagho hEfdele nasuneme naclejovanoa spojkovou tyéku s opérkou. Na buben vnitin{ navlegeme postupné tfect 2 ocelové lanely /t¥ecich lamel je 5 ks, ocelovych 5 ks/. Posledni ocelovou lamelu svez~ ku si pomoct mazactho tuka “prilepine* na tfect lamelu, cok nfm posléze usnadn{ mon- 48, Zkontrolujene spravné zapadnuti gumovéno"o" krouzku do ded%ty bubnu 5 undSeten Jerovien mi 2 drééky vyEnivat asi 0,2 mm, max, 0,3 mm/. Poté vsunene buben vnitiat se svaz~ Ken lamel ¢o spojkovéno Kose a séroveli ozuby t¥ecich lamel urovndme tak, aby prochézely volné do dré%ek kobe. Pozndmke: wa koltky bubnu s undieéen navlékneme pruZiny /masi se lehce posoavat/ a za- Jistime je ponoct Sroubi M 6 5 pruznou 2 rovnou podlezkou. upozornéns! Pied montsi{ lamel akontrolujene tlouitku tfeetoh lanel-roamér 3,5 mm a dale rovinnost ocelovfch lanel- méteno sp4rovimi mérkani na desce max. 0,2 m, Utahovact moment matice M 12x1,25 upeviiu- Hiei spojku je 35 at 40 Na. = nssenbly Pit the ofled cluteh rod /with in the mainshaft and one by one the friction and steel disks /there are five friction and five steel disks/ on the drum, stick the last steel disk of the bundle with grease on the friction disk to make ‘the mounting easier. Check the true E4t of the rubber O-ring in the groove of the drum with the carrier [tho ring should stick out 0,3 ma, but not more than 0,5 ms/. Fit the Anner drun with disk bundle in the clutch cage and adjust the friction @isk teeth to fit loosely in the cage grooves. MOTE: fit the springs /they mast move easily/ on the érum pins fix then with M6 screw plus spring CAUTION: before mounting the disks tent the thiskness of the friction disks /3,5 mn/ and the evenness of the steel disks /neasure on the plate with max. 0,2 mm feeler gauge/. The tightening torque of the M12 x 1,25 nut which holds the clutch is 35 to 40 Nm,Le 5. FOHON RYCHLOKERY Provedene demontaz pri- nérngho pievodu dle kapitoly 1, 3.26 spodnf Seti notoru vySroubujene Sroub M 6, p¥idr- zujicf koncovku ndhonu rychlo- miru a vysunene je) 2 motoru. 4% ndiitku ve spoant eéstt vaitkka levé poloviny motoro- vé skEind of nf roub /Servik/, ktery v nd= Litka zaiéfuje pohon rychlo- ‘oubujems pojist= TyBkou /nejlépe hlintkovou/ vyklepneme téleso pohonu do- vaitl skriné s tésnicim krou2- kem. PFL 2pétné montazi postu- pajene tak, te novf tésniet keowsale @x1627 namunene na hEfdelku pohonu /sprdvad poloha krouzku je tak, kdyz jeho prudinke snéfuje dovnite motoru/ a vhodnou trubkou nebo ndstrékovym k1 {Gem 0 yn&j8in primeru 15 mn opatrné nakleo- neme ponon otvorem ve skt int do ulofent a to tak daleko, af dré%ka na povrehu pohona se kryje se 2éviten ve sk#i- ni pro zajistovact Sroub. zajistovact Eroub po utazent zajistine aOleskem. DOMETER DRIVE and Sealing Dismount the primary gear as described under 1. 3. unbolt the M 6 bolt provided on the engine botton and holding the speedo— meter drive socket and take it out of the engine, unscrew the grub corew fron the lug provided fon the engine housing inner bottom [the screw drives the speedoneter/. Using a stick /preferably an alu- miniun one/ knock the érive casing and the seal ring into the housing space, For nounting, fit the fresh 8 x 16 x 7 seal ring on the drive shaft /the spring should face the engine internale/ and veing a osi- table pipe or a socket wrench of 15 mm outer diameter tap on the arive to push it through the housing to its seat as far fas the point when the groove on the drive surface is in the line wath the thread ror the lock screw in the housing, Once the screw is eorowed hone, drift it with contre punch.JAWA. Sos 1. 6. PRUZINA STARTERU /prinarni prevod odnontovan/ Skertovact h¥{ael pootedine doleva a vysuneme 7 wlozent.Star- tovact segment i s pruZinou vyimeme. PEi zpitné montd#i jeden konec prodiny zaklesnene za hranu secmen- tu a segment poototenin zasunene do sprdvaé polohy tak, aby stfed otvoru segmentu byl v jedné ose se stiedem otvoru v undsetf, pruny konec prugi~ ny se ndm epiré o eadnd oténu skFind motoru, Poté 2acuname starto~ vact h¥iéel /s pru¥inoa/, ktery pootetenim nastavime Go startovact polchy. /erimary gear 1s dismounted/ urn the starter shaft to the left and take it out of its mounting, ‘ake off the starter segment and spring, when remounting the spring, fit its one end on the segment edge. ‘Turn the segment to get it in ite true position, with the segrent hole centre aligned with the carrier hole centre, The other eng Of tho opring eits on the engine housing rear wall. Pit in the starter shaft /with epring/ and turn it to get it in the starting position,1.7. WRfoEL s unésuten = zépaiky Fozent Jprinérn’ p¥evod demontovan/ Heidel starters pootoéine a vyimeme jej spoleéné se segnenten startery a vratnou pruzizou. vyrazime kol{k upeviujic! vatka vypindni spojky na h¥ideli /ze spade nehoru/ a vatku sejmene. Mei Eadie! kulicu a sépadky zacuneme pHidrfovaé 2padoke 8-63 a Fadfef hifdel s undSeten a 2dpadkami opatrn’ vysuneme 2 ulodenf. PFi nonté#i opfene pHidrZovaé 8-53 0 2dpadky und- BeBe a zasunene do ulozent olejem potfeny hfidel. Pritom dbdne te byt aprdvné sacunat nest veatnd na to, apy kolfk und! pradiny v kulise Fazen’. 2 pravé strany motoru nanontujeme vatku poloautomatu spojky. Dalst monta® dle 1. 6. a. 7. SHAPE grm Gear Shift Paw /primary gear disnounted/ urn the starter shaft and take Af off along with the starter segment and return spring. Drive out the pin nich nolés the ciuten-aisengagenent cam on the shaft exon the botton upetaire/ ang take the cam off, Fit the pawl holder $-53 between the gate and the pavis and pull with cau~ tion the shifter shaft with carrier and paws out of the mounting. when remounting the set, support the 5-63 holder against the carrier pawls and fit the oiled shaft in its mounting, See that the carrier pin sits truly between the return springs in the gate. Mount the semi-avtonatic set of the clutch on the engine rignt~ shana flank. Then procced as described under 1. 6.2. 8. DEMONTE? PoLoaurouanzcKsiio vuptuawi sposky ~ ss¥isent Povoline matici pedélu a sejne~ me ped4l brzdy, poté denontuje~ me pravé viko. Povolime Broub upeviiuj ict Larko spojkového bo- wdenu do svorky 2 lanko vyté= bneme, Kigcen 10 vySroubujeme +H: Scouby upeviujfex aebiie vypingng epojky k pravé polovi~ né motora a dr%4k odejneme. Monta provédime opatnfm zpdsobem. POSOR! po nanontovéné poloautonatického vypinn{ spoiky Je toto nutno seffdit: str. 84 DISNOUNPING THE SERI-AUTOMATIC CLUTCH DISENGAGEMENT SBT Adjuetment Toosen the pedal nut and remove the brake pedal. Dismount the right~ hand cover, Loosen the bolt whicn holds the clutch bowden cable in the clanp and pull the cable out. Using the spanner 10 unbo1t three bolts which hold the clutchdisenga— gemert holder on the right-hand engine half and renove the holder. For remounting proceed in reverse sequence, NOTE: After having renounted the semi-automatic clutch disengage~ ment set adjust it /see page 84/1 a/ of of a 9. sBRfzext pouoaunounrr KExO_wpinguf sposuy sejnene pravé vfko motoru se¥izovact Sroub bowdena spojky /n@ bowdena pod hla vou rému/ zaSroubujene /2kré- ime bowden/, ime wolnine Sroub koncovky lanka ve vy~ pinact pice spojky vals mezi vadkou no%ntho vy~ pindnf spodky a wpfnact rolrow seF{dine stavécim Sroubem M & vypinéns sposky tak, aby se dotykaly rile mezi stavécin Srouben @ vypinact tyékou asi Oy1 az 0,3 mm/ seffzovacim Sroubem bowienu spojky se¥fdime radni vypi- ang tak, aby pa@ka epojky na ffaftkéch neméla vOLi a/ bs a + 9 ADoU! Renove the right-hand engine Screw hone the clutch bowden cable adjusting bolt provided on the bowden cable under the frame to Loosen the cable socket bolt pears disencageaenent lever. Adjust the play between the foot clutch disengagement cam and the isengagenent roller with the clutch disengagement bolt M @ to make them touch fon the clutch (the play between ene set bolt is about 0, 1 to 0, 9 mm/. Eliminate with the oluteh howdon cable adjustment bolt the play of the clutch lever on the handlebar.=T 10. SEKUNDKRNE RevEz0vé KOLO = denontae a montaz wvol- aejneme spojkovy auton: nine pojistky gumovych keyti fetésu a sejneme undjad keyt se kunddrniho koletka, Odjist ime pojistnow podlozku pod matics PEi uvolnénén sekundérnim te- tezu vysuneme sekunddrn{ kole’- ko se Hetézen a s vnitinim kry- tom z ulodent. Retéz nenf rutno rozpojevat. onta2 provéaine opatnym zpisoben Mont4% sekunddratho kola prové- afme opatrn’, Kolo musi jit leh~ ce nasunout na arétky, jinek by mohlo éojit pi pffpadnén jeho nardéen{ k posunutf loZiske do motcrové skEiné, ptestoze je lo~ fisko prota pé#néma namdnany 31- BuBno optenou piflozkow. V tonto pESpadé hore{ véiné poskozens Fadseich vidliéek a ko pFevodovky. 1, 10. SECONDARY SPROCKET ~ removing and refitting Remove the automatic clutch release gevice. Loosen tne clips of the rubber cnain guaras, and LIE’ Off the outer cover of the secondary sprocket. Unlock the lock washer under the nut. With the secondary traneniceion chain calckered, pall the sacondary sprocket with the chain ané the inner cover ost of its bearings. It is not necessary to disconnect the chain, Reverse this procedure to refit the secondary sprocket. Be careful when refitting the secondary sprocket, Tt must slide easily on the splines. nore! bo not drive the sprocket forcefully into the bearing as this could result in displacement of the bearing /inside the crankcasse/ in spite of its being secured against normal stressing with buttress plate, ‘The displaced bearing is apt to seriously damage the gear-shitt forks anc the gears of the gearbox.Le 11. BEMONNAD MoTORU 2 RAMU po sejnut{ sedia olpcj ine pojistku u akunuldtoru a sejnene koncovky sviGek. Odpoj ime piivod peliva u nédrze, néarz sejuene, od@roubujene vitho har~ burdteru a yyjmeme bowden se Soupétken. oazzoubujeme matics 4 @ p¥ipeviuj icf ptiruby wifa- kovgch kolen 2 kolena pootoéi- me na stranu tak, aby nam nepfekd#ela. Déle odpo} ime ndkon tachonetru pod notoren a ndhon otdékonéru, Po sejmatt pravého vika notoru odpo]ine kapely alteenétors a po vyErou- povdné Styf Broubi a 6 a vyjmutt ar4x0 uhl teh mbieme sejmout stator alternétoru. Rotor sejmene po vyimutt vatky, za pano- ci péfpravku § 48, odpoj ine kabel o€ Kontakts neutrdlu, Pots vynddme cely svazek kabeld x vo- aitka v motorové skEini. Oapos{~ ine bowden o€ epojkového automaty. a po vysroubovdni tk{ Sroubl M 6 x 20 automat sejneme. Povoline os zadniho kola a matici pfe- yodniku, wrolnime napindky fe~ eu a posunutim kola dopredu Feté2 uvolaime/pro sneanou monté sek. Fetéz. kola/. Sejmeme yntj8f krys eekunddentho koletka, odjistine natici kola a trubkovym ki{Gem 32 am matici odSroubajene, koLeéko vysuneme 4s vaitinin keytem 2 wlozeni. Ketéz nerozpojujeme! pale odSroubvjene a vy}meme pravou stupatk, PEi postoji 7 pravé strany stroje uchopine moter pravou rukou cor vptedu fra’ nadzvedneme a vych¥~ epozkozen{ aku, nejlépe nasazenim rozifznutych za start. kitku, /kLika v poloze start./. Mo lenin doprava vysuneme 2 rému, Dbéme na peyz. hadic na pFeané trubky réma, JAWA. O: A Xt Brouby { evorntk upevinjief motor v rém. ze pravy vélec a levou rukosLs 11. DISHOUNTING THE ENGINE FROM THE FRAME Take off the saddle, disconnect the accumulator battery fuse and take off the spark plug caps. Detach the fuel supply hose from the tank, take off the tank, unscrew the carburettor cap and take off the bowden with the slide. Undue the M8 nut holding the exhau: zo the side so that they would not be in way, Detach the ta bent flanges and tarn the bents joneter arive provided below the engine and the speedometer. Remove the right-hand engine cover, dctach the alternator cables, sndo four MO bolts, take off the carbon brush holders and rerova the alternator stator. Take out the cam using the § 48 jig and the rotor. Detach the cable fron the idling gear contact, and pull the whole cable bundle out fo the guide provided in the engine housing, Detach the bowlen cable from the clutch automatic set, undo three M 6x20 bolst and take off the autcmatic set, Loosen the rear wheel axis and the transmission gear mut, Loosen the belt tensioner and shift the gear forward to slacken the chain /for easy disnounting of the secondary chein gear/. Take off the outer cover of the secondary gear, loosen ihe gear nut and unscrew with the 12 mm socket spanner the nut, and pull out the gear along with the inner cover and mounting. Refrain from uncoupling the chain! Unbole and take off the right-hand foot rest and the bolts and pin which hold the engine to the frane. Standing on the right side, grip the engine with the right hand by the right-hand cylinder and vith the left band by the start crank,/The crank is in the starting position/, Lift the engine slightly on the front, shift 4t to the right and take it out of the frame. Avoid damaging the paint. It is good to £it the longitudinally slitted hose on the front pipes of the frame.IT. DEMONTE! A Mor 2. 1, ZAKLADNE DENONTAZ bo telisti syéraku upnene pfedni cast mo~ coru tak, abychom méli pE{stupnou Levou stra~ nu notore. Odmontsjene karburdtor, pringens pFevod, hlavy vélei, vélce a pisty. Po vyratent notorové sk#in’, do pravé poloviny skéiné motor otofime, vyjne- radaf centrdie 2 levé ar: ne tyéku vypinén{ spojky a vySroubujene 10, Sroub’ M6 spojujicf obs poloviny notorové sk¥iné. skefi vyjmene ze svérdku a polodime na levou stranu. 2. 2. eBreui omonu Jaenontovin alternster = vInitew padlo~ akou a rezpérnfm pouzdren/ Stahovéken S-90 ptifroukovanyn do 2évitd M6 ve sktini /obr. &. 24/ pro uchycen{ stator alterndtoru/, stdhnene rovnonérné pravou polovinu skriné z lozisek kiikovsho ustro}i, pritom abdne, aby pravé ojnice byla v hornt Wvrati @ progla lohea stFadnim vytezem ekEin’. V pifpsdé, 0 pFi stahovént ky se pravd polovina skFiné Ja, poklegnene opatraé na zadni Sst skEing, pEfpadné ototine hi {delem sekandérntho Feté- zového koletka, aby stahoviné probihalo rovno- nérné. Po Edstetnén odddlent polovin vyjneme A vélei, aby monla opnice projit. Dokonéine oaddlent a sejmuts st¥ednt viozku, které Je me: pravé poloviny. Doporuéujemer zajistit jehly proti vypadauts, nejiépe vyplnénim celého Lo#iska tukem PH-Wi2 /LIT0b 24, CASTROLEASE Lli-2 apod. /.ET. DISMGUNTING AND MOUNTING THE ENGINE HOUSING 1. BASIC DISASSEMBLY Clamp the engine front section betusen the vice jaws in such a vay, that the engine left-hand Flank becones accessible. Dismount the carburettor, primary gear, cylinder heads, cylinder and pistone. Drive the rear centring piece from the engine housing left-hand flank inte its righthand flank, teke out the clutch-disengagenent rod end undo the M 6 bolts, which join the two halves of the engine housing. Take the housing ost of the vice and lay Lt down With the left~hané flank down. 2. 2. SEPARATING THE TWO HALVES OF THE ENG! (he alternator with corrugated washer and distance bush is dismounted/. Bolt the $-90 puller in the M 6 thread oles in the housing /sce fig. 24/ /the thread holes hold the alternator stator/ and strip with it uniformly the right-hand housing half from the crank mechanism bearings. During this action see that the right-hand connecting red is in the top dead the housing right-hand naif gets Jamed, knock with caution on the housing rear and/or turn the mitre and pastes easily through the central Lousing slit. 1f, during tne stripbing proccess, secondary chain gear shaft to achieve the uniform otyipping process. Ae soon ap tho tno halves part to same degree, take OFF the mid insert provided between the cylindres to allow the free passage of the connecting rod. Separate the two halves fully and take off the right-hard half. RECOMMENDATION: take sone measures to avoid falling out of the needles. The best way is to stuff the bearing with grease PM-NH2 /LITOL 24, CASTROLEASE LH-2 and the Like/.2. 3. pREVOROVEA ~ Fazen’, V tonto stavu denontoranéno mot- toru 1ze peovést oprayy rychlo- stn{ sk¥in’ a Fadsetho Wstrosi, ani2 bychom vylisovall kiikovy ny PEL kontrole pkevodovky mechanizmus 2 aruné poloy Ken a Earoné vySmeme ty8ka Fadescn widliéek, vidlidky, hi (del péea- lohy, pevodové kola a mékkou paliékou vyklepneme havnt nit del 2 Lofiska. V pifpad’, 22 je tieba odmontovat t6% kulisu Fax zenf, odgroubujene 4 ab1éikem zajigtene zapustné Sroupy v Ku- Lise @ vhodnyn poototenin vyjmene kulicu 20 kin’ cheene-1i vymontovat k11kovy me~ chanismas za WSelen jeho kontro~ ly, pEfp. opravy, pFigroubujere stahovék $-90 avéma Brouby M8 do zévitd pro Srouby levého vika motor, Stahovakem vytlacime kiskové Wstee}f 2 levé poloviny shE Lad. BOL OR! Levd ojnice mst bjt v hort uvrati. JAWA SOS 2. GEARROX = gear-ahigt and crank nechansan With the engine in this dismantled condition, it is possible to repair the gearbox and the gear-shirt mechanism without pressing che crank me~ chaniem out ef the other cxank- ease half. During the inspection of the geargex and ti eoshiet mechanisn, remove the shifter- fork rod, the shifter forks, the layshaft, and the gears, and tap the mainshaft with a soft mallet out of the bearing, If it 13 also necessary to renove the gear ehift gate, remove the four, dot secured countersink screws from the gate, ané take the gate ovt of the crankcase by turning it into a suitable position. If you intend to renove the crank mechanism for inspection or repair, scrov the 6-85 drag with tu M8 screws into the ‘echand crankcase cover fastening screws, threaded holes for the and press the crank mechanism with the drag out of the left~ hand crankcase halt REMBNDER: The Left-hand connecting red must be in its top /T. D.C. / position.2.4, ViMEWA DEMLOW eM LozT5eK PRED. ONDVEHD HRIDELE Po vyimutf pojistek, opotfeband loliska vyrazine vyrd¥e&en dov- nitk skFing. Pro snadnéj8i pra- ci, vymontujeme pohon zychlonéru 2 levé poloviny skfin&. Novd 1o- Ziska vsazujene ao orate pte- ~ — vodove sk#fn /na 60° - 120°ey, Po nalisevént vyplnime logiska optt uke, aby nedoBlo k vypadnuts — — deken. 2. 4. RENEWING LAYSUAP? NEEDER pRARTIGS After the fuses-were taken out, drive the worr bearings into the crankcase with the drift. qo facilitate this job, remove the speedometer drive from the left-hand crankcase half. After heating up the gearkox /80 to 100°C/, fit che new bearings into it. After pressing them hone, pack then with grease to prevent the needles from falling out.2. 5. KONTROLA FovuoseT posspa. fc Proce Po dokonalén o&i8tén{ doseda~ Clean thoroughly the seating efch ploch pEekontrolujeme rovinu urfaces and test the evenness of celé notorové sk#iné podloZnym pra the whole engine housing with a vitken, event. zabrousine na desce. ruler. Grind the surfaces plain - necessary. Clean the Po zabrougeni doseaacicn pioch a plate ifn skting, tyto dOkladné oBistine ground surfaces theroughly of the od brusné pasty. grinding paste2. 6. VEMBNA LO2ISEK A cfcn KROUEKG KLIK, MECHANTSWU| v pe fpad’, He je nutnd vyménit lotiska 2a novi /opottebend hlutnd/ postupujeme takto: Provedeme demontéi notorové sk¥ind, klestémi na pojistky vyjmeme pojistky zajiBtujfet tésnict krouzek. SkEif ohtejeme na cea 100-120°C a vyrazeten 1 vyrazine Lofiske snésem dovnité ok#iné. Vyeatebem §-72 vyrazine t= nfef kros%ek 2 vniting strany sk¥ ind ve. Lo#isko hlavntho hiidele vyrdime ‘obdobnym 2plscbem, po odjistént pojistky a po piedchoz im cdmontovant 2aji8tovact pE{lotky sméren dovnit? trubkou vn8j8{- hop loZiska. LoZisko kola s ndbojen vyrézime obdopnym zpQsoben opét po pledchozim odmontovint 2ajibfovact pE{losky a po vyjmutt kola ¢ nabojom sméren dovnitt skiin&. Monta vech loBisek provddime do sk¥iné onkdté na 100-120°C. Do pfedehidtych polovin motor. skE{n{ vio#ine lo#iska tak, aby byly 2éroveli s opracovanou plochou pro setrvacriky klik, mechanismu. LoLisko Mlavnihe hiidela a kola s nd hojom zasunene ad do hloubky 2aji8to~ vact posistky, kterd must byt pFedam nanontovina. Tésnfci kroufky nazontu- jene a8 po spojen{ polovin sk ini. Po montaEi loZisek Ravntho aF{éele zajistine tyto opét pF {slusnou pF lofkou proti posunutf a Srouby zajis~ tine proti povolent aticrkem. 2. 6. REPLACING THE CRANK-MECHA- NISM BEARINGS AND SEAL RaNGs If the bearing: need be replaced because they are worn or noisy, proceed as described below: Dismantle the engine housing and remove with the lock-ring pliers the lock rings, which hola the seal ring in plac at about 100-120 deg ¢ and drive with the s-71 drift the bearing inside the housing. using the S-72 drift drive the seal ring fron the housing dmstar—wabinouteide, Rele~ ase the lock ring, remove the lock shin and drive out we OUT WARS mainshaft bearing with © pipe of the came outeide diamator as that of the bearing. Drive out the GSiEtpieshub bearing G/ZO¥ dn a sinilar vay after having @isnounted the lock sistmeand pushing the gear inside the housing. ere Prior to mounting the bearings heat the housing at 100-120 desc. engire housing halves getting then in Line with the mactined aurface intended for the crank mechanism flywheel. Push the aainshaft and © [Boye KY BCE Geaeepioenbud betring as far as the depth of the lockking which ust already be in its place. Lng halves have been joined. Lock the mounted mainshaft bea~ rings against shifting with LOCKING PLATES shine and drift the bolts with ceatre panch.efor xrowtx® 2. 6. 1. MiMENA TEs: tBsnfor kroutky, provédime jejich denontaz Posud ménine po a montd? na moteru, 2abudovanén v podvozku, po predchozf demontazt Priméeniho prevodu, denonaze alterndtora nebe sskundéentho Fetézového Kola /1. 9. /. Pokko~ zené tésnict kroudky po vyimu- t{ pojistky denontujene. Nové tUsnicf krouzky narazime a% pe kontrole sprévného spojen{ pro Zinky a potfen{m po obvodé ole~ jem pFipravken s 72 2 9 92. 2. 6. Le REPLACING TRE SEAL ‘RINGS ‘he seal rings alone can be replaced while the engine is peinary gear must be dismounted hefere, az wall as the alternator cr the chain gear /1. 9/ Remove the lock pin and take off the Gamaged seal rings. Then check the true joint of the spring, cil the seal rings and drive the latter in place with the S 72 and $92 jig2. 7. pitevovowxa, cheene-1i mit opravau cob~ Fe sesazenou ptevodevku /v pii- pads vymény ndhradafeh df20 nebo opaku3feich se poruch/, je nutné rapotitat s montaet do polovin skfint bez Klikového mechanism. Ke 2ji8téni eéto vile nasadime do lo~ Eiska pfedlohovy hf{ael sou- casné s kolem 1. rychiosti a obé poloviny skEiné prozatin- nS stéhhene nékolika Srouby, Poruven 2a pFedlohovy hiidel xontrolujeme jeho axidin{f va- Li, kterd mé bjt v romezi — 0 0,6 m. Po kontrole pied lohovy hEfdel op’t vyjneme. Do levé poloviny skEiné vioz{- — ne kontrolované kLikove ustro- jf se atdednim telem /pokud bylo 2 levé poloviny vymonto- — — wino/. Viozenf provédime po ohEat{ poloviny skEiné na 100-120°C. Bri v tomto . pEfpadé un{stnime na ohf{vaé tak, aby byla nejvSce prohes- vana v prostoru klikového 1o- Hska. Ohfdtou skéLi vypodlo- Eime vpfedu a vzadu afevinjas Spal fky a co mono neSrychle- ji do nf vlodine kLikowy ne~ chanismus tak, aby zajiS¥ovact kolik st¥ednfho kruha za~ padl do vybréni v motorové skFini. Pro nasazovand plati, fe kLikovy nechanismus must byt do loziska viozen, aikoliv - ndeilnS narden. PEL nardiens hy doglo k roztFedéné kl ikové~ ho Gstroji a mohlo by se pos- - kodit 1 klikové lo¥iske. ¥ ptfpad’, Ze klikovy mecha~ nisnus v lo#isku avazne, je bs autné je} vytlae: viz demontae motoru/, opakovat ohfey na vyS~ teplotu a provéct opdtné vlozen{, Kulisu Fazen{ nastavime do nékteré ze stted- nich poleh /krajni polohy jsou Ziska v levé nevhodné/. Do 1 poloviné skiine nasunene hlavni nPidel, na ke pérka a kolo, zajistene arae ————_—-G nae én je 332 roz-2. 7+ GEARBOX For the correct reassembly of the gearbox /after its repair and renewal of some part/ it is re~ - commended to begin with the crank mechanism removed fron the ersnkeage halves in order to eneure the maximam clearance of the layshaft. To ascertain this clearance, fit the layshaft into the ballhearing together with the Ist~speed gear and then clamp both crankcase halves togehter provisionally with se~ veral screvs. Move the layshaft forwards and backwards to check its axial clearance which should be in tre the range fron 0 to 0,6 mm. Then remove the layshaft and locate the crankmechanism vith the face plate /if this plate has been removed/ into the left-hand crankcase half heated up to a temperature from 100 to 120 °c. Th under the frontand the rear part of the crankcase half and insert the crank mechanism into it as quickly as possible and so that the lock pin of the centre ring fits anto the recess in the crankcase. Rear in mind that it is not permitted to drive the crank mechanism into the bearing forcefully as this highest temperature must be around the crankshaft bearing. Put wooden blocks woald result in its "uncentering" and aleo in damaging on the bearing. If the crank mechanien becomes Janmed in the bearing, drive it out of the bearing /see the capter on engine dismantling/, reheat the crankcase, and refit the crank mechanism in the bearing. Set the gear-shift gate in one of the centre positions /extrene positions are unsuitable/. Then fit the mainshaft with the spacer and gear locked in position with the wireformed ring {nto the bearing in the left-hand crankcase half. Fit the 16-tooth gear on the shaft splines with its three claws pointing downward. 7. BORTE DE viTesses sf 1a botte de witesses dott dere vrtinent bien assenblée /apz¥s Le rechange de certainas jices ca des panes txequeates/ UL fat in loger dacs tan deeivcarvers anne aabielioge anvurant ia jeu maximal de l“arbre secondaire. Déterminer ce jeu en engageant dans le roulement 1“arbre secondaire ensemble avec le pignon de 1™* et serrer provisoirenent les deux demi-carters pour des vis. Tr Déjuacer 1arhce secondaire pour comadier aon toi aual qui doit Gere da G1 O16 rae vapoace eaute | tecondaire aprés le contzOle. ioger dans ie deni-carter gatche 1-eabiellege contz8lé avec le pitce nidre qu/Ll colt chaufeé curtout de 1“eepace du roulenent do vilebroguin. Poser sous le carter chauffé en avant et en arribre des blocs de bois et engager aussi vite que possible 1“embiellage de manitre que 1“ergot de blocage du disque central pénttre dans 1“évidenent du carter moteur. L“en- T biellage doit Stre logé dans le roulement avec précaution et non enforeé, car 1“enbiellage pourrait @tre aécentré et le roulement de vilebrequin posrrait méme tre endomagé. $i 1“enbiellage se coince dans le roulenent, il faut le retirer /voir le chapitre consacré au désassemblage du moteur/, T chauffer de nouveau le carter 3 une tenpérature supériews et remonter 1embiellage « amener le cadran dulevier de changement des vitesses 4 1“une des positions médianes /les posi tions extrémes sont dgconseiliées/, Engager dans 1e roulement monté dens le deni-caxter gauche 1 “arbre principal /1/ portant aéj& 1”entretoise et le pignon blogué par un fil métallique. Foser dans lee canelares de l“arbre le pignon avec 16 dents de manibre que ses trois ergots se trowvent on bas.Na drézky hifdele viodime ko- Lo 162, se temi ozubei smétu- jfctmi dol0. Do doint = horni ardéky kulisy Eazené vio#ine vodics Copy Eadéeien vidlséer. Hornt vidlicku zdroven zasu- nome do kel 162, ne hlavnim REGdoli. Vidligkani prostrés- ne vodicf tytku esazenym kon= cen dold. Kole 242. vickine plochou strana k jehlovéaw lofisks ana dolnt vidlicha vlo#ime kolo 16 z, t¥emi ozub- ci nahoru. Obe kolecka spo} ine pfedionovj nefdelem opet = podem nasazenjn a sajiBtényn 202. koletkem. Natdéensn kau- Lisy do polchy jednotlivych plevodovych stupii provedem kontrolu Fazen{ avl4Sté v tom pE{padé, je-1i nanontovana no~ v4 kulisa zpisoben déle uvede~ nym. a/ 2atadine 1, pfevotovy stu- pei a kontrolujene eda ko- Lesko 16 2. na phedlohovén hFt= deli apsdaifet do ola 1. ry- ehlosti /242/ nd axidinf vali nejnéné 0,2 -0,3 mm. PH té- 20 poloze kontrolujeme té3, zda je vile mezi voafcimi 6ip~ ky vidlitek @ xoncem ardzek kur Lisy b/ sa¥adime poloha neutrélu mezi 1. a 2 rychlost{ a kon= trolujeme 2da ozuby 162. na p¥edichovém htfdeli neza~ chyewif © elo kola 1, rychlosti a pei nadadvizent dolné Fadict yiaiscky 0 ozupy Kola 2. ry- eniosti /192/ c/ pis razent | ryehiosti né Belo éréikového hlavni- ho hbfdele p¥eénivat z kola 3. eyehlosti 162. 0,1-0,2 mm. Soutasné kontrolujene, zda vo- afet &spky fadfeich vislitek se neopiraji o konce v kulise J viz boo 3./TT 2&5 Pat shifter-fork guide pins into the top and the hottom slots of the gate and fit the top fork Anto the 16-tooth gear on the mainshaft at the same tine. Then thread the quide rod through the forks so that its shouldered end points downwar' | Locate the 24-tooth gear with its flat side toward the needle bearing, and place the 16-tooth gear on the hottom shifter fork with its three clave pointing upward, Join both gears by the layshaft with the previously fitted on and secured 19-tooth gear. Check gear shifting by turning the gear-shift gate to the individual positions corresponding to the individual speeds /especialy if a new gear-shift gate is used/ in the follow ing manner: a/ Shift in the first gear and check vhether the 16-tooth gear on the layshaft meshing with the Lst-speed gear /24 teeth/ has an axial clearance of at least 0.2 to 0.3 mm. Likewise check that, in this position, there is a clearance between the shifter fork guide pins and the end of the gate slots. b/ shift in the neutral between the first and the vecond gear and check that the claws of the 16-tocth gear do aot fuel the face of the 1st-spoed gear and also the claw: of the Ind-spood [N9-t00th/ gear shen 1ffting the bottom shifter fork. c/ When shifting in fourth gear, the face of the splined nainshaft should protrude 0.1 to 0.2 mm fron the 3rd-speed gear /16 teeth/. At the same time check that the shifter fork guide pins are not abutting against the ends of the gate slots /see paragraph a/. Pigs. 29 through 33. Loger dans les cannelures inférieure et supérieure du cadran du levier des vitessed les axes ae guidage des rourchetves de commande, insérer simultanduent 12 fourchette supérieure dans 16 pignon & 16 dente sur 1’arbre principal, Faire paseer par les fourchettes le tige de guidage de ma nidre que son extrémité épaulés se dirige vers le bas. appliquer le pignon 4 24 dents par sa face plate contre le roulement 8 aiguilles et poser sur 1a fourchette intérieure le pignon & 16 dents avec les trois ercots en haut. Raccorder les deux pignens par 1“arbre secondaire au pignon & 19 dents posé davance et verrouillé. Tourner le cadran du levier des vitesses dens la position répon- dant aux différents rapports pour vérifier si le changement des vitesses est correct, surtout aprés le montage d“un nouveau cadran. Procéder comme suit: a/ engager 1a 1"* vitesse et contréler si le pignon & 16 dents nonté sur 1“arbre secondaire ot svengrenant avec Le pignon de 1a 17* vitesse /4 24 dents/ a un Jeu axial mininum de 0,2 & 0,3 mm. YVérLEler égelenent dane catte position le jou entre les ergots de guidage dos Fourchettes ot 1e fond dea cannelures du eadran, b/ engager le point mort entre la 1® et 1a 2° vitesses pour vérifier si les cents du pignon & 16 dents monté ‘sur 1“arbre secondaire ne s“accrochent pas & la face du pignon de 1a 1" et aprés Le soulévement de le fourenette de commonde inférieure aux dents du pignon de 1a 2° /a 19 dents/ ye e/ aprés 1“engagenent de 1a 4° le front de “arbre principal cannelé doit dépasser le pignon de 1a 3° /& 16 dents/ de 0,1 0,2 mm. Vérifier simultanénent si les ergots de guidage des fourchettes de commande ne s“appaient pas contre Le fond des cannelures dans le cadran du levier des vitesses fvotr le point a/ ~ fig. 29 3 332. &. sporent rovovre sxktnt OhEejeme pravou polovinu skEin8 obichnjm zplsoben Jako polovinu Levou, Desedacf plochu levé poloviny sk#in& potfene ts- snicim tmeien. Konce nffaeld ry- chlostn£ skE{né @ pravy klikovy Sop potfene slejen. ta¥adine ne~ NEU otra] mezi 1. a 2. rychlostt a pravou ojnici nateéine do hornt polohy, aby snadnéji profla vj- Hezem ve skiini. Do st¥edného vy- bring skE{né vlozine st¥eant vlo#ku. Dobfe ohrétou polovinu skin’ se vseml 10Zisky \Setné jehlového pro p¥odlshovoe hE {del co nejrychlejl pFilo#ime na druhou polovinu skéiné, pit Zens pootééine kolem s ndbojen, aby pEevoiovd kola mohla do sebe zapadnout. Narazine zada{ centré~ mf klik. Obs poloviny skt {né stdinene Srouby M 6/za@indne oa prostiednfeh/, které po vychla— Gnukt ekEiné JeBt# dotdbnene a proéistime cdv8tract otvor skFin’. ALVES the right-hand housing half the same way as the left~nand one. Coat the left-hand housing half sea~ ting surtace with sealing putty. the titinebetween the 1st and 2nd gears and move the right-hand connec ting rod in the top position to make ie pass easier through the housing slit, Mount the mid insert in the housing nid recess. Heat the right- hand housing haLf along vith all bearings as Well as the councershare nocdle bearing well and join ie a6 quickly aa possibie to the other - housing half while turning the GI OVTEUT guee-plus-bab to get the geare mate each other. Drive in the rear centring pin. Bolt tightly the two housing halves together with #6 potes /scart with the mia botes/. Tighten the bolts once more eéter the housing has cooled doun and clean the housing vent hole,vaitint kroudky kulidkowick Lodisek ne klikevén hE{deli trubkou vhodnéhe Klepneme, aby se dosdhlo sprév~ né polohy kulitek v ob82né aréze loBiska, Loziska pronazeme motoro~ vin) olejem, Harazine oba t8ensot krowtky klikevsho néidele. Pred montd#i kroutki se pFesvédzine, zda konce spirdlové pruliny jsou Féané do sebe zapojeny. Nardzent providine nara%eten $-72, Tésnf- cf kroukky zejistine proti vysu- nut{ pojistkami. Mixné dokjepne- me st¥eani viozku. PEO dalst monté® notore doporuéujene opét upnout pFadné Bist motors do svéréku a postupuieme zpisoben popsanyn v j12 d¥fve uvedenych kapitoléch, Ole} do ptevodevky nalévéme co nejpozdéji, aby do~ Blo k dokonalému zaschnutt t&e- nici hmoty mezi polovinant skri~ née Using a pipe of suitable diameter tap on the ball bearing inner ring to achieve the true position of the balls in the bearing raceway. Lubri- cate the bearings with engine oil. Drive on both crankshaft seal rings. Before mounting the rings make cure that they are duly joined with each other. Use S-72 drift for the driving operation, Lock the seal rings with the lock tings to prevent their shifting. Tap down slightly the mid insert. For the next engine assembly steps clamp the engine tront section in the vice and proceet as described above. Pour the oll into the gear box as late as possible to allow the sesling putty between the hou~ sing halves to ary fully.PEA montaéi postupujeme opatinjm rpsotem nei jak jome provadéli denentéé. P¥ed nonté- 21 artdku vypinant spojky nana~ zene kulléka pod sefizovacim Srouben tukem. Po namontovéns motors do rima motooykiu a za— pojen{ spojkového lanka prove- done se¥izent poloautonaticksho a ruéntho vypinént spojky. 2.9, MomTING THE PRAM At nounting process proceed in reverse sequence of the assen~ bly. Before mounting the clutch disengaging holder coat the ball under the adjusting bolt witn grease. once the engine is mounted in the motorcycle frane and the clutch cable attached, adjust the semi-automatic and hadn disengagement of the clutch.TIX. DEMONTAE A MONA2 xLTKO- vio dstRost 3. 1. DENONTA2 KLIKOVEHO dsrKOot rubkovym Klien 12 od Eroubujeme matice Sroubi stau- 3fei dvojdfiné Gel. Obs polo viny Sela od sebe cddélime. nikay neputivime k rozpojent se~ kdée nebo Sroubovéku. Rfsovact jehlou si dle theln{ku pfiloze- ného k setrvacnikim oznatime ryskaml Jejich v2éJennou pole~ has Nejvhodnajzf je 90% o4 ony ojnitnich Eeph ma oboa polevi- nach. K rozlisovdnt setrvatni- KO a k jejich pozdéjsima sli- soviné je zapottebf nit k dispozicé lise tlaku ces 8-10 tun a specielat pocpérny dvoudtiny pEtpravek /S 203/. Using the eize 12 cubsler spanner, anserew the nuts of the bolts holding together the twopart face plate /Fig. /and separate the two halves of the od plate. Never use 2 chisel or 2 screwdriver for this purpose. apply @ set square on to the rly- wheels ani make index Lines with a ecriber to mark their mutual position /Pig /, preferably 90° from the axis of the cearkpins. For pressing the flywheels apart and for their sub- sequent pressing together, you will need a press with a pressure of about 0 to 10 tons and a special tvorpaxt supporting Sig /8-205 pressing 3ig/3. 2, MONTAZ KLIKOVEHO UsTROIL ¥ adie uvedeném postupa Je popséna monté# rozebraného klik. Wstrogf. PEL provédént ailéfch montd’{ postupujene podle pifsiuinych odstaved.. a/ nejprve nalisujeme do vniti- nfch setrvatnik® ojnitnt Se- py tak, aby jejich cela byla v roviné $ vneJ8£ plochou setr~ vainckd. Copy must amé¥ovat pteané kolno k plofe setrvas— nik. K této préci pouztvame Whelniku nebo voditka, které je sousést{ sady speciélaich pt- praved pro denontd? a montdé kLikovych mechanisni. b/ na Sep levého vnitintho se~ ervacniku nasadime ojaicl s Loficken @ distenénim podlod kami. Levy vn8j8i setrvatnte pHilo#ine, pomocf shelnitku vy- rovnéme a slisujeme, Po sliso- vin{ zkontrolujeme, 24a se rysky, kterYmi byl klik. mechanismus pied rozlisovdnim oznaten kry- 3%, pkSpadné dorovndme 5 pouzi~ tim nédun€ palitky. 2. MOUNTING THE CRANK HECHANISM ‘The aesenbly of the dionantled crank mechanisn is described below. For the specific assenbly operations adhere to af b/ the relevant paregraphs. Press the connecting rod pins in the inner flywheels, whereby the faces of the pins must get in Line with the flywheel outer surface. The pins must face in the precise perpendicular positi- fon the flywheel surface. Use for the job a set square or the guide which is included into the set of the special crank mechanism dia~ ssembly and assenbly jigs. Fit the comecting rod with bearing and distance washer on the left-hand iner flywheel pin. Altach the cuter flywheel, adjust it with the set square and press it in. After having finished the pressing job, check the gauge lines the crank mechanisn was marked with before it had been dismantled /they mus lie in line/. Use a copper mallet for the readjustment 1 necessary.ef a ef po dorovndat viokine levos polovinu do piipravku a s pono! voditka $-204 zalisuje~ ane stiedovy Sep. Na stfedovy Sep nasadine lo#isko 6106 ¢ 36 wyplnéné tuken a roapéiny krou- uek. Labyrintove tesnent nasa~ Gime na tukem potfeny sozpéray kroutek tak, aby jeto ocazent /niB84 8Sst/ suBfovala k pravé poloviné Klik. mechantanu. Poté nalisujene aruhé lotisko, na st¥ed. Sep aasadine pravy wnitin£ setrvatnik /ojnigat Sep je zalisovén,pozor na poo tocens @ 180°/p0 urovnéns po die £20k se snontovanc Levou ranow #Lisajeme. na oinitat ep pravého setr- vaeniku nasadine ojnics = Lo¥iskem 2 distangnini kroudky. Po pFesazent v lisovacim pFi- pravkv usadime k11k. mechanismus cak, aby ognicns Sep py2 co nejvétss plochou opien © seBau Ligovactho bubnu. Poton pEilotine pravs vni8£ setr~ vaénik, ktery urovnéne podle rysek na kolmost k Eepu a sli- sujene, e/ Then put the Left-hand half of the crank mechanism inte the Jig and use the $-20¢ quiding insert to press in the centre pin. Fit the bearing No, 6206 ¢ 36 /packed with grease/ and the dis tance ring on the centre pin. smear the éistance ring with grea and fit on ie the labyrinth packing so that ite /lowor part/ under the collar is turned toward the right-hané half of the crank mechanism. Then press in the other bearing 4/ Pit the right-hand inner flywheel on the centre pin /the crankpin is already pressed an/ so that it is tusned through 160° 7g. /, and after aligning it according to the index Lines, press it together with the assenbled left~ hand side of the crank mechanism. e/ Pit the connecting rod with the bearing and distance rings on the crankpin of the right-hand flywheel and then re- position the rank mechaniam in the pressing jig so that the larsest possible area of the crankpin bears against the side of the press drum. Then locate the right-hand outer flywheel, adjust it in perpen dicular position on the crankpin according to the index Lines, and press the accenbly togetherJAWA Sos KLIKOYY MECHANISHUS = sttedéat - pied stkedénfm Je nutné ptemé- Fit, 2da se rysky kry}{ a jsou v jeané roving. PESpadné odrov- nére poklepem nédénou palitkou pravy nebo levf setrvatntk do 2Adana poloby a zkontrolujeme axidin{ vali ojnic dle tabulky. PEL stfedént nikay nekiepeme na setrvatniky nebo Sepy Zeleznym kladfvken. Pékys-201 nebo speciel~ nfch kledt{ 5-203 poutiiene v pkfpadé, te je tieba setrvaéntky rozevift. 3. 3. CENTRING CRANK MECHANISM Before centring the crank mechanism check that the index Lines coincide and that tehy are in a single plane, If necessary, tap the right-hand or the left-hand flywheel with a copper mallet bring 1t into the required position, and check the axial clearance of to the comecting rods according to the table. When centring the crank mechanism, never tap the flywheels on crankpins with an iron hamer. Use the $-201 lever or the S-203 special pliers only when it is necessary to spread the flywheels apart. Tas) sass 38882pals. povaiovat za zd4kladné voaftko k provédint této price, nebot se jedné 0 ukon, Ktery vyzaduje be vy rovnévén{ Klikevéhe mechantemu popis st¥edéni je moino ooberné vySkolent a peklopen na setrvaénsky prové~ ine vyhradné na vyimutén klik. mechanismu z hrota st¥edfeino péistroje. Upozorkujene, Ze stFedicl pistroj must byt v bervadnén stavu, aby nedoslo ke zkreslent vysiecka métent. pale uvédine ndvod k edatrantn’ ejiseinfeh vysEsch dohy lok vystiednosts ne¥ piedepisuse dckunentace , t. . vy88{ nex 0,02 -0,03 mm obr. &. 1 Povechy setrvatnikd nejsou 7 jedné roviné/nekryif se/ Mista, kde indikatororé hodinky vykasujé maxandint hoanetu, oznatime kEfdow na povechu setrvainsu. Klikovy mechanismis vy3mene 2 hrotl a stfednf setrvatintky podepfeme tak, aby krajn{ setr~ vetnik byl oznatenim nahote. Na eznatend m{sta klepnene dle potfeby médénou palickou, a% dosannene 2dcaneno vysiedku. ‘The following description can be considered a guide to the centring of the crank mechanism, 2 Job vhich has to be done by a skilled and experienced worker. Yor aligning the crank necanism ty tapping the flywheels, the nachaniem haz to bo removed the centres of the centring fixture, This fixture mst be in perfect order to ensure that the measuring results will not be distorted. Here, we also in clude instructions for removing the ascertained excentricity ae viations exceeding those ve commended hy the docusentation, + @. greater than 0.02 to 0.03 mn /Figs. / Fig. 1: Surfaces of the flywheels are not in a single plane /4o not coineide/. on the surface of the flywheel, mark with chalk the points at which the dial in dicator indicates the maximum value. Take the crank mechanism out of the centres and support the middle flywheels so that the outside flywheel markings are on the tp, Then tap the Flywheel at the marked points with the copper mallet until the desired result is obtainedDmista, kde indikéto- rové hodinky zaznamena}i naximin{ hodnoty pozna~ mendme kEidou. V naSen piipad® je cel klikovy mechanismus prohnut. Po vyjnutf z hrotu podepfeme jeden z krajnich se- tevetnik® tak, aby kEfdeu o2- paBond mésta byla vantzu, Pro- 838 S4st mechanismy pFidr#{- me rukou a médénou paligkou Klepnene na st¥ednf setrvatn thy v mist® oznatent, nebo rozpinacimi klektimi S-203, je nono pi ino v hrotech v misté proti canaéent vnitent setrvatnthy xoztdhnout. Btevé @ pravé setrva- Enfky jsou v misté proti ojnignim Sepin sevFeny. Pouzijeme rorpinactch klesti $203, Klikovy nechanismus opt kontrolujene v hrotech a Jedna-11 se 0 nepatrne ro- zevieni, nO¥ene setrvatnthy poncchat v heotech a ponoct pé- ky'S-201 je rozev¥ft. Jsou-i keaing setrvatntky sev¥eny v m{stech proti ojnitnin tepin je nutno je rozevift. Po wyj- muti 2 hrotO uhodine na setr- vaéniky ze strany jak naznacuji sapky. Fig. 2 + mark with chalk the points, where the dial indicator records the maximum values. In our case the whole crank mecha~ nism is bent. Take the crank me~ chanism out of the clamping between the centres, support one end flywheel in such a way that the chalk marke are up. Fold the opposite end with a hand and tap with the copper mallet on the a mid flywheels, on the places where they are marked, you nay expand the inner flywheels apart i at the points opposite to the marks while the mechanism is still clamped between the centres. Fig. 9 + the left ond right-hand flywheels are closer at the points opposite to the connecting rod pins. Use for expanding the -203 pliers. ‘Test the crank mechanism clamped between centres. If the closing is minor, the expanding operaion mey be made with the §-201 lover. If the ond = flywheels are closed at the points opposite to the connecting rod pins, they must - be forced apart, after having removed the crank mechanism from the centres, give the tiywneeis plows in the aire- ction indicated by the arrows.A.nevé a pravé setr- veéniky jeou rozev- Je tieba je v mietech 1 ojniénim cepm seveit. Po vyjmuti = heot@ uhodime na setrvaniky 20 strany jek nan znatuif Sipky. yrozorntut: Upozorfujeme, 4e stBedénf = kontrola provédine tak dlouho, dokud nedosshneme dovolené radi- Sing hécivosti cept kLixoveno mechaniams mexinélné 9,02 1 0,09 mm Po wyatfedind klikevého mecha~ nismu zkontrolujene axiint vile a nanontujene Gisty st¥edns klikovy kruh /ée10/. Pig. 4: lefe~ and right han flywheels are too opened and must be closed at the points opposite to the connecting rod pins. Take the crank mechanisn from clamping between the centres and give the fyvneels blows from © side indicates by the arrows. Nor Go on centring and testing so long until you achieve the admissible radial ron-out of the crank necha~ nisn pins, which must be less than 0,02 + 0,03 mm, acter having centred the crank mechanism test the axial play and mount the cleaned mid crank ring /face/on. 007 ay 002% 006 vtWV. Fouvoz 4.1. Vyjmuts pfednthe Kola Povolime a vySroubujeme matic’ hifdele kola a seimeme podlozku, povoline stahovact Broub hifdele kola na levém kluzdku a htfdel vysuneme. Dbéme na to, aby se pti cemonta2i kola z pfedn{ vidlice neuvolnily brzacve desticky. Po vyimut’ p¥ednthe kola deporutujene vsunout meri bradevé doatishy viotku o stejné tlovstce jako je bra2dovs kotoas, nebo silnéjB{, a tuto zaiistit proti vypadnutf, PFi montééi abéme, aby po vy}mut{ vlozky /nezi bra. destitkani/ Sel kotoxé brzdy lehce nasunout mezi brad. destitky, 2 aby hFidel kela byl naprosto tisty, slabe potteny tukem. Do nasunut’ hEfaeie do hole Hagroubejene matici a datéhneme. Pro pérujeme nékolikrat p¥edng vidlicé a potom teprve stdhnene osu kola Sroubem na levém kluzdku. IV. CHASSIS 4.1, PRON WHEEL REM Loosen and usnerew the nut of the froun west axle and renove the dust protecting xing, toosen the clanping bolt af the wheat shaft on the left hand slider ana shift out the shaft. Watch not to loosen the brake plates vhea removing the vheel fron the front fork. After removing the wheel it to recommendable to enter between the brake plates a filler of the Sane thiskness as the brake disk, OF a stronger one and secaro te against falling cut. During assembly watch the brake disk to get easily slipped between the brake plates after having re-~ moved the filler /between the brake Plates/, as well as the shaft to be absolutely celean and smearek slightly with greace. after slipping the shaft into the wheel, screw and tighten the nut. Push down several times the front fork and only af- tervards tighten the wheel axle with tne clamping bolt on the left hadn slider.JyaMuTE PREONIHO KOLA 638 ‘Odpojime Sroub lanka brady u pée- ky brzdového kliée. OdSroubujene natici héidele kola @ sejmeme pérovou pod- Lozku. Povoline stahavact Sroub ne prave kencovce kluzaku, hfidel vysune- Pei montazi duame, aby hEicel by] naproots cioty, slebs me a kalo vyjnene natfeny tukem. Pe zasunut{ hEfcele de kola nagroubujeme matici 2 dotahneme Propérujeme nékolikeat pfedni vidlici a pak teprve stéhnene Srouben pravou koncovku kluzéku. /Podle névodu sez i- dine brady AWA SZ OS REMOVING FRONT WHEEL 638 Renave the screw fastening the front brake cable to the brake can lever. Unscrew the nut of tha wheel spindle and 1ift off the spring washer. Lo~ osen the clamping bolt of the right~ hand slider and piece, teke out the wheel spindle, and remove the wheel. Before refitting the front wheel, cle fan the spindle well and emear it spa- rinply with orease ted the wheel, tighten the spindle nut and then press the front fork down several times before tightening the clanping bolt of the right-hand slider end Piece. Finally adjust the hand brake Atter having refit- accaraing to @ pertinent instructi~4.2, WOMUTE ZADNHO KOLA VySroubujeme keidlovou maticl Lanks zauni bezdy, adsroubujeme matici ntidele, vejmene pérovou podlozku a vyjmeme nriuel ‘anu. Na levé etrané vy jmome zéchyt ceakce arzdy, rozpérku a vysuneme kolo 2 undSede. Po nachyleni motocyklu ne pravou stranu kolo i s bradavjm vikem s Belistmi vyjmene. PEL apétnd montési p0- stuaujeme podobnyn zadsoben. Péekontralu- jeme voli brzdy /xolo se musi volné oté~ t/, zd2 Je zéchyt veakce spravne nasa ren ve voditku na kyvné vidlies 4. 2. REMOVING REAR wi Screw off the winged nut of the rear brake cable end the wheel spindle _ nut, Lift off the spring washer, and pull the spindle out to the rigne cide. Then remove the brake reaction link with the spacer form the left band side and disengage t! fron the rear wheel sprocket. Tilt the is machine to the right and take out the wheel with the brake cover /backing plate/ with brake shoes. For refitting the reer wheel, reverse tne proceaure heel of its renoval, Check the rear brake Jehe wheel mist rotate freely, the brake mast not drag/ and the correc: installation of the brake reaction Link in the guiée on the swinging arm. 160 wes CUT tbs sin?)4. 3, sexunngenf ter’z Pro furket a Zivotnosti Fetézu je rozhedujiet, jak je provadena jeho Wdriba a seFi- zen. "avin poadavken Je, aby v kaldé poloze kyvné vid tice mb1 Fetés potfebnow whli, tan. He v E&iné poloze kywné vidlice nesmf dojit k jeho Uplagms napnuti. se¥izované fetézu je nutno provadét takto: a/ stro} postavime na stojan, povoline matici héidele zad~ agho Kola /na levé strane stro je/ a adie matics pousdea Foti sového kola /na pravé strané stroje./. Poton povoline pojistnou matict M6 nap{ndku Fetézu na oboa strendch kyvaé vidlice. b/ vlastn{ napindn{ tetézu pro védime postupnym utahovénin broubt cbou napindkd 0 ste}ncu hoanets /napk. 1 1/2 otaoky/ o/ fetée ad bgt napnut tak, aby pEi nadzdvizeni pretem hor- ngho gunovéto krytu /nchavice/ n&1 volny prihyb alespofi o 3 cm. ento prdhyb zeruéuje, Ze pri propruzeni kyvné vidlice 2ati- tengno stroje nedojae x Upiné~ mu napautt Hotteu, keeré by skeacavale jeho Hivornost, pif padné zpisobile poskozent 1o- Hiska fetézového kola v pkevo- dové skFini. @/ déle je natno ébét, aby 2aa- nf kolo pli sefizovind Feté: zu bylo Vv podéin€ rovins vozid~ lay €J. aby obé Kola byle v sdkeyts. & m¥en~ roviny Kol poutijeme vhodné upravenou lat. Nesprdvné rovina kol /tj. zadni kolo nesleduje stopu predniho kola/ nepéiznivé ovliviuje vlastnosti rotocyklu. a 4. 3. SECONDARY cHATN Proper care and correct ten- sionning of the chain are decisive for its funciton end long service Life. re Ls important for the chain to have the necessary slack in every position of the svinging arm, i. e, the chain must never be streched tautly whatever the position of the swinging arm. To adjust the chain, proceed as follows: a/ With the machine standing on ite stand, loosen the rear wheel spindle nat /on the lef hand side/ ana the nxt of the rear-wheel sprocket bush /on the right-hand side/, Then loosen the H 6 lock nut of the chain tensioners oa either side of the swinging arm. b/ ghen tension /or slacken/ the chain by gradually tightening fox loosening/ the screws of both tonsicners by the cane number of turns, ©. g. 11/2 turns /Fig. c/ The chain is tensioned correctly if, after releasing the top rubber chainguaré, the chain can be lifted with the finger at least 3 centimetres, This slack be fully stretched during the ride due to the up and down eving~ ing of the swinging arm, which otherwise would result in shorten ing of the chain service life and damaging ef the bearing of the secondary sprocket in the gearbor. 4/ rt 4s aiso important that both wheels are perfectly slignea when adjusting the chain. to nea sure the alignment of the vheel, use a suitably adapted lath. A misalignment of the wheels /AE they do not follow one and the same track/ unfavourably affects the ricing properties or tne machine.e/ po nastavent vole Fetécu, a vyrevnént kal do jedné roviny detdhnene nejprve ob& po- tice napindku fetézu, jistné ma natict pouzdra Fetézového kola amaticl hE{dele, Po dotazens natic se pkesvédéte, Ze nedoslo k opatnéma napnuti a ze te~ kez mé pledepoany vylyv. Poté sefsaine tadnt brady. £/ konce horn tho gunového krytu ravigkneme do vloteni a stdtnene objimkou. Retéz napne ne zpsobem uvedenym v “napinénd Fetézu' gf setiasne zadnf brsdu a po- piipade tez"brzdovy spinet* o/ After having adjusted the chain ang aligned thi first tighten the loc! chain tensioners, and then the nut of the rea: wheels, Neel sprocket bush and the rear wheel spindle nut. Then recheck the chain tensioning /the recomended sa: and adjust the rear brake and the S70? signal Light swith, #/ Refit rubber chainguard into its mount: ing and secure it with the clamping sleeve. g/ Well reguiate tne boven he end of the top ef rear brake and if needed also the bowden of stop auiteh.4.09. 1. vitwiua, vomuer a NasAzENE sekundéenino fetézu, bez danontdze coloszav¥endho krytu pale uvadénjm postupem provaas- me vyaénu nebo vyimuti Fetéza za pfedpokladu, 22 néme k dis- pozici novy nebo vyBazeny né- hradni Feté: stejné adiky. a/ povolime maticl zadné nes- geie a matiea prevogntky 2a- dnghe kola. evolatee napinary FotS2u a zagn£ kolo po neivice dopteau. b/ odSroubujeme Sroud 2adné tor- af objimky gumového krytu a tuto sejneme, Stahnene horné gunov? kryt /nohavici/ 2 ulozent u zadniho krytu, ¢/ ovaeime zaanim kolem tak aloo ho, a& se na Tevezu /v prosto~ ru ctdhnutdho gumového krytu/ ob- Jevi jeho spojovact éidnek. aby po rozpojeni spojovacthe &ldniu ne- zapadl levy konec Fetézu do ple- chového krytu, zajistime je} pieden tin, Ze mezi véletky Fete au poblize spojovactho éléaku provigtnene slaby Sroubovak nebo tythu, Po stlatent gunovene key- ta 283 ime také provy konce Ee= a/ spojovect Blinek rozpo} ime a pEipo}ime jin konec néhradntho vodictho Fetézu nebo konec nového Fetéu k levé strané plvodniho revezu. RENEMING SECONDARY CHAIN without renoving fully closed chainguara The following procedure can be adopted for reneving the secondary chain provided you have on hand a new or an old, discard ed chain of the same length. a/ toosen the rear wheel spindle nut and the nut of the rear-vheel sprocket. ‘Then loosen the chain tensioners ana nove the rear wheel forward as for as poseible b/ Remove the screw of che rear top clamping sleeve of the rubber chain guard, and Lift off the clanping sleeve. Pull the top part of the chainguara out of its mounting at the guard rear part. ¢/ Spin the rear wheel till the mester chain Link appeare in the area from which you have renoved the top chainguaré part. (Fig. J. 7 prevent the Left-hand end of the chain form falling onto the metal guard after discon necting the chain /naster chain Link/, put a thin screwdriver or "od between the chain rollers near the master Iink. arter pressing a side the rubber guard, secure in the sane manner also the right-hand end of the chain / Now disconnect the master Link and connect the end of the Prepared olé.or new chain to the e original chain which is now ready to be left-hand end of removed ,e/ vymene zejistén! Levéno konce pivodniho Hetiau, nadzvedneme zadni kolo a steinonérajm tahem za pravy jeho konec navléenene Jopatené, abychon neposkoaili la~ kovand nebe chronevané dfly/ ne~ vy fetéz na obb Fetézord kola. Pred opétnyn rozpojentu spe jova~ eho Eldaku eajistéme oba kone navigknutsha Fetéau zphsoben "ec" a plivodné Zetéz odpojine a wi- mene. V péfpadé, Ze jsne uvedenfm zpisobem provedli vyméau za novy Fetéz, zajistime tento novym spo- jovacim Elénken a pokraéujene v préci podle bedu “f* sekunadrnt fetes G1. 4. 3. ¥ pifpad’, Be jome # odet¥ont, ofettine Je} anémin = vyjmuld pouze 2a WBelem zptsobem,opét zanénine 2a vodict Fetéz a spoj ine spojovacin e14nkem. - BOZOR! pojistka spojevactho tlénku must améFovat v/Fezom proti oméru po- you Eetéaat o/ Bake sway the sorewiriver ox rode securing the end of the original chain, Lift the rear wheel, and by pulling carefully and evenly the right-hand end of the criginal chain, slip the new chain on both sprockets. Take care not to damage the varnished or chrome-plated machine parts. Before disconnecting the old /original/ chain from the master chain link, secure the ends of the new chain as described in paragraph c/. Then use the new mater chain link to joia the ends of the new chain, Then adjust the chain as described and fit the top rubber chainguard in its mounting and secure it where with the clamping sieeve. If you have removed the chain only for maintenance purposes, clean and lubricate it in the usual ma sr, and then refit as described above using an auxiliary chein for pulling it over the sprockets. REMEMBER: The clip fo the master chain Link mast be turned with the cut-out in the direction opposite to the movement of the chain. OO > -=e aa, Atzent Ynéna lozisek K(zent ~ dolntho nosnikw /nédre a piedni kolo vymentovéno/ Abychom nohli denontovat kryt avétlometu musime odSroukovat pééku nakldpéni svétioneta, povolit natice na trubkdch plikaéa a vysroubovat ava Broubky M5. Déle odpojime stopspinaé pednf kotougové brady a 2 Haitok denontojene hlavat brzdovs vélec = patkou a zredtken, Ktery rolozine tak, abychom jej pfi dali nontazi nepotkodili. vyéroubovdnim Sty Sroubh 2 horatho nosniku denontujeme soutasné fiditka (Kiera nechéme zavesend na bowdenech spoJky a plynu/ a pifstrojovy panel, Vicor} Cdpes ine rozpojenia dvau avorkovnic od elektro instalace a odSroubovdnin ndhonu otésko- méru a tachometru/. Pro jednedusSi montas je nutné rospojit kenektroy vypinate 2apalo- vant, odpojit klakson a kost¥ ici kabel odSroubevat 04 hornfhe nosniku. Dale poveline 2 vyjmene horns 2dtky ramen vidlice a coubaend povo- Lime Srouby M10. na dolnim nosntku stahu}{cf ramena vidlice, které spo- Leéné s blatniken vy}mene. Po denonté%i pfedaf vidlice @ bla tniku musine Go ramene vidlice zasroubovat zétky, aby se pri neopatrné maripvlaci ole} nevylil. Sejnene pFedn{ ovétlomet spoletné » blikaéi a nechime je viset na kabeldti nebo vhodnjm zpisoben pFichytine k rénové trubee. Po odjisténé a vy8roubovéni horni matky sloupku Fizen{ /klit 8.81/ hozn£ nosnik sejneme. Pow2itim opatné strany klige $.61, povoline spodn{ natku sloupku #zent, apy ndn 2 LoELsck nevypadaly kulithy,pEidezu~ Jeno 04 dolns noentk v hornt polese, Po vytotenf matice spodn{ nosntk opatrné vyjmene, PEA nutné viméné misok F{zeni poudije- me k jejich vyratent de18f ty&ky. Misku 2 dolniho nosnfku pomoci ostrého sekite nejdfive na nékolika m{stech odrazime a pote opatrné sejneme. 4.4. STECRING REPLACEMENT OP snEEAz OF THE LOWER BEARER / the tank ané front wheel dismantled/. Bearmce In order to be able to dismantle the head-lanp quard, we mast unscrew the level of the head-lamp tilting, loosen the auts on tne flasher conduits and unscrew two screws M5, Further, we disconnect the stop switch of the front disk brake and we dismantle from the handlebars the main braking cylinder including the lever and the mirror. We place the main braking cylinder se as not to damage it during the further assembly. In unscrewing tour serevs fron the upper bearox, we dismentie at the came tine the handlebare /that we let hanging on the coupling and gas Bowden cables/ and the instrunent board /that we disconnect by releasing two terminal boxes of the electric insta~ Llation and by unscrewing the speedo neter and tachometer drives/. in view of 2 simpler assembly, it Le necessary to disconnect the comnectors of the ignition exiteh, 40 disconnect the horn and to unscrew the earthing cable from the upper bearer. Further, ve Loosen and take out the upper plugs of the fork arms loosening at the same time the screws M10 on the lower bearer clanpidg the fork az that we take out together with the mud guard, After the disassembly of the front fork and of the madguara, the plugs must be screwed in into the fork arm in order not to pour out ol} in case of a careless handling. : We take out the head lanp together with the flashers letting then hanging on the cabling or attaching 1t in the cultable manner to the frame pipe. on releasing and sereving out the upper mut of the steering coljann /key S-81/, ve take out the uppeiiibearer. Using the opposite side of SHA key 5-81, ve looson the Jower aut of the steering column, we role the lower bearer in upper position in orderPHi xpétné montd#i dbime na to, aby misky hlavy Fizenf byly napinény pfedepsanfm cukem a ob’ lodiska mela po 18 kulickécn 9 1/4" 1635. sn/ uoozornént: ZpBtnou monté% provédime opataym zpdsoben a védy dbéme téchto 24- sad: NeJdi{ve lehce dotdhnene spodnf matici sloupku Fizent a poté povolime o tolik, aby se pohybovala bez lence vidiie vale v lotiskéen. /81iSem §.81 ee dvims osubet/ that the balls do not fall out fron the bearings. After having unscrewed the nuts, we take out the lower bearer carefully oat. - In case of an urgent replacement of the steering bearing shells, we use a longer har to drive them 01 first, we push the bearing shell from the lower bearer by means of a sharp chisel on several spots ané then we take it carefully out. In reassembling, care must be taken tp have the bearign shells of the steering head filled vith the prescribed grease and to see to it that both bearings contain 10 bells of dia 1/4" /6,35 mm/ each. NOTICE: We carry out the reassembly in the opposite way observing alvays the following principles: At first , we recighten the lower nat of the steering column and then lossen it just enough in order that the fork mover in the bearings wi play /by means of the key S-81 with two claws/. After having tightened the upper nuts, St is necessery to verify ence more if the fork moves easily and only then we secure the upper aut. oatav by a ef pREDNE VIDLICE 1. QEVONTA2 RAMEN PREDNE VEDLICE /pfednt kolo vymontovéno/ sejmene kryt svétlonetu fpovolenin vn&i8ich atic tyékach blikagi/ a demonta~ jeme timen kotoudové brzdy /vysroubovénim dvou IMBUS sroupll na praven kuzaku/ cdmontujene pedni blatntk /4 Srouby M 6x16, 4 Srouby MB x20/ / vySroubujeme horn 2étky wvolnine Erouby spodniho posniku /M 10 x 65/ G0 nosné trubky na’roubujene pE{pravek /S-93/ a poklepen uwolnine trubku 2 nosngha. 4.9. PONT FORK -5.1. REMOVING FRONT FORK LEGS /Remove the fcant wheel/ af Remove the headlamp cover and dismantling of the brake disk stirrup b/ Remave the front wing /four N6x16 and four WBx20 balts/ cf Remove the top fork leg plugs @/ Loosen the bolts /M10x65/ot the front fork bottom lug e/ Sorex the 5-93 jig /fork leg axtractor/ into the fork leg tube and tap the tube to loosen it from the lug4.05. 2. DEMONTAY KLUZAKU PREONT upuice tlurige, vfmina eteniné a/ povoline objimky na manietéch ‘a oboje stdhneme z kluzéku 1 nosné trubky, vyjmeme pera Anbusovjm k1iven 8 vySrou- pujene Sroub 10x25 / 2 / ve spodat S4ati kluzdku /1/ @ klu- 24k sejmone vyjmeme podistka /4/, fibrovy krowgek a tlumié stéhnene 4/ po vyimutt pojistky 2ai8€uj ict tésnén{ v hornf Gésti kluzéku simering vy}neme. Tésnicf krou- Zek must byt po kaldé demontzi nahrazen novim. PEL montd2i postupujene cpaényn zpdsoben Snontované rameno naplnine pfed vsunutin pera tlumigovym olejem /viz kap. 4.5.3/. Po nasazen{ ramene do nosniku utdhnene nejéfive hort zatku /5/ pots cotannene raneno Srou- bem 19 ve spednin nosndhu, a/ ” ef as SLIDE Replacement of Seals Release the sockets on the co- Lars and strip both as well as the carrier pipes from the slide, take off the springs. Using Allen wrench @ unbolt the M10 x 25 bolt /2/ provided at the slide bottom /1/ and take off the slide. Remove the lock /4/ and fibre ring and take off the shock absorber. Remove the lock which holds the seal in the top section of the slide and take out the seal ring. A fresh seal ring mst be employed at each dieassenbly ‘The assenbly proceeds in the reverse sequence. Before fitting in the spring, £111 the assembled arm with shock-absorber ot} face 4. 5. 34/+ Mount the arm in the beam, tighten the top plug /5/ and then the ar with the M10 bolt provided in the bottom beam.viuNa onere v pRepwf vEDLECr Jako népli se pou2{vé notoro- vy ole] SAE 30-20. celkové népli obou tlumiéa je 400 cm’ oleje, tzn, 200 em? do ka¥déhe ramene, sumo Cumtex MSinky slows{ eoudaané clei k mazdn{ klv2dkb. Pfod pevné vyménow po vypustént oleje doporutujeme oka tluniée propldchnout proplachovacin olejen. a/ prvni wYnénu oleje provedte pO ujeti prunch 500 km b/ dalse vymeny oleje proveae}~ ke pravidelné po wet! kak Ach 5.000 kn postup price pir véntiv® onese v PREpvf_vrnurer a/ vySroubujeme vypoustéei Sroub b/ pro rychlej8{ vypouBténi ole je 2 tlumiée vyfroubujene hornt pinic{ matice €/ po vplném vypustént oLeje proplichnéte tlumié propla — chovacin clejem / zkontrolujte neposkozenost tésnfcich podlozek pod hla- vou tsnicich podlozek pod vou vypaustéefch Sroubl a tyte zaSroubajte €/ napiiite oba tiuniee olejem 4.5. 3, CHANGING OIL IN FRONT FORK LEGS Use @ misture of danper oli and lubricating o11 of a viscosity per SAE 30-40 mixed in the ratic 1+ 1, and £111 200 c. c. of thie mixtare in each ley /schock absorber/. In addition to the Ganping effect, this mixture also lubricates the slider bushes, After draining the ofl for the fixst. 041 change, it si recommended to Elush both schock absorbers with flushing oi1 a/ The first oi1 change should take place after the first 500 kilometres travelled. b/ Then chenge the oil periodically after every 5.000 kolonetres. CHANGING PROCEDURE a/ Renove the front wheel, place a vessel for catching the O11 under the fork leg, and renove the drain sorav from the outer sida of the eid b/ To make the oil flow quickly oat of the shock absorber, unscrew the tap /filling/ cap mute ¢/ Then flush the shock absorber with flushing oil. a/ Check the under the heads of the drain screws, and then screve in and tighten the drain screws. e/ Finally, £111 both shock absoroers with the recommended oil mixture. tactness of the sealing washer4, 6, UIAMCENE STROJE Provdat se pta dpiném stocent Hiaftek do pravé strany na doraz. KifSck zasuncte do adnku, pooto8ite Jin Goprava a sousnen® zasunete z4nek dovnité hlavy rému, Ki{8ek pooto- &fte doleva a vyjmete jej ze zémka. Tin je Hzen{ uzaméené, odenknati zénku provédite opatnjm xpisobem. 4.7, sufuiut soba K1XGek easunete do 2éaku, poo- bet fte jim dopreva @ soutasné zének vytshnete. Sedlo nadavednéte v pledas Béati cea 9 10-15 om, tahem ved vysunete sedlo te 2échytu na réma, Nasazenf provédéjte v opatnén potadt. LOCKING THE MACHINE ‘The machine can be locked vhen turning the hardlebars to the right as far as they will go. insert the key in the lock, turn it clockwise and et the sane time push lock inside the frame head. Turn the key anti-clockvise and withdraw it fron the lock. To unlock the steering, reverse the procedure of tis locking. 4.07. UEETING ae saDDLE Enter the key into tha lock, turn {t a bitto the right and si- multaneously take out the Lock. Lift the saddle in ite front part approximately 10-15 en. Pulling it forward, disengage the sacale from its cateh on the frame, Have 1t civted on in the roverse order.8. zapnt pfrovént Demonté® tlumise zadntho pérovéng 2a weelem vyminy oleje nebo tésnén{ provédine tak, 2e mezi rozeviené Eelisti svérdku optene dolnt kryt pérovant a PEL stlaseni pruziny sejmeme s télesa clumte, point oko téle- ee tlamie upevnine ve svizdiu a ELStem 22 mm od¥roubajeme 24¢~ ku 2a pistnici s pifslugen- stvim vyjmene 5 V pEipadé, Ze pfstnice se nead a tlumige, Lehce vysunout 2 pracovniho vélee, Je tHeba poklepat mékkyn pEednéten na valce a takto je} srazit 2 vodstha. PEL ka2ad denontdEi tlunise vio#ime de PEeviedné matics nove t&endnk a tBenfol kroviek. section through schock absorber Z£ you intend to disnantle the rear suspension for chanigng the o21 or renewant the packings, clamp the bottom cover of the pucpeneion anit between the jaws of a vice, compress the spring, and remove the bottom cover. Then clanp the bottom eye of the shock absorber in the vice, un~ screw the plug /2/ with the size 22 spanner, and pull the piston roo assenbly from the shock ab= sorber body. Tf the piston rod sticks in the working cylinder, tap the cylinder with 2 soft object to strike it off the guide, Whenever dismantling the shock absorber, put a new packing and sealing ring inte the cap nut. a)4,8. 1. PUNEWE OLEJEN A Mowrdt bo télesa tlunite vie#i- me pracovn£ vélec 8 nalijee 0,047 1 tlumscovéne oleje os-1. opatené vioEime pfstnici 9 pis: é en naSroubujene a dotéhnene zitky. MBkoLikréte vytah= heme a zagunene téhlo pfstnice, abychom se piesvédéili o sprévné funkes tlunize. v pk{padé, 0047 | ON-1 Ze pistnice klade odpor smérem dold, J Je tkeba 2étku povolit a opakovat vytdnnuet @ zasunutf pfstnice, aby veduch neko nadnéené mnetetv{ oleje vyBlo ven 2 tSlesa tlumise 2atka opt dotdhnene. vyse uvedend prdce se providt pti uchyceném dolnin oku tlunite ve evérdku. PFed nasazentm kry- th pot¥eme pruZiny na povrchu slabs tukem, P&i monté2y avoj~ fing pojistry /1/ abine, aby 5ei£ ekosend heana byla smérem ke keytu. péle se pfeavédtine, zda vai ry eilenbloky jsou nepoSkozery. 4.8. 1, FILLING WITH OTE AND REASSEMDLING REAR SUSPENSION = Lace the working cylinder into the shock aheorber hedy and pour in 0,047 Litres of ON-2 damper oil. Carefully slide the piston rod with the piston into the cylinder, and screw in and tighten the plug /2/. Then check the correct: function of the shock absorber by pulling and pushing the push- rod of the piston rod several tines. If you feel a resistance when pushing down the piston red, loosen the plug /2/ and operate the piston rod again to exped the air or surplus oil from the shock absorber. Then retighten the plug. During these operations, the bottom e vice. Berore reritting the covers, anear the spring sparingly with grease. Be sure to refit the cotter /1/ se that its bevelled edge faces the cover. Finally, inspect all silentblocke and renew thom if they are damaged. eye of the shock absorber must be clamped invyoMUTE zapNt xyvug vipurce oes roeposent sekun- adenino Fetéeu/ vymontujene zadné kolo ¢ kyv- né vidlice odpoj ine bowden zadné brady a odmentujene rad- nf fetézové kolo © krytem, kte~ x6 ponechéme viset na Zetézu. gadng tlunic pérovéni odpo} ime © vysunene ze spodnieh denyed po pledchorin uvolnin’ natic horngeh pi chyth 0 cca 4 otss- ky. Na levé strané hiidele bezdového peddlu odgroubujeme matici M10 2 mékkou palidkou vyraz{ne hEfdel i s bradovym peddlem ne pravou stranu. ca- Jistime a vysroubujene jednu z matic hE{dele kyyn€ vidlice, hifdel vyrazime poneet h1int- kového Sepu 2 ulodenf a zadni kyvnou vidlici vyjiene. Po sejmit{ prackovek vyjneme snaé no vy}fnatelné pouzdra 2 meta- loplasta, Sins ot moneaet: VISEIy « metaloplastu hmubou seein viidadna waa) abyohon nezanéni11 polohy bYvatiy, obé- me nato, aby Sep zéchreu reak~ ce bredy byl na Levé strand a taani konec vidiice pled zasunut én do ulofent avednut na tiuniee vytuks. Mueno abée na toy eby netosio k wypaannes ayeieh mlsek a tSanfefen rou REYOVING REAR SWINGING ARN fwichout disconnecting the secondary chain/ Remove the ear wheel from tho rear swinging arm, detach the rear brake cable, and remove the rear-wheel sprocket vith cover while leaving them suspended on the chain. Detach the rear suspension unit / shock absorber/ and slide At out of the hottom retainers after having Loosened the nuts of the top retainers by atout 4 turns, Unscrew tne M 10 nut on the left-hand side of the prake pedal shaft and use a soft mallet to Grive out the chafe vith the breke pedal to the right side. Unlock and un gerew one of the nuts of the swinging am shaft, drive the shaft out of its bearing with an aluminium drift, and take off the rear swinging arm. After removing the dust covers, take out the re~ novable metal-plastic bushes. GAUTHON! on reassembly, be sure ko replace the bushes with their rough side outwards co ae not to change the position of the rear swinging arm. The pin of the brake reaction link must be on the left-hend side, and the rear ends of the arn mast be Lifted above the exhaust silencer before sli- Ging them in their mountings. ‘Take care that the cover plates and the packing rings do not fallGrzdy motocyklu vy2adujt jen obfasné setizent, kdy2 je oblozent Eelisti ponékud onotiedeno, coz se projevi delsim krakem vrzdovjcn pék, t1ige brzd jsou opatfeny uka- zatoli cjetf oblozent gelisti. v piinad® dosazeni krejni polohy aut no oblozent pra uezpetnost jizdy vymenit SEREZENT PREONE OVOUKL GOVE BRZOY a/ nejprve uvalnime dostatetn® natici M5 /1/ spojovectho tahla b/ kEidlovou matici /2/ setidine sprdvny krok, a% do nepatznéno zachytavani spodnt ¢elisti &/ maticl sojovactho iéhle patom phitahnene tak dalece, 9% uet— tine, afi otdteni kols, zachytavani i horni Gelisti. Pate povolime kfidloveu natici M6 0 1 - 1,5 otétky zpat. Zadni brzdu sefizujeme povze kEidlo- vou matici. d/ obs Kola 90 must pf: poatavens mte aa havnt stejan volné otacet The motorcycle brakes have to oe adjusted only occasionaly when the bra~ ke levers have a longer free travel ue to worn beske-shoe lining. The bra~ ke come ore provided with brake-snoe Lining wear indicators. When the indicator reaches its extreme position, it necessary to cenau the brake-shoe 1i- nigs to ensure safe riding. AOQUSTING FRONT TWO-CAM BRAKE a/ first loosen sufficiently the 46 nut /A/ of the tie-rod b/ agjust the correct free travel by the wingea nut /2/ ané check 1t by operating the front breke lever /on the nadiebar/ c/ tighten the out of the tie-rod un til you feel the brake drag /drag- ging of the brake shoes/ when spin- ing the wheel, and then back off the nut by 1 to 1,5 turns. For ad justing the reer brake, use only the uinged nut. / with the motoreycle propped on its parking stand, both wheels must rotate freely, without eny drag4.10.1. KOTOUGOVA BR20A JANA REedn{ kotoutovd treda JAWA se shiéad A. Hlavny vélec = packou jehot soutésti Je sddobka na bezdovou kapalinu 8 stopspinaé pfsdnf bezdy 2, Hadice = pE{vodnim Sroubem 3. Tmen kotougové brady 4. Kotoué nebo po opravé/ potdmnene vEechny tésnfet spoje, nali- Jeme bred. kopaliny do nédobky hlavacho beadového vélee. Opakovanym matkénim pédky pteanf brady dopravine brzd. kapalinu 40 celého bred. systénu /pro urychient mazene opatrné stéfknout brad. kapalinu do tine nu brady oavedudiiovactm Sroubkem, ktery lehce povolime/, Jestli-fe se ném po~ @arito napinit cely systén xapalinou, pro loot mu inek bredy JeJf odvaduindn{. Wa odvedutovast Sroubek, na levé poloving timem brady, naviékneme pri- hlednou hadiéku, 324%: do skleaitey s kapalinou. Pa@ka pEedn{ bredy ntkolikrat zmétkneme a pii stdlem tlaku na pa&ku odvedusiiovact Sroubek lence povolime. Pra prondéknutt patky a2 k rukojets plynu cdveduBliovact Sroubek opt utdinene, druhj kones ponof ine ‘Tuto oparaci providime tak dlouhe, dokud ném neprochézf br2d. systémen pouze Sisté kapa- Lina bez bublinek. Mussme pfi tom abst, aby v né@obce byl stdle dostatek kepaliny. 4.10.1. DISC BRAKE Jaw The front disc brake JAWA is composed 1/ Main cylinder with lever, a part of which is a can for brake fluid and 2 front brake stop signal switch. 2/ A pipe with an inlet eezev. 3/ Disc brake yoke. 4/ Disc. Putting a new disk brake into operation ‘Yprand new, or after repair/ waghten all pressuce tight joints, pour the brake f1uia ino the cup of the brake cylinder . py xepeatedty pressing the front beake lever pump the brake fluid into the entire braking system / to speed it up you may carefully inject the brake fluid into the brake stirrup through the deaeration screw, which your may loosen slightly for this purpose/. Tf you marge to £411 the wnowe system vith brake €luid, you must dearete it in order to obtain 2 1008 braking effect, slide a trans~ parent hose over the dearation screw on the left hand half ot the brake stirrup and dip its other end into a glass with brake fluid, Press several times the front brake lever and under a constent pressure upon the lever, loosen stightly the desacra- tion screw. Under pressing the lever to the very accelerator twist grip. tighten again the dearation screw. Repeat this operation so many tines brake fluid without bubbles flows through until obtaining, that only pt the system, yatch to have always enough fluid in the cup.SS Provoz a fdrZba hydraulické kotoutové bredy 1. Kontrola pied ka%aym vijezden Optické kontrola hladiny bradové kapa- Liny @ tésnostl celdho systema, zkontrolovat funkei bredevého spinate. PF: poklesu hladiny pod 1/2 kontrolntho okdnka kapalins dopinit. Kontrola se provddf pi poloze nte na kelech 5 1 jezdcom, 2. Kontrola kafdjch 2,500 km Optickd kontrola ojet{ oblozent bradovjch destiéek, promazdni Gepu patky. 3: Kontrola kalayoh 5.000 km Provést denontdz bradovch destiéek, akontrolovat tloustku oblogent. V pi fpad’ tloustky men8i nez 1 mm destisky vyménit. bredové destithy Je nutno montovat setfznutim k vatifma $ kotouse /emirem od osy kola/ Poz0r, pKi demontovanych dastikéch oe neamt Pohybovat pakou brady, nie doi ft } vwytlatenf pistku z bradize, Kontrola tloustky bradového kotowe min, 4,5 mm, 4. Hontrola kaiagch 25,000 im nebo 2 roky Demonté% timenu brady, kontrola afla, vyména brzdové kapaliny, prachovex a tésnicich kroutki pfstkt, Provéd’t v odborné dfing, pouzivat pEedepsanou brzdovou kapalinu a provést ochranu Sroubovyen spoja prot korosi, 5. Kontrole 90 50.000 ka nebo 5 letsch Kompletni denont42 brzdového systems Mm. vélec, vrzdic/. Zkontzolovat pracovnt plochy, provést vymenu vsech pryZovjch G4sti /tBendnt, prachovky, soojovect Hadice/ Provadet v odborné dfiné /viz kapitole 4./ Operation and maintenance of the hydrav- Lic dist brake 1, Checking prior to every departure Optical checking of the level of the brake Liguia sino. xD 205 and of the Impereability of the whole system. Checking the fun= ction of the brake ewiteh. refill the Liquid once the level drops below 1/2 of the sight hole. The checking os to be carried out vith the motorcycle resting on its vheels and one rider seated, 2. Checking every 2.500 an Optical checking of the wear and tear of the brake plates 1i- ning, lubrication of the brake lever pin, bisnantling the brake plates, checking the thickness of the Tining. replace the plates in case of their thickness below 1 mm. the Brake pla tes are to be mounted with bevel tou wart the bigger dianeter of the aiak Hin the éizection from the whee! a¢le/. Attention, when the plates are removed, you mist not move the ~ brake lever, the piston coulé otherwise be pressed out of the beske valve, Checking of the Ls thickness of the brake dick, which should be mininum 4,5 mm 4, Checking every 25.000 kn of 2 years Disnantiing of the brake stixcup, checking the parts, brake fluid exchange, replacement of the dust rings and piston cas- kets. Carry it out in an authorized workshop, using correct brake fluid and carry out anti-corrosion protection of the bolted jointe 5. Checking after 50.000 kn or $ yeare Complete dismantling of the brake system - foain cylinder, brake valve/. Checking the functional working surfaces, reple~ coment of all rubber parts /packings, = Gast rings and connecting hoses/. Carry it out in an authorized workshop /eee chapter 4/. Oe >~ JAWA, Zo ~ Servisn{ limity je nutno kontrolovat Service Limits have to he checked min. 1x 2@ $0,000 km nebo Ix po 5 latech. minimun once every 50,000 kn or once every five years.| | Depoatsi timeny kotousovs brady JAMA se provede po dilcladném oBisténé-1 én /aenaturovany/ forzdové tkect segnenty vyjmuty/ Povolime tii imbueové Srouky 4 po jejich vykroubovan{ 0d sehe odd lime obé poloviny timenu. vyjmene pruzncu vioiku a gunové tésnént po vyjnutt protiprasnych nandet vytdhnome oba pfsty. V piipadé poBkozen{ nebo opottebent Ize vyimout i oba t&snfcf krouzky. PEi zpetne monté2i timeny Kotoucové breay apdne na dodrZovdn’ téchto zdsad: 1. Gousseei ee potfou kenzervainim prostied- Kemevyrobce brad pous{vé konzervatnt kapalinu BREOX fluid. ‘ésnici krouek pfstu/novy/se ponokt do ‘6to kapaliny minindlné na 1 todinu pied montdit. 2. Do arétky vélce tinena se vo#{ tés- nfet krouzek. 3. Na pfst se do ardzky nasads protipratns manista a pfst se opatrn’ nasune do vélee t#menu a% do jeko spodn{ poloby. V této poloze Ise manéetu nasunout do arézky na vntj8im obvedu vélce timenu. Do vifezu v levé polovin’ timenu vio%ime prugnou vlo#ku a pro utdentnt Plochy mezi cbéna polovinami poutijene tesnict krouzek a obé polovany trmenu stéhaene Ufent Brouby imbus, Tkeef sognenty vlo#ime do timenu a® pFed monts#{ p¥edniho kola. Dismantling of the yoke of the dise brake JAWA shall be carried out after a thorough cleaning ~ /denatured alcohol/ /erake Friction segments to be taken out/ We have to loosen three dowel screvs and after their unserewing we can separate both yoke halves. we take out the elastic insertion piece and the rubber packing, after taking out dust protecting, sleeves we can extract both pistons. In case of being damaged or worn we may out also both sealing rings, When re-mounting the yoke of the Sige brake wo have te watch 69 pdhere to following principles: 1/ the parts shall be sneared with @ preserving agent - the manu facturer of the brakes uses the preservation fluid Breox fluid. A new packing ring shall be dipped at least one hour before the assembly into this Liquid, 2/ the sealing ring shall be located into the grosve of the cylinder 3/ An antivdust sleeve shall be fitted on the piston into the groove and the piston shall be carefully slipped into the yoke"s cylinder until its hottom position, In this position the weve can be slipped into the groove on the oater periphery of the yokes cylinder. Put an elastic insertion piece into the excision in the left hand half of the yoke, using a pakeing ring to seal the surface between both halves and have both halves clamped by three dowel bolts. The rrictien segnents shall be put into the yoke only hefore mounting the front wheel.1. Demonté# niaynfno vdlce se provede: Lf Procegure of dismantiing the main po vypusténi bredové kapaliny, oddrou~ oylin bovénén hadice, denont4is pathy a dtkladném after discharging the brake fluia, o18ténS-1{h/denaturovany/. unscrewing the pipe, dismantling Po demontééi prachovky a vyjmut{ pojistky leh the lever and thorough cleaning vysunene vechny vnitin{ soutésthy. /aenatured alcohol/. After dismantling the dust cover and 2. Monta hlavnfho vice provedene opatnym removing the safety piece one can zpasobem, a pfi dodrZeni téchto zésad a. Dbéae na t0,aby nedoBlo na pfstech k zduéne easily pull out all internal parts. maniet /ptedn{ a sadn{ / a k jejich podko- 2/ Ascembly of the main cylinder is to be zeni pit nonedit. arried out in the raverse way and b. DodrEujeme maxindln{ Sistotu a nové manzety with the understanding that following Jaunitky/ miningin& na 1 hodinu pfed ront42{ principles shall be maintained: ponofine do kapaliny BREOX fluid, a/ We watch not to confuse the sleeves on the pistons /the front one for the rear one /and aot to damage then dering the assenbly. b/ We have to maintain maximun cleanliness ané have to have new sleeves /of rubber/ Aipped for at least one hour before the assenbly into Broox fluid. 1 ~ vitko, 2 Broup NS x 14, 3 - podlotke 5,3, 4 - valec Mavns, 5 ~ pruéina, 6 - manZeta, pfeant 7 - pist ptednf, 8 - nanieta zadni, 9 - podlozka, 10 ~ pojistka, 11 - prachovka, 12 - zadnf pfst 13 ~ méen. 1+ cover, 2 - screw MS x 14, 4 - washer 5,3, 4 - main cylinder, 5 - spring, 6 ~ front sleeve, 7 = front piston, © - reax sleeve, 9 - washer, 10 ~ safety picce, 11 ~ rear piston, 13 ~ bellowsGoRZ0A - pormfraDe viMENA Koroute Peon! sazov PE potkozené nebo nadmirnén opotietend je nutné kotous vynénit, Jestli prac. plochdch jemé ry, nenf t¥eba kotoud pfebrugovat ani ménit 2a novy. Tento jev je zoela bbénf. Je-1i v8ak kotoud poSkozen viditelnéji /hlubsf rfhy/, Ize je} ptebrousit. ge to véak velmi problenatické, protoie je natné brousit soucasné obé strany /pri brouBent jedné strany se kotout krouti/. Kotout nesiif byt sleb5{ nek 4,5 mn, proto oe ade 2 fe jsou na jeho kalaé ctrany obrousit peuze 0,35 mm. PFL viminé kotouse je nutné dbét, aby hézivost kotoute byla min. 0 » ideéin{ rovina /maz. 0,2 mn/ MAINTENANCE ~_AND/OR REPLACEMENT OF THE FRONT BRAKE DISK ‘The disk must be replaced either ‘whem danaged or when the disk is exce- ssively worn out. If there are fine marks on the face, it is rot necessary to regrind the disk nor to replace it by a new one. This yenonenon 1s quite normal. However, if the disk La damaged more visibly /the marke are decper/,it may be Feground. This is, however, very problematic because both the sides are to be ground at the sane time /when grinding on one side only, the disk is twisting/. The disk mst not be thinner than 4,5 nm, therefore it can be ground ~ off only 0,35 1m on each side. in reply ng the disk, care shoud be taken that the cxeentrie be mininum 0 = idela plane /max. 0,2 ma/.4.11, viutwa Kuurtxovsio yo. 2iSKa_zaDutHo RerBzove- HO FOE Po vyjmati zadn iho kola vySsoubujeme kiséem 22 mm matics Fetézového kola, které i s kryten vyjmeme z ranene kyvné vidlice. Odpojine objiaky na zaanich konefch /prutnf keyt Feté2u/ a po cdSroubovént dvou Sroub’ NS rozpo} ime obé poloviny krytu a fetézord kolo vyjmene bez reepojovén! Feed 20. vylisujeme nebo apatend vyklepnene rezpérné pouzdro a z pravé strany Fetézového kola vyjmene rozsrnou vjozku, pra~ chovka # pojistku lo2iska, Lo- Zisko vyrazine trublou ze st: ny undSete. Nové lotisko ‘nalisujeme trubkow pEiblizn 0 prd- mira yn835iho krousku lo~ Hiska. Nikdy nenardine 1o#iske na vnit¥at krouzek, doflo by k poBkozent loziska. LoZisko pied uzavFeaim prachovkami Promaieme taken PM-NH2. 4. 11, RENEWING BALL BEARING OF EAR-WHEEL. ET After having removed tne rear wheel, unscrew the aut of the sprocket using the size 32 spanner, and then take the sprocket with its cover out of the tear swinging arm. Detach the sleeves on the rear ends /flexible chainquard/, remove two M5 screws, and separate the two halves of the chainguara. Now you can Lift off the sprocket. without diseannecting the chain Pig. /. Then carefully press or drive out the spacing bush and proceed to remove the spacer, the Gust cover and the bearing lock ring from the right-hand side of the sprocket. using a tube of @ suitable diameter, drive out the bearing from the side of the driving lug and then press home the new bearing with a tube having approximately the éiane- ter of the bearing outer ring. Never Grive in the bearing over the inner ring as this vould result in damage vo the bearing. sefore reriteing the duet covers, lubricate the bearing with PN-NH ? grease.4. 12, YYMENA KULI@Kov¥CH Lo: 2ESEK PREDNTHO A ZADNT- HO KOLA vyjneme viko bradevéno bubnu $ @elictni a 2 obou etran ndboje hola opatend odstranine prachovky, Po sedmut{ pravého krytu bubsu /u pkednsho kola/ vy- Jmene pojistku lo¥iska az protilehlé strany zarazine pomocnou trubkou drubé lozisko tak daleko, a% lodisko které bylo odjisteno vypadre. vysmeme ro2pérnou trubku a Lisova- now pedlo#ku lofiska. zbylé lo¥isko wyrazime ponccnou turb- kou zpét na druhou stranu ndboje. PEA 2pitné monté3i postupujeme ndsledovni NeJdFive vlo#ime lisovancu pod~ lozku co té strany naboje, kde Je lo¥iske 2a5isting pojistkou 3 0 tsk, aby Je3¢ vypoukls strana améFovala do nébese. Po= mocnou trubkou zalisujere nové Lozisko /tlakem na vn8j8£ krou- %ek lobiska/ a% dosedne na pod- loBka a zajistine jej pojistkou, % druhé strany bubnu vio- zime rozpernou trupku, kterd mysi zapadnout do stfedu liso vandipodlosky a nalioujene arché Lo¥isko. V lo#iskéoh must byt Efstedné 4 v nébopi tuk PM-NH2. 12. RENEWING BALL BEARINGS OF FRONT AND REAR WHEEL Remove the brake back plate with brake shces, and carefully remove the dust covers from either side of the nub. After naving removes the right-hand brake drum cover /of the front wheel/, take out the bearing lock xing, and drive the other bearing form the opposite side with a suitable tube Until the unlocked bearing faile out. Lift avay the distance tube and the stamped wacher of the bearing. Then drive the remaining bearing hack to the other eide of the hub, again using @ suit able tube. 70 REFIT THE BEARINGS, PROCEED AS FOLLOWS, ! Firat put the stamped washer in that side of the hub where the bearing is secured with 2 lock tube, press in the xing with the convex side of the Washer turend inside the hub. Using a suitab new bearing /apply the tube on the bearing outer ring/ t111 1t bears against the washer, and secure At with the respective lock xing. Proceeding from the other aide of the brake drun, insert the dia~ tance tube, uhich must fit into the centrs of the stamped washer, and then pr iH 2 grease bearing. The bearings and also partly the hub must be packed with Puaiiupen munrte Po demonté#i sedla, hotnich schrének a palivové nédrie sejmene téenici kryt z umélé hmoty zabroiujicl vnikdat netistory do prostora pod sedlen # cdej— meme plastikevou spoiku mezi karburdtoren a tdlesem tlunite sani. Sroubovékem vytotime Sroub stahujicf k sobé podsedl schrnku a téleso tlumise sdni. Naklopenim smérem doptedu opatrn’ vyymene téleso tiumite 2 rdmu, 4.45. jumit_v¥ruKy, Levy i pravy tlumit je zaménitelny po obrécen{ arééku, Po vyjmutt tlunicf vlogky dopo- rucujene vysnout cely tlumé a viozku vytieeit vhodnow trubkow se omiru od vyf. kolena, p> of Sroubovanf évou Sroubl m4. ced tlunfef vodka je rozebirateln4 ovlem dodéva se jako celek. Matky M5 na konci viodky nikdy nepovolujeme pli smontovaném tluniti!!! Pri jejich dotahovnt abdne na to, aby nedoslo ke rborcent pEepstiy koncovky, cok nO¥e mit 2a ndsledek Spatnow prdchodnost vyfukovych plynt. 4. 14. TAKING OF THE INTAKE erEENcER Take off the saddle, side boxes, fuel tank, plastic seal cover /which prevents drain of dirt into the space below the sadéle/ and the plastic coupling provided between the carburettor and the intake silencer casing, unbolt vith a screw driver the bolt which holds the saddle box and silencer together, tilt the silencer casing forward and take it cautiously from the frame. 41s. AUST SILENCER The right-hand and left-hand exhaust silencers can be interchanged after reversing the res~ pective brackets. If you intend to take out the silencer core, remove the complete exhaust silencer, land push the core out in the direction from the elbow pipe using a suitable tube after having re~ moved two M4 screws. The exhaust silencer core is disassenblable, but is delivered as a unit. Never loosen the N 5 nuts at the end of the core if you do not intend to dismantel the exhaust silencer! If you have loosened them, retighten then carefully so as not to warp the baffle in the tail pipe which would then obstruct the passage oF exhaust gas.JAWAL CARBURETEUR — VERGASER - CARBURAUIE Le. KARBURATORLEGENDA E. 1. Soupétko kompiecat . 2. Jeblovy venti @ 2 hompletnt 8.3. tryska volnobénu /40 8. 4, Teyska pEfdavnéhe systéma /72/ 8. 5, Teyaka hlavat /638 - 92, 639 - 92, 640 - 100/ &. 6. Jehla Soupacka 8 7. Polistka jenly LEGEND 1 = Sleeve valve, complete 2 = Needle valve, dia 2 mn, complete 3 = Slow running Jet /40/ 4 = get of auxiliary system /72/ 5 = Main petrol jet /638 -92, 639 - 92, 640 - 100/ 6.~ Fuel netering needle 7 = Needle securing clip LeceNDE no. 1 Cheminée compldte no. 2. Pointeau diam. 2, complet no. 3 Gicleur de ralenti /40/ no. 4 Gicleur de syst®me auxiliaire /72/ no. 5 Gicleur principal /638 - 92, 639 - 92, 640 - 100/ no. 6 Aiguille de cheninée no. 7 Arc@toir d“auguille LEGENDE L ~ volist. Schieber 2 = Vollst. Nadelventil ¢ 2 3 - Leerlautdiise /40/ 4 = Kaltstartatse /72/ 5 = Mauptduse /638 - 92, 639 - 92, 640 - 100/ 6 = Sentobernadel 7 = Naaelsicherung cue No. 1 Corredera completa No. 2 vaivula de aguja # 2 complera Wo, 3. Tobera de la marcha en ralent£ /40/ Yio. 4 Tohera del cistena adicionador /72/ No. 5 Tobera principal /638 - 92, 639 - 92, 660 - 100/ Ho. § Aguje de 1a corredera Wo. 7 Seguzo ée 1a aguja ee eee G@> eee ai TECUNTCER DATA setéaent karburétors Je stanovenc pode vfsiadid skoteks Hiiadnt set eens Je provedeno of virobce., polohe ehly I. e4ter of thera Sroub volnabth povolen © 1 ot, VfSka hladiny paliva v plovdkové komote, méfené od délfcf roviny télesa 2 plovékové konory, —pfi tlaku 1,837 kPa/280 nm sloupoe paliva/, je 11 f 1 mn, Foullté trysky Jeou ornadeny prdtolovimt hednctant SOHED-JTHOV. YECHNICAL DATA ‘The carburettor adjuctenente are determined in accordance with test results. Basic adjustment of the carhurettor {= done in the factory. The noodle ie in the second notch from the top, the fast-idling screw ie backed off by 1 to turns t ‘The height of the fuel level in the float chamber measured from the carburettor body and float chamber dividing plane is 11 + 1 mm at a pressure of 1.837 kPa 1250 mm fuel colum/, The used jets are marked with the Somet - Jikov through ~ ‘es flow values. canacrentsriquns Le régiage du carburateur est déterming dvaprhs le réeultat des essais. Le réglage fonéamental est assuré par le constructeur /aiguille au second cran du haut/. La vis de ralenti est dévisée de 1 \ tours. Le niveau du carburant dans Ja cuve & niveau constant est A la pression de 1,837 kPa /250 nm de colonne Ge carburant/ de 11 * 1mm, mesuré & partir du plan de joint du corps et de la cave 2 niveau constent. Les gicleurs utilisés sont désignés par les valeurs de debit fomet - dikov. TECHNISCHE DATEN Der Vergaser wird entsprechend den Priifergebnissen eingestellt. Die Grund- einstellung wird im Herstellerwerk vorgenommen, Dabei liegt die Nadel an gveiten Einschnitt von oben, die Leerlaufdiisenschraube ist un 1 Undrebungen zurickge- mi Greht. Der Krartstoftpegel in der scnvimnerkammer betragt 11 t 1m, genessen von der Teilebens des Schwinnerkamnerkirpers bel einem bruck von 1,837 ka /250 mm kraftstoffeiule/. Die verwendeten Diisen sind mit Durclsatswerten Gomet - Jikov narkiert. CARACTERISTICAS TECHICAS BI ajuste del carburador 1 determinan los resultados de los ensayos. EL ajuste bisico estd hecro por le rabricante, posicién de la aguja - segunda entelledura desde arribe. 21 tornillo de la marcha en ralent{ aflojaco en 1 yocltae. La altura del nivel do combustible, en la cfimara de flotador, nedida desde el plano divisoric del cuerpo y de 1a cénara de flotador, asciende a a 1 nm a 1a presign de 1,837 kPa /250 mm de 1a colunna de conbustible/. Las toberas utilizadas van designadas con los valores de paso de Sonet-Jikov.Tye, TYPE, Tipo 638, 639, 640 Bryska hlavni 92 100 nryska prfdavacho systema 2 veduingh pi{aavného aystému 120 Teyska ekonostate 50 ‘Tryska syti¢e a5 ‘Tryska volnobshu 40 nryska vyistéat volnobéhu 80 Sroukek volnobéha 1£0,5 ot Poloha jehly I. 2éfez zhora Jenlovy ventit p2 Main petrol Jet 92 100 Petrol jet of auxiliary eystem 2 Air jet of anciliary system 120 Fuel economizer /Ekonostat/ jet so starting device jet 85 Slow running jet 40 80 Auxiliary Ldling jet /at idling oritice/ Past-idling screw Needle position 1 20,5 cow Ast notch from top. Necdle valve dia. 2 Gicleur principal 92 100 Gicleur de systtme auxiliaire n Ajutage dautomaticité 120 Gicleur a”éconostat 50 Gicleur de bistarter 85 Gicleur do ralenti 40 Giclour de sortie de ralenti 80 vis de réglage ée ralenti 1 £ 0,5 tours Position de 1“aiguille 21°F cran du haut Pointeau aan. 2 nauptause 92 100 Kaltstart-Kraftstoffduse n Keltetart-uftduce 120 Gronostatdase 50 sehockduse 8s Leer laufduse 40 beerlaufmundungsduse 80 Leerlaufluftechraube 1 + 0,5 umar Schiebernadellage I, Einschnitt von oben Nadelventi2 a qobera principal 92 100 mobera del sistema adicionador n camara de aire del sistema adicionador 120 obera del econéstato 50 ‘obera del cebador 85 ‘obera de la marcha en ralenti 40 ‘Tobera de la desembocadura de 1a marcha en ralenté 80 tornillo de la marcha en ralentt 140.5 woelta iF entalladura desde arriba Posicidn de ta aguja divala de agusa o2 ———_—————Ce) paa 5.1. PRBHL uézev tarovka tarovka Bérovka 2érovka Rarovka tarovka Larovka tarovka tarovka EKTRTC) aaRtzent sportepre6 canadien, zv=60/ 55" 45/408 avai 12v-21W ava 1ay-an lav -W 12v- aw azv -2W Pouzitt ks Hlavat svetio Hlavag avétlo 1 Readowé avétlo vkazatelé sméru Koncové sv&tlo Parkovacé svétlo Kontroiné Z4rovey Osvatlent tacho. Osvatient ote. Vv. ELECTRICAL EQUIPNENT 5. 1. EIST oF pULBS __Rating_ Use anti Bulb /twin filament/ 12v-45/40W Headlamp 1 Bulb H4 12V-60/550 ead lamp 1 Bulb 12v-218 Stop signallight 1 Bulb 12-21 Direction indicators 4 Bulb iav-aw rail tight 2 bulb 1av-an Parking Light 1 Bulb 120-20 relltale lanps ‘ Bulb 12v-20 Speedometer lighting Bulb 12v-20 Engine-speed indicator}SERIZENT SVETLOMETU A ZADNY Zetitent matosyklu 0 PEROVANT SeFizent zadniha nérovani Posice 11 Posice (II. | Posice IV Nezatizeny ; /vlastni haotnast vozidle/ 1 Repouttvat | nepoudivat dezdec 75 kg 1 nepovzivat | nepouzivat Jezdec + spolujezdec 150 kg nepou2ivat 2 nepouz ivat Jezdee + spolujezdec 100 ke RepouELvat, | aepeuztvat 2 + zovazedls Poznénka 1 ~ havnt svatlo v 2ékladef posici, tj. - 1,3% 2 ~ hlavni svétlo sklopené korekénin zafizenim Sefizent zadnich prusicich elementi do polohy I. se u notacyklu Jawa 350 typu 639 nepravadi 1 Loading of the motorcycle ADJUSTEMENT OF THE HEADLAMP AND REAR SUSPENSIONS Adjust the rear suspensons sod Gigoine 90K | papyaett | pga apts | Note 1 = The headlamp in the hase position /-1,3%/ 2 - The headlanp in the inclination position Adjust in the position I is not work !a 5. 2. VENENA 2AROVEK VE SVETLOMETO Po denontazi optické viozky nejprve o¢e}- neme svorkovnict, potom plastikevoy obj nku ratladine 9 poototine Jf enéren doleva a vyou- PAL SUPER muti vyinene. Tn jane uvolnili £ obj gale Farovky cbrysorého avBtla, kterou nizene vy1~ CHAMPION nowt 2 optické vlozky. 2érovku hlavnich sve tel vyimene 2 objinky obdobnja 2pAsoben. PHL BOSCH nontd#i abéne na sprdvné nasezent 2ézovky do LODGE Cyfer8 vlothy a nakeuth plaseitové ob day to sybeant v sikrathr optiché viotiy a ta to, tor byl eoeye prutngwo Loneattu e patio KLG rovky obrysového svétla, NGK 5. 3. gapaLovact svftxy Yootky bez odgoru/ ndzev BEEnj provoz PAL SUPER NReLS, NEO, N15, Nad cuawes0n 281 osc w 225 m2 Loose 2 aN KLG F 75-5 80 NK Be 7 HE 2. RENEWING HEADIMAP BUL! ake out the headlamp insert, remove the terminal board, and then push and rotate the plastic socket anti-clockwise to disengage it. By pulling it out, you will also release the socket of the parking light bulb so that it can be renoved from the headlamp insert /reflector/. To remove the nain, twin-filament bulb, proceed in the same manner. When reinstalling it, take care that it fite correctly 1 the cut- outs of the neadlanp insert/reflector/. Likewise, the collar of tne plastic socket mst £it in the recess of the heedlamp insert collar, and the felxible contact must touch the base of the parking light bulb. 5. 3+ SPARKING PLUGS /cable shoes without resistors/ Make ype deeignation PAL Super NRCS, NR-14, N15, NoLd Champion Lat pozeh W225 7 Leage 2s KLG F 15-F 80 NGK Ha,JAWA 0S settzent phessezay 5. &, IGNITION ADVANCE aDTUsmuENT ruco préei mizete provést prt you may carry out this job dodréené déle avedenéne postapu, Péedevsin by yourself, if you adhere to che je nutné skontrolovat dotatent upeviovactoh folloving procedure. Firat of all Sroubd statoru alterndtoru. Pi viastnin 1s it necessary to check the dagres sefizovént plati, Ze pledstih pravého of tightening thefixine scrove of the rélee setizujene nejative, a to hornin alternator stator. When adjusting pterusovaéen. Pfed sanctnjn sef{zenin the advance, the rule fas to be pledstinv je mitno zkontrolovat a ‘odistit observed, that the advance of the — kontakty pFerusovata tek, aby desedaly celou right cylinger must be adjusted first, ploshou. nanely by the upper contact breaker. / Vebroubwite svithy 0 de otvoru pro pravoa Before the actual adjustment of the ~ —— eviBies aabroubajte milinotrové ma¥idio. ote aavance the contact-brosker points denim k1ikového mechanisim ve sméru hom nave to te checked and cleaned, in dinovych ruéiéek za pomoc{ kliée M 10 order to cover the contact of their — —nastavte horns svral, entire surface. b/ 7 této poloze nastavte vali mezi doteky a/ Unscrew the plugs and serew on pierudovate na 0,3 m. Hidete pouzft into the hole for the right hand plug ___pfekevé métky dodévané v pohotovostntn a milinetric qeuge. Rotating the Adtads. Nérha o sfle 0,3 mn prochézt mect cranksnazt clockwise by means of the dotoky ovvné, s11n8]84 0/4 mm neami projét. X20 spannex, edjuss the top acca ¥ phfpads, fo v2délenoct neodpoviaé, cotidee 54 canter. ~ nastavenim pevného kontaktu. b/ Adjust in this position the ¢/ latadenie kiskowého sechanisma prot smira ho- gap between contact breaker points dinovjch rueigek, snitte polohu pfseu 0 to 0,3 mm, You may use for this pur — 2,51 3'3 mn pied hnorni surat. v této pose the Feeler gauge of a thickness poloze se must kontakty otvirat. Zilatine to 2a of 0,3 mm in the too] kit. This feeter pomoci powzits kontrolné lampy zapojené na must be a slide fit between the contact — Kontakt preruzovate nebo za pomoct tenké réite rosnts /0,3 am/, thethteker feeler of 0,4 Jeon 0,05 mn/ vounuté mesi kentakey. tm must not pass. In case that the gap 6/ PEE seftzovens pFedstitw éruhsho/tevéro vélce, je does not correspond, fix 1 by adjustaent ~ — postup shodny, poise s tin rczdiien, te pFi of the fixed contact. pispadnén sefizovéni pfedstitu nootdéine 3 eo) Rotating the crankshafe mechanisn : 2dkladn{ deskou, ale pouze destitkou levého anticlockwise, lover the piston position by pterubovace. 2,5 #943 mm hefore the top dead center. In this position the contacts must be opening. PEL nutndn avéthent ptedstinu otéeine 2é- We can tind Lt out by means of a coftrol | Madng deskeu /Acstitkos/ proti snéru nedinovjch lamp, connected with the breaker point ruidek, pHi ananden{ opaéné « or by noane of a thin fein /apros.0,05/., sliding between the contact pointe. 4/ When adjusting the ignition advance of the other /L.H./ cylinder, the procedure is thecame with the only difference, that in case of eventual adjusting we do not ratate the backplate, but only the con tact plate of the Lert hand contact breaker. Ef we have to inereas: we rotate the backplate /contact platat anticleckwise, in case of reducing it- the advance, clock-wise,AWA SO POSTUP PAT NONTA2I BEZKONTAKTNEHO ZAPALOVANI NA MIC AWA 350 VYBAVENE 12 ELEKTROPRISLUSENSTVIM Bezkontaktové zapalovan{ ESE~Twin, které vyrab{ AG TRIDELTA se sklédd 2e £84 komponentii: Ef@fof Ail, pSlovy kotout a anima’. Po sejmutt vike zapalovint a adsledného edpojent Anédého a Cerného vodice of ramének plerusovact ndteme celou destitku 1 8 Kondenzdtory denontovat ze statons alterndtora, péle j¢ t¥eba 2 rotara yy3nout vad Po demont4#i néarie paliva odsojime oba vodite shnéay a Semy/ 2 vyvodl zapalovacich exvek /15/. Pod Sroub objimky civky upevnine Ffafef é{1 a pod aruhy Eroub naviéknene oko bilého zennsto vodise. Na jedau 2 civek pridéme pod matici MS na yyvodu 15 Jesté jeden konektor = o¢kem a 2apo7ime na a8j konektor Servengho vodite vychérejfeiho = Bafatho aflu. piven’ prapasen’ efvek mosey vodiéen zietévé zachovsno. Na rotor upevnime pomoc{ Brouby N6 x 30 a podlotky "Pélovy kotout™ tak, aby Jeho vYstupek sprévné 2apadl do vyiezu u otvoru rotoru. Drédk sninaée upevaime na stator alternétoru pomocf Sroubu pivodné urtenéma destitce kontakt. Sanotny snimae dotdhnene ak kéy2 Jame se presvédcil, ze se netotyra pélovene hoteude ani pEL otoden’ kiskového hEsdele. Svazek tFf slabjeh voditi v budicce velouct 2 Fidfefho a{1u vhodnfm zpisoben p¥iveiene a2 k alterndtor a jednotLivé voiite pfi- pojime k sninati /éerny +, hnédy -, 2bfvasfes o/. bva siln&jSi kabely vychd4zejfet 262 2 ELagesho flu /obvykle barvy zelené a Hlusé/ pripoj ine na volné v¥vody civek /1/ tak, aby zapa~ lovect efvky pracovaly ve sprévasn pofads. soFizon{ pFedstibu u bazkontaktového sapalovéns bo pravé hlavy vdlee nairoubujeme nérku pFedstinu a pfi otdent po sméru hodin. ruéivek aastavime 2édanow hodnotu R, zapalovani a do kabelové kencovky - 2,8/, zécovel méme zasunuty k1iSek v viozenou zapaiovact svitku. Snimaten po- eunujene ¥ rosmeet dvéthy v dv8dhu ad pkeskoéy jiskea an avféce. V této poloze ark sninave zajistine Srcuben a znova zkontrolujeme sprévné nastavens predstinu. Doperutujeme znovu anérit a v pEpadé potteby zvolit takoveu polchu snimate, pfi které je v obou valeseh péedatih v © PROCEDURE OF ASSEMBLY OF _coNracr- LESS IGNITION OW IE MOTORCYCLE BWA 35 ELECTRIC SxErEN EQUIPPED WITH 12 V contactless ignition BSE-Twin, manufactured by TRIDELTA AG is composed of three components: the control part, the pole dise and the sensor. Arter having taken off the ignition cover and after the dis connection of the brown and black conductor from the contact breaker arms, we may renove the entire plate together with the condensers from the stator of the alternator. It is fur~ ther necessary to remove the cam trom the rotor. Aftcr removing the fuel tank, Gieconnect beth conductors /brown and black/ from the cutlets of the ignition cols /15/, Fix the control part under the screw of the coil holder and slip the cable eye of the white grounding con~ euctor below the secend screw. ‘Add another connector with eye co one of the colle under the pat M 5 on the outlet 18 and have it connected with the connector of the red conductor preceeding from the control part. the original interconnection of the coils by a biue conductor remains. Fix the “pole disc eo the rotor row MG x 30 and by means of a fs wseher 20, that ies lug fite correctly into the excision at the mouth of the rotor. Fix the sensor holder to the stator of the alternator by means of the screw, originally intended for the contact plate, Have the sensor tightened only after getting convinced that it does not touch the pole aie oven when rotating the crankshaft. Conduct in a proper manner the bundle of three thin conductors in the sleeve proceeding from the control prt until to the alternator and connect the individual conductors with the sensoz /black +,JAWA’ AO AO rozmezich wéééné tolerance. brown ~, the remaining one 0/. Zaverem mizeme zbyvaj ict pavodni Connect to the Free outlets kabely /aneay 2 terny/ bud 22 of the cotis /1/ stronger cables, svarka odstranit ancko je proceeding also from the control vhodné péipeuni® aby nepfe- part/vouslly green and yelow/ in kdtely. such vay, that both ignition coile may work in correct sequence. ADJUSTING THE ADVANCE WITHA cownacr- LESS_IGNITION screw an advance gauge inte the head of the right cylinder and adjuct the required value /2,2 - 2,0/ while rotating clockwise, have at - the sane tine the ignition key switched on and have a spark plug loca~ ted in the cable eye, Slide the ser— u sor within the linits of the groove in the holder until the spark appears on the plug. Secure the sensor holder in this position with a screw and xe-chock again the correct adjustment of the advance. We recommend to measure again and re-check the values of the ignition aévance on both cylinders and select~in case of need-such a position of the sensor, an vnich the agvance in both cylinders As within the Limits of the mentioned tolerance As a conclusion we way may either renove from the bundle - the renaining original cables Pbcown and black/ or have ‘then properly fastened as to avold - their interference.5. ALTERLATOR Nab{jecS souprava je’ tvo- Bena elterndtorem, usmérhova- bem @ polovedicovys reguldto~ em nepati, Pro ovldléng hont kolng Efrovky dobsjent 30 pou Zito relé s rozpinacimi kentak- ty, napdiené 2 uzlu alternétora, 5. 5. 1. KOWTROLA spacvus mNNOSTT a/ ¥ Klidovén stavu: na svorce B + usérfiovaée namétine na~ peti paterte cca 1zv (9) b/ Po eapnuts H1ESKU apfnacs akEGiky do polohy pro denné jizdu: Rozsvft{ se kontrolné Rérovka nabijent. Napétt cca 12V nan&Eime na sv. Bt usméri vace, sv. D+ reguldtoru napétt @ sv. "30/51", "87" a "relé kore srolky nabijend. ampérmetrem zapojengm do obvodu buzent fav. "DE"/, nam¥ine oa 20 fan) ~ ef Ba chodu motoru /otatky vet- 8f nez 1.000 min ty kontrolnf Zérovka nabjent . nesvitt ~ napeti site se svysi na hod notu regulovandho aapsts cea niv (A), napsts pei ton na- enf pfesdbnout 14,50 > badéet proud sv. “DF prt sprévné funkei regulétoru na~ Wd oté@ka- pitt se varlistaj ic mi a konstantni 24t62f klesd ~'mezi svorkami X-¥,¥-2,X-2 salverndtor @ usmérovat/ na- mé¥ino otEfdavé napatt v ros mezf 10.8-12,2v (1). sapere 2ilet{ na otétkich a proadu alterndtorn. = mezi svorkami x-86,¥~86, - 2-86 /alternétor a usnério~ vad/ nanéFine st¥idavé napée- ef v rormezs 6,0-7,20 (() Napect edle¥{ ne otdexéch a proudu alternétors IE CHARGING sysTEy comprises the alternator, he rectifier and the solid-state youtage regulator. The charging warning lamp iz contiolled by @ relay vith break coy gized fron the alternator star point. "UNCTIONAL CHECK a/ At rest: 2 battery voltage of about 12 V/A / will he measured across the terminal "Bi of the cectifier. b/ After tarning the key én the switch box co the position for driving at daylight: A voltage of about 12 ¥ will be measured across the terminal "BH" of the rectifier, the terninal "D+" of the voltage sgulator, and the terminals "30/51", "07" and the relay of the charging warning lamp. Using an ammeter switched=in in the excitation cirouit /terminal "oP"/;measure about 2 amperes / ) /. c/ With the engine running /at @ speed higher than 1,000 r. p. m./ = the charging warning 1amp does not glow | the voltage of the vising harness increases to the value of regulated about 16 SO /s a voltage in excess of 14,5 V is not voltage, 4. permissible ~ if the voltage regulator functions correctly, the excitation /fiela/ current of the terminal "DE" drops at increasing speed and constant doad alternating voltage ranging from 10,8 to 12,2 V / () / should be measured between the terminals "Key", "eI" and "X-2" / alternator and rectifier/: the measured voltage depends on the engine speed and alternator current, = alternating voltage ranging from 6,0 to T/2.V/ A) / should be measured between the texminale 1X86", "Y-86" / the measured alternator and rectifier, voltage depends on the engine speed and alternator current. oea/v klsdovém stave po odpojent alterndtora of s{t@ l2e né- Fit szolatn{ viastnosti /zkeat na kestru/ vinuti stator feworky %/%42/86 prot kos~ tHe a vinutt rotoru/lroulky prot kost¥a.). Neal avorkari Ke, YZ, Ion na statery a nezi obéna krouzky na rotoru nesnf byt vinutf poru- geno. Posledn{ ave mé¥en{ pro- vadime po seJnutf konektord na vyvodech drzaiu kartaca nebo po sepmuts ariéku primo na krouz~ eich. e/ V klidowém stavu po odpaien’ vSech vivodi usmirfovase 1ze kontrolovat jednotlivé diody usnérhovaciho bloku a to v pro- pustném i advéeném eméru. Kon~ trola ponoct #4rovky a baterie nebo powoci okmetru je pouze infomativns, ana opie ste Eketicke rkugenost’. Roshodu- fet je méten! voltampérové charakteristiky. Vjrobce ptede- pisuje ubytek napétt v propust- nén snéru max. 1,2V pEi proudu 15, provd v zévérnén sméru max. 50 A pYi napéet 100 v. d/ With the alternator disconnected Jat rest/, you can measure the insu- lating properties /earth short-circuit/ of the stator winding /terminls"x", "Y", "2", "BE" earthed/ and the rotor winding /earthed slip rings/. The Winding must not F interrupted between the terminals "xe", ‘y-u" and "x-2" on the stator and between both alin rings of the rotor. The two last mentioned measurements have to he carried out on the brush holder cutlets after palling off the connectors, or directly on the rings after renoving the brush holder. e/ With the alternator at rest and after disconnecting all outlets of the rectifier, you ean check the {ndividual diodes of the rectifier unit both in the forward and reverse Girection. The check with use of an auxiliary lamp and battery or an otmmeter is only a test of informative character as it is based practically on statistic experience, Decisive is the measuring of the voltampere characteristic. The mexinum drop of voltage recommended by the nansfacturer is maximally 1,2 V, for the forwara current of 15 A, the maximun cut-off ent is 50. at 100 Vv.Metody kontroly died 1ze pejiépe vy}4arit tapurkou: Zpiseb néfeni janoci|ponoci | pomoci | pronéfeni vA 7 ESrosky |Brmmetrs | megnetu | therekteristiky a zdcose |/omeaa/ | SOV debré prapustay zécavke — |moiy ruroey | jmenovity diods amas suits fodpor odpor proud vavbcny Zicorka [velki onetny | sdvernj omés neavits —[odpor odpor proud charekter wefent pouze Informetivat eb jektivat Kontrola samostatného polovodivového regulétoru nen{ bSunjmi ailenskjmi metodami proveditelné. Jeho z4védu /souprava nenab{j{ nebo ptebt}i/ Ize pouze prakticky aiagnostikovat vyloutentm moznosti jiné zdvady /viz tez, "C"/. Sefizent nent ¥ obvyklych podminkéch mozné - bylo provedeno dobrousentm odporu ve virobnin 24voaé. ‘The diode measuring methode can best be understood on hand of the following table: Neasuring method iemp and onmmeter | megger measuring vattery |/omega/ | Sav volt-anpece eo - characteristic Faultless forward Lamp Low zero nominal currant diode direction glows resistance| resistance reverse Lamp docs [high infinite | cut-or? current ditection not glow [resistance] resistance Character informative only objective The separate and self-contained solid-state regulator cannot be checked ox tested by current workshop methods. Tks defect /failure to charge the battary or overcharging of the battery/ can be practically dlagnozed only by excluding any other possible defects /see also paragraph //. The regulator is factory adjuste and no re-adjustment is possible in usual workshop conditions.5. $8. 2. KONMROLA GrunosTT wa gS. scAWy V pEtpad’, Ze je k Aispozict zkubebni stav, je moino provést kontrolu alterndtoru = usmério~ vatem na zkuS, stava. Proboh sejmuté KEivky dle obr. spélka wyEnivey fot S4atl kaxtd- de 2 drééia kartaei mimo alterndtor must byt min. 2 mn. Je-li cpotfabent kartdéi vitit, nebo nejsou-li kartéée ve vodont dostateéné pohyblivé, vyméiite arZak yartaéi jako celek™ AWA INCTIONAL CHECK on ‘TEST_STAND| ‘he function of the alter~ nator with the rectifier can be checked on a test stand 4€ this is available. The course of the plotted curve is shown in rig. NOEICE: "The parte of brushes projecting from the sleeves must be at least 2 mm long. If these parts are shorter dae to excessive wear or it the brushes do not nove freely in ti box, renev the complete brush holder assembly.” 1000 2000 3000 4000 5000 6000 min-’6. AKUMULATOR 12 V SAN /typ 12 Al/ Popis: Akunuldtor je uzavrené Konstrukce v nddobe 2 prosvitnsho polypropylenu. Viko je opatfens S-ti 2dtkaml se systénem centréiniho odvetravént @ Je 2 neprahledného plastu. vyveay Je0u olovéné, shodného provedent = oF pont as eee voren @ 5,5 nm. Vyuody jzou rozlizeny = vyvod odvétravant je na strané zéporného vyvodu. Na prihleiné stiné nédoby akumuldtoru je setkami oznatena minimdin{ a maximéln{ hladine elektrolytu. Akunuldcor je dodévsn v p¥ednabitén stavu. spliuje és.atdend nommy Cou 364316 a CSN 364318 a rovnde mezindvodn{ norny RVHP ST SEV 165-75. Rozméry akamuldtoru: V¥Ska 130 me pélka 12) me Site 61 mw tnotnost prdzdného akumulStoru: 1,7 kp Neplaéného po hernf hladinu + 2,07 kp 5. 6. 12 U/S Ab BATTERY /type 12AL/ DESCRIPTION the jax of the battery of enclosed design is made of translucent polyprophylene. ‘The cover of non-transparent plastic is provided with six plugs vita a system of central deaeration. Each cf the terminals, of identical design, has @ hole with a 5,5 sm dieneter. Por identification, they are marked with the eymbole "1" and" on the cover. The aerating hole ie on the cide of the negative terminal. Lines on the wall of the transparent jar indicate the mininum and maximin electrolyte level. ‘the battery is delivered in precharged condition. Tt complies with recommerdations of the Czechoslovak State Standards /CSN/ No. 36 4316 and No. 36 4318 and also the CMEA ST SzV international standard No. 165-75. pettery dimensions: Height 130 ma nengeh 122 mm Width 61 mn Keight of enpty battery: 1,7 Xp Weight of battery filled with electrolyte to the top level indicating line: 2,07 kp =o - +| | | | 5. 6. 1+ OVEDENf po GxwnosTy PLNEN{ AcUMULATORU ELEKTROLYTEW Oastrané se kryct lepies piska ples odvétrdvacl otvor a eéthy se odGroubui. Kaldy Eldnek je tieba naplnit eleltrolytem do vjée horat znatky ne obalu /pouzdru/. Elektrolytem je 2¥edénd kyselina sfrovd podle CSN 651230 0 hustoté 1,28 g/ci pfi teploté 25°C.+ Po napinén{ je t¥eba 20 min. nechat desky akumulétory T4dné nasdknout elektrolyten pledepsané hustoty bez dalsfho nabijenf. zkontrolovat @ pEipadné dopinit hladinu elektrolytu k hornf znatce. Poté uzaviit eétky, ekumulé- tor opdennovt, osusit, nasadit odvétrévect haditku aa vyvod odyétrévént # akumuldtor nanontovat ado notocyklu. Po namontovdn{ akunulftora je t¥cba ihned uréet vosidle do provost a absolvovat jfzdv 6 aéice cea 100 en + V tropech je tieba pouztt kyseliny 0 hustoté poze 1,23 g/en? : EADY FOR USE [0 PILL THE BATTERY WITH ELECTROLYTE 3 Renove the adhesive tepe covering the deacrating hole and unscrew the plugs. Fill each cell with electrolyte to the height of the top tne /mark/ on the Jar, The electrolyte 1s diiuted sulphurie Ms acid according to CSN 1230 with @ apecific gravity of 1.20 /at 25°C/, Ia tropical regione, the spe cific gravity mist not excesd 1.23. After Filling in the electrolyte, let the battery plates soak it in for abaut 20 minutes without charging, then check and if necessary too up the level. Screw in the plugs, rinse and dry the battery, fit the deaerating hose on the deaerating hole, and install the battery, in the motorcycle. On the same day, it is necessary to make an approximately 100-kilonetze~ long trip on the machine.Nabéjen akamuldtor uvédénf do Ginnosti po uplynut{ doby 6 nés, ode dne vyroby a akumilétor, ktery nent inned po naplrént eleKtrolyten v provozu, je nutno nab{jet. Rovnée akunulétor, ktery m4 napéti ndg8{ nei 12 V a elketrolyt hustotu ni28i ne¥ 1,26 g/cm? je t¥eba nabfjet. Nabfjent akunulatoru se provadi proudem 0,25 - 0,5A nabijatkou s oZnosti ‘regulace proudu tak dlouho, a napéti a hustota elektrolycu se dale nenenc, ppozernta: poba nabfjent je 2dvisld na stavu a tapacité akumuldtorn. shen nabijenf je t¥eha sledovat teplotu akumuldtoru, kterd nemé pfekrogit 40°C. PE pfekrotent uvedené teploty se musf akumulé- tor ochlazevat./napé. tekouct vodou/, PHi vEtSE hustoté elektrolytu dolévime hladinu pouze destilovancy vodou. Napétt plné nab: akumuldtoru je 12,6 V tedy 2,1V na ELének. Napétf jednotlivjch Elankl baterie u tchoto typa nelze 2 konstrukénfch divodd merit. PEL provozu metocykiu je nutné, aby svorky byly trvale spojeny 5 baterif pFi chodu metoru. Neni PEfpustné ani "2huSebal* odpojovént akumulétoru za chodu motors! upozort yeme dale, aby pi event. evafoving ol. obleukem ra stroji byly vidy epolu se svorkamt uanéviovate odpoieny 1 svor— ky regulétoru /pifpadné i oko ukost¥ent na plaeet raguldtors/ CHARGING THE BATTERY following the date it 1s necessary to charge a hattery which is not used until six ment! manufacture and a battery which ic net used immediately after it is filled with electrolyte. Like charge a battery whose voltace is lower than 12 volts and whose electrolyte wine, it is necessary has a gravity of less than 1,26. For charging the battery, use a charger enabling the current to be regulated as required. Charge with a current of 0,5 amperes till the voltage and the electrolyte gravity change ne longer. norrch: the tine required for charging the baterry depends on the condition and the capacity of the battery. During charging, the battery temperature must not exceed 40°C. Should this happen, cool the battery, for instance vith running water. if the electrolyte gravity exceeds the recommended value, top up the level with distilled water only. The voltage of @ fully charged battery shoald be 12.6V, i, e 2, 1. ¥ per cell. Owing to the dosign of the battery, it is not possible to measure the voltage of the individual cells. When operating the motorcycle, terminal connectors nust always be connected to the battery poles during run of the engine. Do not disconnect the battery with the engine running even for testing purposes1 I | aa LL. tt “Tr == ZQwmoAwe a- CeRNY Black Noir Schwarz -—sNegro. = E ~ PLUTY Yellow Daune Geld —Anarillo B-BfLY white © @lanc Weiss Blanco F ~ GERVENY Red Rouge Rot —‘Rajo C- MODRY Blue Bleu = Blau Azul G-SE0Y Srey Gris Grav Gris b- ZeLeNy Green vert — Grin verde = H-HNEDY Brown Brun Braun Castane‘ i B ¢ 1 D i |p) E E 6 " A= CERNY lack Noir Schwarz —Nagra’—«E = LUTY Yellow Jaune Gelb Amarilla 8 - BLY white Blanc Weiss: Blanco F ~ CERVENY Red Rouge Rot Rojo c-MoDRy alue leu — Blau Azul Srey Gris. Grau Gris = ZELENY Green vert. Brin verde frown @eun Braun CastanaI iy sO: AWA. Schema elekirictéinstalace - JAWA 640-1, Electric installation Giagram ~ JAWA 641 Schema de cablage - JAWA 640-1 AWA 5. p.THMEG MAD. SAZAVOU CERNY Black Noir Schwarz Megro.=—«E ~ CERVENY Red Rouge Rot Rojo B-ofy white —Blenc eles Bianco Ff - 2UTY Yellow Jaune Gelb Amarillo C- MooRY Siue Bev slau Azul B-Seoy Grey Gris, Grau rk. 0 - ZELENY Green Vert Griin Verde H- HNEDY Grown Gran BraunCONTENTS Pre-sale servicing 4 Technical gate a9 Special repair tools sees = 16-21 Lubricants cose 22 List of main besrings and sealing ringe 30 Piston grading .. 32 Cylinder grading 33 List of gudgeon-pin bearings 35 I. ENGINE - dismantling and reassembly without removing engine trom frame Lil. Removing and refitting cylinder heads and cylinders . ee 36 1.2. Pistons - removal and refitting : 38 1.3. Primary transmission, cluten - oismantling .....ceeeeesseeeeeeseeeesstseteeeees AB 1.3.1. Reassembly .. “ . an ~ ae. cluten - ressenbly aver 46 1.5. Speedoneter drive shaft and its sealing ring sevesworerrers: 48 1.6. Kickstarter return spring : 50 — ir) Gear-shitt shatt vith driving dog ~ gear-shift pavis - : 52 1.8. Removing seni-automatic clutch release mechanism - adjusting .....0s.seeeeeseee 58 1.9. Adjusting semi-automatic clutch release nechanism ......06--e0ee000e+ 56 — 1.10. Secondary sprocket - renoval and refitting ae 3B L.11, Removing engine from frame .......eeeeeeceeeeeeseeeeeeesteees cettesssteetteeeeee 62 — IE. GRANKCASE DISMANTLING AND REASSEMBLY / engine removed from frame / 2.1. Basic dismantiing . eeeereees a 65 2.2, Separeting crankcase halves « os ~ 2.3. Gearbox - gear-chift and crank mechaniom .......0.0+. 68 2.4. Renewing layshaft nesdie bearings a . weimnewe 70 2.5. Checking flatness of crankcase joint faces 2 — 2.6. Renewing crankshaft besrings and sealing rings - 1 2.6.1. Renewing shaft sealing C1NQS .....6.cceccsceeeeerceeecesseceeesteeetistseesetseee 76 2.7. Gearbox .. * Ee 0 — 2.8. Soining crankcase halves . Deere SAPS ESS EERE TIES . 88 2.9. Refitting engine in frane ‘ 88 — TIT, CRANK MECHANISM DISMANTLING AND REASSEMGLY 3.1. Crank mechanism dismantling .....00--.2c0seceeseeeeeeeeeeeeeceetsteetttneeeersess 90 3.2. Crank mechanism reassembly me . 98 — 3.3. Centring crank mechanics 98 Tv, CHASSIS — ai. Removing front wheel oe 106 4.2. Removing rear wheel uo 4,3. Secondary chain we 1S oesreeeer uz — 41511. Renewing secondary chain without removing fully closed eheinguard 7 . U6 4.4, Steering head disnantling .... whitened eens ceeece seees 120 4.5. Front fork 124 — 4.5.1, Removing front fork legs 7 2 ara 12a 4.5.2. Removing front fork sliders, shock absorbers, cenewing packings 126 4.9.3. Uhanging LL an front rork leg 128 ~ 4.6. Locking the machine 130« Filling with oil and reassenblis Removing the saddle Rear suspension far suspension Removing rear swinging arm Brakes Renewing ball hearing of reer vheel sprockst Renewing ball bearings of front and rear wneel Removing fuel tank Removing intake silencer Exhaust silencer Carburetor TRICAL CQUIPHENT List of bulos Renewing heasianps bulva Sparking plug Adjusting ignition sdvan The charging system = Functional check . Functional check on test stand 12 V/5 An BATTERY /type 1281, Making the battery ready for use Electric diagram 130 132 a 136 be 152 1st 156 be 16 160 164 168 Lee 170 170 1a 184 186 168 200RETURN SPRINS Coy NY See seAced cue ORS henet SPA IG (ance) i N] wistaer cent Plates a ae SPR S G = 2 = PLAIN WortnEn “B SPRING Wage iGEAR CHANCE SPRANG HOLDER OILENSKA PRERUCKA JANA 350/638, 639, 640 1. vygant 1992 PRANA 10 7 v koryt SAUA sp 115k Inven 4 nukiedaterska agentura

JAWA 350 Manual (638, 639 and 640)

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JAWA 350 Manual (638, 639 and 640)

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