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WORKSHOP MANUAL

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CONTENS

Presale service

Technical data

List of special tools

Lubricants

Maintenance plan

List of main bearings and sealing rings

Piston grading

Cylinder grading

List of gudgeon pin bearings

I. ENGINE

1.1 Removing and refitting cylinder heads and cylinders

1.2. Pistons – removing and refitting

1.3. Primary gear, clutch dismantling

1.3.1Reassembly

1.4. Clutch reassembly

1.5. Speedometer drive and sealing

1.6. Kickstarter spring

1.7. Gearshaft with carrier, gear shift pawls

1.8. Removing semi automatic clutch release device

1.9. Adjusting of semi automatic clutch release device

1.10 Secondary sprocket – removing and reassembly

1.11 Removing engine from the frame

II.

CRANKCASE DISMANTLING AND REASSEMBLY

2.1. Basic dismantling

2.2. Separating engine halves

2.3. Gearbox – shifting, crank mechanism

2.4. Exchange of needle bearing of layshaft

2.5. Check of flatness crankcase joint faces

2.6. Exchange of bearings and sealing rings of crank mechanism

2.6.1.Exchange of sealing rings

2.7. Gearbox

2.8. Joining halves of engine

2.9. Refitting engine into the frame

III.

CRANK MECHANISM DISMANTLING AND REFITTING

3.1. Crank mechanism dismantling

3.2. Crank mechanism refitting

3.3. Crank mechanism centering

Crank mechanism tolerances

IV.

CHASSIS

4.1. Removing the front wheel

4.2. Removing the rear wheel

Содержание 350

Страница 1: ...WORKSHOP MANUAL JAWA 350 638 639 640 JAWA Moto spol s r o Týnec nad Sázavou 2004 ...

Страница 2: ...eccomended tools and special jigs and fixtures will be used for them All information illustrations and technical data contained in this manual are based on the latest knowledge gained in and during manufacture The Jawa Moto spol s r o reserves the right to change its products any time without a previous notice Any changes and or deviations from the standard version for certain territories will be ...

Страница 3: ... and starting the engine Motos without Oil master By motorcycles with Oil master filling in oil deaerate whole systém filling in petrol and starting 11 Adjusting the idle run on warm engine retightening of cylinderheads and exhaust elbows 12 Control of bolted connections 13 Instructions about attendance of machine and handing over to the customer TECHNICAL DATA DIMENSIONS OF MOTORCYCLE Length 2100...

Страница 4: ... hydraulic Type telescopic in suspension units RIMS Front wheel steel deepened profile Dimensions 2 15 B x 18 Rear wheel steel deepened profile Dimensions 2 15 B x 18 BRAKES Front disc type hydraulic control Dimensions ø 265 mm Rear drum mechanic control Dimensions ø 165 mm ELECTRIC OUTFIT Ignition magneto VAPE A67 contactless Output 12 V 180 W Battery lead type 12 V 6 Ah Headlamp asymmetrical rec...

Страница 5: ...5 WORKSHOP MANUAL ___________________________________________________________________________ LIST OF REPAIR TOOLS FOR TYPE 638 639 640 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 ...

Страница 6: ...2 28 86 765 1 Drift 15 S 93 28 86 766 1 Fork leg extractor 16 S 94 28 86 814 1 Primar chain adapter 17 S 201 9 96 55407 3 1 Lever 18 S 203 28 86 767 1 Pliers 19 S 205 28 86 725 2 1 Pressing jig with accessories List of lubricants recommended for motorcycle JAWA 350 Use of oil type of oil in the Czech rep Viscosity Class notes A gearbox Mogul Trans 90 API GL 4 temperature over 0 C brake lever pins ...

Страница 7: ...n K K K M K V M K V Wheels and rear suspension bearings M M M Brakes brake lining K K K Bowden cables K K K K K K Battery K K K K K K K K V Alternator K K Ignition spacing between rotor and catcher S K K K S K S K S Spark plugs C V V Front fork oil exchange V V V V V V V Wheels spokes stretching K Brake lever pins joints stop switches accelerator twist grip K K K K K K K K Piston piston rings tran...

Страница 8: ...A BN 16x22x12 1 engine right side 324 232 050 000 bearing 3205 1 engine right side 324 232 050 003 bearing 3205 C 3 1 engine right side 324 162 069 566 bearing 6206 2 ckrankshaft 273 521 008 617 sealing ring 30x52x10 1 engine right side 273 521 106 807 sealing ring 25x52x7 1 engine right side 273 521 006 917 sealing ring 25x62x8 1 engine leftt side 273 521 100 417 sealing ring 8x16x7 1 speedometer...

Страница 9: ... is necessary to check the bore of the rebored cylinder by measuring it at several points and to use a piston of grading corresponding to the measured dimension The grading mark on the top face of the cylinder has to be changed accordingly In the engines new or rebored the right hand and left hand may be of a different grading class but not of different rebore grading In the case of cylinders with...

Страница 10: ...7 0 008 0 019 I ENGINE 1 1 Disassembly and Assembly of the Cylinder Head and Cylinder Prior to disassembly take out the carburettor flange wich is shared by both cylinders Using the box spanner loosen and remove the eight M10 nuts to be able to loosen and remove the cylinder heads Rotate the engine until the piston of cylinder which should be removed is in the bottom dead center Take out the cylin...

Страница 11: ...reccomendable Take off the cylinders see sect 1 1 plug the crankcase holes remove piston rings and using suitable plies remove piston pin locks Fit the auxiliary insert S 88 into 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 end and lock the auxilary insert S 88 held between the needles in t...

Страница 12: ...ks i e A B C correspond to each cylinder Make this check before mounting the piston rings to be sure 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 if the piston have the identical clearance on each side when it is in the top dead end position If it leans permanently against on...

Страница 13: ...acer and pull it out and remove the cage 1 3 1 Assembly Fit the primary chain gear on the clean dry crankshaft taper and the washer and spacer test the run out rate of the spacer faces before the assembly on the mainshaft Place a steel ruler on the gear flank against the gears to make sure that both gears are alligned admissible tolerance is of 0 5 mm The true alignment is important for primary ch...

Страница 14: ...e and sealing Dismount the primary gear as described under 1 3 Unscrew the M6 bolt provided on the engine bottom and holding the speedometer drive socket and take it out of the engine Unscrew the grub screw from the lug provided on engine housing inner bottom the screw drives the speedometer Using a stick preferably an aluminium one knock the drive casing and the seal ring into the housing space F...

Страница 15: ...ring Drive out the pin which holds the clutch disengagement cam on the shaft from the bottom to up and remove the cam Fit the pawl holder S 63 between the gate and the pawls and pull with caution the shifter shaft with carrier and pawls out of the mounting When remounting the set support the S 63 holder against the carrier pawl and fit the oiled shaft in its mounting See that the carrier pin sits ...

Страница 16: ...refitting the secondary sprocket It must slide easily on the splines Do not drive the sprocket forcefully into the bearing inside the crankcase in spite of its being secured against normal stressing with a buttress plate There is danger of serious damage to the gear shaft forks and gears of gearbox 1 11 Take out the engine from the frame Take off the saddle disconnect the battery fuse and take off...

Страница 17: ...a way that the engine left side is accesible Remove the carburettor primary gear cylinder heads and pistons Drive the rear centring element from the left side of engine housing to the right side Take out the clutch automatic release device and remove M6 bolts holding two halves of engine housing together Take the housing out of the vice and lay it down on the left side 2 2 Separating two halves of...

Страница 18: ...left half crankcase cover Push out the crankshaft out of left half of case Remember connecting rod must be in its top T D C 2 4 Exchange of layshaft needle bearings After removing locks drive the bearing into the crankcase with a drift To facilitate this job remove the speedometer drive from left half of engine Put new bearings into the crankcase heat case to 80 120 C After pressing them home fill...

Страница 19: ...box For the correct reassembly of gearbox it is recommended to begin with the crank mechanism removed from the crankcase halves in order to ensure the maximum clearance of the layshaft To ascertain this clearance fit the layshaft into ballbearing together with the 1st speed gear and then clamp both crankcase halves together provisionally with several screws Move the layshaft forward and backward t...

Страница 20: ... 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 following manner a Shift the 1st gear and check whether the 16 tooth gear on the layshaft meshing with the 1st speed gear 24 teeth has an axial clearance...

Страница 21: ...with mod bolts Tighten the bolts once more after the housing is cool and clean the housing vent hole Using a pipe of suitable diameter tap on the ball bearing inner ring to achieve the true position of the balls in the bearing runway Lubricate the bearings with engine oil Drive on both crankshaft seal rings before mounting make sure that they are duly joined with each other Use S 72 drift for driv...

Страница 22: ...its pins press out first the end flywheel také off the connecting rod and press the mid bearing pin out of the nearest mid flywheel Press the connecting rod out of the latter flywheel If replacing the mid pin labyrinth bearings or mid ring dismount the crank completely to pieces 3 2 Mounting the crank mechanism a Press connecting rod pins in the inner flywheels whereby the faces of the pins must g...

Страница 23: ... flywheel adjust it in the perpendicular position on the crankpin according to the index lines and press the assembly together 3 3 Crank mechanism centering Before the centering the crank mechanism check that the index lines coincide and that they are in a single plane If necessary tap the right or left flywheel with copper mallet and bring it to the required position Check axial clearance of the ...

Страница 24: ...__________________________________________________________________________ C Cr ra an nk k s sh ha af ft t m me ec ch ha an ni is sm m c co om mp pl le et te e d di im me en ns si io on ns s t to ol le er ra an nc ce es s ...

Страница 25: ...xpand the inner flywheels still clamped in the centres on opposite side of marking Pic 3 Left and right flywheels are closer to each other at the points opposite to the connecting rod pins For expanding use plies S 203 Test the crank mechanism clamped between centres If the closing is minor the expanding operation can be done by S 201 lever If the end flywheels are closed at the points opposite to...

Страница 26: ...ller Shaft has to be clean and greased a bit After slipping the shaft into the wheel screw and tighten the nut Push down the front fork several time and then tighten the wheel axle with the clamping bolt on the left slider 4 2 Rear wheel remove Unscrew the winged nt of therear brake bowden and wheel spindle nut remove the washer and pull the spindle out to right side Than remove the brake reaction...

Страница 27: ...ensures that the chain will never be fully stretched during the ride due to the up and down movement of swingarm This could shorten the lifetime of the chain or even result in damage of bearings gearbox sprocket d Than it is also important to allign perfectly both wheels when adjusting chain To measure alignment of the wheels use a suitable adapted lath A missalignment of the wheels not in same tr...

Страница 28: ...ntenance purposes clean it and lubricate as usual and refit it on the sprockets as described above using an auxiliary chain f Refit the end of the top chain rubber chainguard into its mounting and secure it with the clamping sleeve Tighten the chain well as described g Adjust the rear brake and brake light switch Remember The clip of master chain link must allways be turned with the cut out to the...

Страница 29: ...ake sure about it and then secure the upper nut 4 5 Front fork 4 5 1 Removing front fork legs front fork removed a Remove the cover of headlight and dismantle the front brake caliper b Take off front mudguard 2 bolts M6x16 4 bolts M8x20 c Unscrew plugs of fork arms d Loosen bolts of lower bearer M10x65 e Screw the S 93 jig into the fork tube and tap the tube to loosen it from the bearer 4 5 2 Remo...

Страница 30: ...ar suspension To dismantle the rear suspension unit for oil exchange or renewing the packings clamp the lower eye of the shock absorber into the vice Unscrew the plug 2 with the size 22 spanner and pull the piston rod assembly from the shock absorber body If the piston rod sticks in the working tap the cylinder with a soft object to strike it off the guide Whenever dismantling the shock absorber p...

Страница 31: ...ear swing arm After removing the dust covers remove the metal plastic bushes Caution These metal plastic bushes have to be put rough side outwards The pin of the brake reaction link must be on the left side and the rear ends of the arm must be lifted above the exhaust silencer before sliding them in their mountings Take care that the cover plates and the packing rings do not fall out 4 10 Rear bra...

Страница 32: ... in the master cylinder reservoir and to have end of hose in brake fluid in the glass Operation and the maintenance of the hydraulic disc brake Check before every ride Optical check of brake fluid level and leaking of the fluid from the whole system Check function of brake light switch If the level of fluid gets under 1 2 of control window add brake fluid maximally to the top of window This check ...

Страница 33: ...In this possition the sleeve can be slipped into the groove on the outer periphery of the caliper s cylinder Put an elastic insert piece into the excision in the left half of the caliper using a packing ring to seal the surface between both halves Than screw both halves together with three imbus bolts Brake pads insert into the caliper just before the mounting of front wheel Dismantling of master ...

Страница 34: ... would amage the bearing Prior to refitting the dust covers fill the bearing with grease PM LA 2 4 13 Exchange of ballbearings of front and rear wheel Remove the cover of brake drum with brake shoes and carefully remove the dust covers from both sides Unlock the bearing and from other side drive the bearing so far as the primary unlocked bearing falls out Remove the distance tube and stamped washe...

Страница 35: ...t side of the motorcyle Remove the seat side cover and unscrew the bolts M6 from side cover of filterbox Remove the cover and take out the old filter When fitting a new one be sure to sit it truly the side cover is also centring element 4 16 Exhaust silencers exchange Silencers should be exchanged after 25 000 km 4 17 Carburettor Technical data The carburettor setting is determined according to te...

Страница 36: ...CAL EQUIPEMENT 5 1 List of bulbs Use Pcs Bulb H4 12V 60 55W Headlamp 1 Bulb 12V 45 40W Headlamp 1 Bulb 12V R10W Brake light 1 Bulb 12V 21W Indicators 4 Bulb 12V R5W Rear light 1 Bulb 12V 4W Parking light 1 Bulb 12V 2W Control lamp 4 Bulb 12V 2W Speedometer lighting 2 Bulb 12V 2W Rev counter lighting 2 Legend 1 Sleeve valve complete 2 Needle valve Ø 2 complete 3 Idle jet 40 4 Jet of auxiliary syste...

Страница 37: ...must touch the base of parking light bulb 5 3 Spark plugs shoes without resistor Make type BRISK NR15C N15C CHAMPION L78 5 4 Ignition advance adjustment Ignition advance is adjusted on value 2 5 mm before T D C of piston When mounting a sensor the marking onsensor capture is positioned against on stator plate 5 5 Contactless ignition The set of contactless ignition contains of magneto A67 1 rotor ...

Страница 38: ... always at the moment when projection is passing the sensor core The mentioned system differs in concept from existing system Vape type Z04 The coil Z67 is based on principle of capacity i e energy for spark is obtained of condenser discharging The source of current for this condenser is one black coil on alternator stator A67 i e not battery 12V This is the basic difference when comparing with ex...

Страница 39: ...n t sparkle This memory effect can be called as normal The system of charging the battery and lighting of motorcycle is based on another principle than the existing one which is using alternator with rotor excitation through carbons Alternator A67 is using as an energy source the permanent magnets the energy of those is induced innto coils on stator during rotor revolutions The outlets cables from...

Страница 40: ...gh short circuit in motorcycle cables can cause damage of this sensor In all these cases motorcycle stops because the spark won t anyway be generated or it will be on wrong engine cycle place Being thus wrongly switched on and at the same time the alternator winding and coil Z67 are connected too there is a danger of damaging the coil Z67 Summary no harm for S01 to be short circuited on frame but ...

Страница 41: ...s in Z67 If there happens to connect yellow conductor to battery it s necessary to disconnect it quickly within 5 sec max otherwise the entry parts in Z67 are damaged The preceding points show that S01 and Z67 being switched on there is a higher danger for damaging Z67 than S01 when battery 12V is getting on connection between S01 and Z67 If the engine cannot be switched off by means of blue condu...

Страница 42: ...oltage higher than 1200V under higher revolutions 4 000 rev min There is danger of breakdown and dammage of winding The core spider must be separately connected with motorcycle frame It is necessary to avoid the short circuit on stator core The windings are insulated even from each other If there happens that some of outlet conductors signal the ohmic short circuit or leakage on frame event short ...

Страница 43: ...s decreasing of about 0 1 to 0 2 V saving battery in heated environment Regulator R67 allows machine to be in operation even without battery The output voltage moves from 12V to 15V according to attached load on outlet R67 Most intensive voltage is registered under lowest loads e g 5 W The horn and indicator switches are working wrongly in such a case The measuring of resistance between individual...

Страница 44: ...oad of headlight it s either the battery which is discharged or there is defect on R67 verified by accumulator 8 If the battery is O K but still discharged check up the possibility of short circuit somewhere in cables event what loads are connected to motorcycle electrical network system overloaded 9 If all the points 1 8 are O K and battery is not yet charged enough measure what current is the ca...

Страница 45: ...67 including their eventual leakage on current winding for headlights 5 Measure by direct current ohmmeter whether red conductor on Z67 is not short circuited on frame 6 Verify by compass the polarity of magnet in S01 7 Control if some of wires are not fallen out from rotor A67 Check up by means of auxiliary magnet changing of magnet polarity in rotor 8 Check up the setting up of advance When anal...

Страница 46: ...f production and accumulator which is not immediately in operation after being filled with electrolyte has to be charged Likewise accumulator with voltage lower than 12 V and electrolyte with density lower than 1 26 g cm3 has to be charged The accumulator is charged by current of 0 25 0 5 A battery charger with possibility of air regulation as long as the voltage and density of electrolyte are not...

Страница 47: ...47 WORKSHOP MANUAL ___________________________________________________________________________ Electrical schema of Jawa 350 ...

Страница 48: ... outlet The oil tank has the capacity of 1 5 l In its front part there is mark indicating minimum oil level Oil supply to pump It is realized by elastic transparent tube From the reason of assembly this tube is detachable above the rear engine part Oil supply to engine Oil supply to engine from pump is also realized by elastic transparent tube of smaller profile which is connected with check valve...

Страница 49: ...ked up after covering 500 kms To pic 1 segment A original gauge MIKUNI X space for gauge 2 attachment B new gauge JAWA 6 3 Cleaning out of the oil pipe system In case of blocked oil pump with filth it s necessary to proceed as follows 1 Dismantle oil tank from rear part of underseat space of motorcycle Pour out the oil from tank and flush the empty tank spirit benzine The original outlet placed in...

Страница 50: ...tch release device 15 1 9 Adjusting of semi automatic clutch release device 16 1 10 Secondary sprocket removing and reassembly 16 1 11 Removing engine from the frame 16 II CRANKCASE DISMANTLING AND REASSEMBLY 2 1 Basic dismantling 17 2 2 Separating engine halves 17 2 3 Gearbox shifting crank mechanism 18 2 4 Exchange of needle bearing of layshaft 18 2 5 Check of flatness crankcase joint faces 18 2...

Страница 51: ...ke 31 4 11 Front disc brake 31 4 12 Exchange of bearings of rear sprocket 34 4 13 Exchange of bearings of front and rear wheel 34 4 14 Fuel tank removing 35 4 15 Removing filterbox airfilter 35 4 16 Exhaust silencer 35 4 17 Carburettor 35 V ELECTRICAL EQUIPEMENT 5 1 List of bulbs 36 5 2 Exchange of bulbs in headlight 37 5 3 Spark plugs 37 5 4 Ignition advance adjustment 37 5 5 Contactless ignition...

Страница 52: ...strative information provided in this manual for its further copyright or publishing is prohibited All claims arising from the copyright laws fall axclusively to JAWA Moto ISSUED BY Commercial Technical Service JAWA Moto spol s r o Týnec nad Sázavou Czech republic JAWA Týnec nad Sázavou ...

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