www.jawamoped.com
Reassembling 2nd-speed clutch
Observe utmost cleanliness during the clutch re-
assembly. Degrease the drum (large pulley) with a
degreasing agent (e.g. alcohol, acetone, clean petrol,
etc) and wipe it dry with a clean cloth. The roughness of
the drum working (friction) surface must be at least 0.8,
i.e. the surface must be polished with fine emery paper.
A rougher surface has an unfavourable effect on the
service life of the friction lining.
Make sure that the GUFERO sealing ring (15 x 24 x 7)
in the drum is not damaged. Put the shoe carrier (base
plate), with the two 2nd-speed shoes mounted in
position together with the regulating driver located
between them into the drum. All parts must be dry,
without any traces of oil.
If oil has got between the joint faces during the
dismantling, remove the 2nd-speed shoes and dip the
carrier in a solvent (degreasing agent). Then dry the
carrier thoroughly.
The hard chrome-plated lands of the regulating driver
which touch the brass friction layer on the shoes must
be bright, clean and dry. Rotate the shoe carrier together
with the regulating driver anticlockwise and fit the parts
in their position by a slight pressure of the hand.
Never touch the friction lining and the friction surface
of the drum with greasy hands. Place the ,’O’ sealing
ring on the recess (clean and undamaged) of the carrier
hub and locate the metal bush on the ,’O’ ring. Then
apply a tube of sufficient length and the same diameter
as the bush on the bush, and by rotating and pressing
down the tube, press the bush through the ‘O’ ring
inside the hub. Then install the inside driver which
ensures that the regulating driver controls both shoes at
the same time. For this reason, the holes must be
perfectly clean and the parts must have a certain
clearance along the circumference with the exception of
the contact areas.
Locate the circular sheet-metal washer and the clutch
cover, and then screw down and tighten well the M10 x
1.25 nut
5. Carburettor (Fig. 21)
The moped is fitted with the JIKOV 2912 DC
carburettor with the following parts and adjustments :
Main jet
63
Idling jet
35
Needle valve
- needle position
2
nd
notch from top
Fast-idling screw
540º (1 to 1½ turns)
Routine maintenance of the carburettor includes its
removal, flushing and swilling with clean petrol, and
blowing through with compressed air. Clean the jets
only with petrol (or acetone) and compressed air, never
with lengths of wire or other hard objects which are apt
to damage the calibrated holes.
To give the carburettor a thorough overhaul, proceed as
follows:
1. Remove the carburettor 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 needle and the fast-idling screw as
recommended and reassemble the carburettor.
7. Refit the carburettor on the engine. Start the engine,
warm it up, and adjust the richness of the mixture by
means of the air-correction screw. Then adjust the
idling speed (from 1,600 to 1,800 r.p.m.) by means of
the stop screw, and the needle valve and the free
movement of the twistgrip by means of the throttle
cable guide.
ZVL model 210 Workshop Manual Page 14
jkw
