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www.jawamoped.com

WORKSHOP MANUAL

moped  model 210

CONTENTS

I.  Moped specifications

II. General technical data

    1. Assembly tools and jigs

    2. Moped lubrication — Lubrication Chart

    3. List of bearings, scaling rings and bushes

    4. Engine torque transmission — diagram and description

III. Engine

    1. Removing engine from frame

    2. Removing cylinder head, cylinder and piston

    3. Grading of cylinders and pistons

    4. Clutch dismantling

    5. Carburettor

    6. Crankshaft

IV. Frame

    1. Front, telescopic fork

    2. Front, and rear wheel

    3. Rear wheel telescopic suspension

V. Electrical equipment

    1. Alternator

    2. Ignition system

    3. Wiring diagram

    4. Diagnosing electronic ignition defects

VI. Causes of defects and their removal

ZVL model 210   Workshop Manual   Pages 1 & 2 

jkw

This workshop manual is intended primarily for all repair shops and their

workers concerned with repairs of our model 210 moped. It does not

contain servicing jobs and repairs described in the Rider's Manual but

only repairs for which special assembly tools and jigs are required.

The purpose of this manual is to facilitate the work of the repairmen and

to improve servicing of our products. Any changes and deviations from

standard procedure? will be announced in our Service Bulletins.

ZVL concern
Povazske strojarne
Klementa Gottwalda works

sales and technical service
department

Summary of Contents for ZVL 210

Page 1: ... 1 Alternator 2 Ignition system 3 Wiring diagram 4 Diagnosing electronic ignition defects VI Causes of defects and their removal ZVL model 210 Workshop Manual Pages 1 2 jkw This workshop manual is intended primarily for all repair shops and their workers concerned with repairs of our model 210 moped It does not contain servicing jobs and repairs described in the Rider s Manual but only repairs for...

Page 2: ...nternal expanding shoe brakes controlled by levers on handlebars Brake dimensions 85 x 20 mm Tyres 2 x 16 Wheels 1 60 WH1 x 16 Inflation pressures front tyre 196 kPa 2 atm 28 psi rear tyre 245 kPa 2 5 atm 36 psi Moped dry weight 51 kg Moped running weight 54 kg Road speed sustained 35 km hr maximum 40 km hr 5 Fuel tank filling capacity 4 litres Fuel reserve 0 7 litres Maximum climbable gradient wi...

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Page 7: ...torque is trans mitted to the rear wheel by means of secondary 1st speed gearing transmission It is formed by two pairs of involute spur gears 3 4 5 and 6 meshing with the freewheel D The force closed clutch engages the respective between the gears 4 an 5 on the layshaft From gear depending on the road speed the drive taken the gear 6 the torque is transmitted over a force off the automatic transm...

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Page 9: ...em aside in the order of their removal so that they can be reassembled correctly and in the shortest possible time 2 Removing cylinder head cylinder and piston a Unscrew the four M6 nuts and lift them off together with washers from the studs b Remove the cylinder head c Remove the cylinder Fig 5 d Remove the circlips securing the gudgeon pin and use the drift No 50 12000 1 1 Fig 6 to drive out the...

Page 10: ...g 9 With a screwdriver remove three circlips from the recesses to loosen the clutch starting shoes Fig 10 For re assembly use the washer No 4T 210 2100 and clutch drum drag No 4T 210 2200 01 and secure the clutch with the circlips Fig 11 After having removed the drum with starting shoes rotate and gently pull the starting drum with the sma11 pulley to remove it together with the indented belt Work...

Page 11: ...he drum Insert the tips of the screwdrivers under the top arms of the shoe near the pivots and opposite each other By carefully pushing the screwdriver handles downward you will lift the carrier with the shoes out of the drum Wipe the oil off the parts immediately and put the parts in a clean place If the drum or the shoe linings are stained with oil they have to be degreased thoroughly Finally re...

Page 12: ...000 1 1 pull of the rotor Fig 20 and the loosen the lock pin c Remove two M4 x 22 screws fastening the stator and pull the stator out of the crankcase right hand half together with the leads After having removed the transmission clutch and the alternator use a hand press to press the crankshaft out of the crankcase Engine re assembly To re assemble the engine reverse the procedure for its dismantl...

Page 13: ...burettor from the engine take it apart and clean its parts thoroughly 2 Discard worn parts and replace them with new ones 3 Check the flatness of the flange and true it up if necessary on an abrasive cloth stretched on a flat board 4 After trueing up the flange clean the carburettor body thoroughly once again 5 Check the jets and adjustments for compliance with the recommended values 6 Adjust the ...

Page 14: ...index line with With the carburettor removed from the engine a tolerance of 1 mm If this is not the case ad remove the float chamber cover Turn the carbu just the floats by bending the arms upward rettor so that the floats are directed upwards or downward as necessary The fuel level adjusted Check that the floats move freely on the spindle in this way complies with the manufacturer s and that they...

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