Professional Documents
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350 Manual JAWA PDF
350 Manual JAWA PDF
JAWA 350/638,639,640
JAWA Moto spol. s r.o. Týnec nad Sázavou
2004
WORKSHOP MANUAL
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The purpose of this Manual, intended primary for specialized Jawa repair shops, is to
facilitate all jobs connected with repairs of Jawa 350 motorcycles. All the described
dismantling, refitting and adjusting procedures have been elaborated under the assumption,
that the reccomended 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 published in the form of Supplements to this
Manual. It is not permited to reproduce this Workshop manual or its parts in any form
whatsoever without written consent.
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PRE-SALE SERVICE
1. Unpack the motorcycle, free it from preservation grease, assemble the separately
delivered units and parts of accessories /control of completeness/.
2. Check engine and frame numbers – to be conform with the documentation.
3. Take out the accumulator – charging – forming, assemnbly.
4. Control the oil level in the gearbox – refilling.
5. Control all the functions of electrical accessories.
6. Basic adjustment of the headlight /page 50 operating instructions/ and vertification of
headlight tilting.
7. Check ignition – spacing between catcher and rotor.
8. Adjustment of coupling.
9. Adjustment of brakes. /idle run, dearate front, clearance of stop switch cable/
10. Filling the machine with min. 1 liter of petrol – lubricated 1:50 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
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1 2 3 5
4
6 7 8 9 10 11
12 15 16
13 14
17
18
19
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Use of oil type of oil in the Czech rep. Viscosity Class notes
B engine lubrication
B1 lubricated petrol Mixture ratio 1:60 – after running in, 1:50 during running in
For whole year riding use oil of viscosity class SAE 30-40 for two stroke engines and
with classification according to API TS.
B2 Lubrication with Oil–master system For whole year riding use prediluted or syntetic
oil for two stroke engines according to recommendation of individual oil producers.
For riding in temperatures over 0°C can be used oil for two strokes engines of
viscosity class SAE 30-40 and with classification according to API-TC.
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G secondary chain special spray e.g. Castrolů Mo S2, Gleitmo 582 ……..
Maintenance plan
10000
15000
20000
25000
30000
1500
2500
5000
500
km
Transmission oil * V V K V K V K V
Clutch * K K K K K K K K
V
Carburettor S
Air filter *** K K K V K K V
Steering head K K M K K
M
Rear suspension V K
Secondary chain 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, transfer ports K K
Brake plate K K K V K K V
Screws, nuts and packings *** K K K K K K K K K
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Piston grading
Grading D2
+ 0,000
- 0,010
Standard A 57,972
B 57,982
C 57,992
1. re-bore A 58,222
B 58,232
C 58,242
2. re-bore A 58,472
B 58,482
C 58,492
3. re-bore A 58,722
B 58,732
C 58,742
4. re-bore A 58,972
B 58,982
C 58,992
Cylinder grading
Note: The manufacturer delivers spare cylinders exclusively with the basic /standardú bore.
The other dimensions given in the table are guides for cylinder reboring. As it is very difficult
to rebore the cylinders accurately within the tolerance limits of hundredths of millimeters, it 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
rebores in between of two grading groups, it is possible
to use a piston of B or C group. With the B piston is
running in quicker, with C piston nocking is likely on
cold engine (after start).
Standard
Grading D1 D2 D3 I.re-bore II.re-bore III.re-bore IV.re-bore
A 58,01+0,01 58,01+0,01 58,01+0,02
B 58,02+0,01 58,02+0,01 58,02+0,02 +0,25 +0,5 +0,75 +1,00
C 58,03+0,01 58,03+0,01 58,03+0,02
D 58,04+0,01 58,04+0,01 58,04+0,02
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I. ENGINE
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1.3.1. Assembly
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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. For mounting, fit the new 8x16x7 seal ring on the
drive shaft (spring should face the engine internals), and using a suitable pipe
or socket wrench of 15 mm outer diameter tap on the drive to push it through
the housing to its seat as far as the point when groove on the drive surface is
in the line with the thread for the lock screw in the housing. Once a screw is
screwed home, drift it with centre punch
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2.7. Gearbox
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 to check its axial
clearance which should be in the range from 0 –
0,6 mm. Then remove the layshaft and locate the
crank mechanism with the centre face plate (if
this plate has been removed) into the left
crankcase half heated up to 100-120°C. The
highest temperature has to be around the
crankshaft bearing. Put wooden blocks under the
front and rear part of the crankcase half and insert
the crank mechanism into as fast as possible so
that the lock pin of centre ring fits into the recess
in the crankcase. It is not permitted to drive the
mechanism into the bearing forcefully because
this would result in its „uncentering“ and also in
damaging of bearings. If the crank mechanism
becomes jammed in the baering, drive it out of
the bearing (engine dismantling), reheat the
crankcase and repeat the operation..
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Pic.1: Flywheel surfaces are not in a single plane (do not coincide).
On the surface of the flywheel, mark with the chalk points where the indicator shows
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 top. Then tap the marked points
with the copper mallet until the desired result is obtained.
Pic.2: Places where indicator shows the maximum value sign with the chalk. In our
case the whole mechanism is bent. Take it out of centres, support one end flywheel in such a
way that the signed places are on top. Hold the opposite end with a hand and tap with copper
mallet on the middle flywheels – on marked places. Or you can use plies S-203 to expand 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 the cennecting rod pins, they must be
forced apart. After having removed the crank mechanism from the centres, give the flywheels
blows in the direction of arrow
Pic.4: Left and right flywheels are too opened and must be closed at the points
opposite to the connecting rod pins. Take the crank mechanism out of the clamping and give
the flywheel blows from the side indicated by arrow.
Note: Continue in centering and testing until you achieve the admissible radial run out
of the crank mechanism, wich must be less than 0,02-0,03. After having centered the
crank mechanism test the axial play and mount the cleaned mid ring (face) on.
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IV. CHASSIS
Loosen and unscrew the nut of wheel shaft and remove the dust protecting ring. Loosen the
clamping bolt of the wheel and shift out the shaft. Be carefull not to loose the brake pads
when removing the front wheel from the fork. After removing the wheel it is recommendable
to enter between the brake pads a filler of -at least- the same thickness as the brake disc and
secure it against falling out. During assembly watch the brake disc, to get easily slipped
between the brake pads after having removed the filler. 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.
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 link with
the spacer from left side and disengage the wheel from the rear wheel sprocket assembly. Tilt
the bike to the right and take out the wheel with the brake cover with brake shoes. For
refitting the rear wheel, reverse the procedure of its removal. Check the rear brake (wheel has
not to drag) and correct installation of the brake reaction link in the guide on the swing arm.
Alloy wheels
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The following procedure can be adopted for renewing the secondary chain when you
have another chain of the same length - to be exchanged with
a) Loosen the nuts of rear wheel spindle and sprocket. Than loosen the tensioners and
move the wheel forward as far as possible
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b) Loosen the screw of rear top clamping sleeve of the rubber chain guard, and lift off
the clamping sleeve. Pull the top part of the chainguard out of its mounting at the
guard rear part.
c) Turn the rear wheel until the master chain link (connection) appears in the accesible
area. To prevent falling of the chain left end into the metal cover, put a thin
screwdriver or wire between the chain rollers next to master link. After pressing aside
the rubber guard, secure the same way the right end.
d) Now dissconnect the master link and connect the end of the prepared new chain to
the left end of the original chain.
e) Take away the screwdriver securing the end of original chain, lift the rear wheel and
by carrefully pulling, slip the new chain on both sprockets. Be carefull not to damage
painted or chrome plated parts
Before disconnecting the original chain from the master chain link, secure the ends of
new chain the way described under c) and remove the original chain. Then use a new
chain link to join the ends of the new chain. In case you have removed the chain only
for maintenance 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
direction opposite to the movement of the chain.
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After disassembly of the front fork a mudguard, put back the fork plugs to avoid pouiring oil
out of fork. Remove the headlight and indicators and let them hang on cabling or attach them
to the frame in the suitable way. On releasing and screwing out the upper nut of the steering
column (key S-81), take off the upper bearer.
Using the opposite side of the key S-81 loosen the lower nut of the steering column. Hold the
lower bearer in upper position in order that the balls do not fall out from the bearings.
Remove the nuts and take out lower bearer carefully.
In case of an urgent replacement of the steering bearing shells, we use a longer bar to drive
them out. At first, push the bearing shell from the lower bearer by means of sharp chisel on
several spots and carefully take it out.
When reassembling, take care to have the bearing shells of the steering head filled with
prescribed grease and to check if both bearings have 18 balls of dia 1/4“ (6,35 mm).
Notice: Reassembly is executed in opposite way, always observe these principles. First
retighten the lower nut of steernig column and than loosen it just enought in order that the
fork moves in bearing without play. Use S-81 for this job. Make sure about it and then secure
the upper nut.
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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.
Rear brake of motorcycle needs to be adjusted only sometimes, when brake lining is
worn. This is manifested by longer way of brake levers. The brake cam is provided with
brake-lining wear indicator. When the indicator reaches its extreme position, exchange the
brake shoes to ensure safe riding.
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4.17. Carburettor
Technical data
The carburettor setting is determined according to tests results. Basic adjustment is
done by the factory. Needle position is 1st notch from the top. Idle screw is backed off by 2
turn. Level of fuel in float chamber is 11+/- 1 mm (measured from carburettor body and float
chamber dividing plane at pressure of 1,837 kPa (250 mm fuel column) Used jets are signed
with SOMET-JIKOV flow values.
Typ 640
Main jet 100
Auxiliary system jet 72
Auxiliary air jet 120
Fuel economizer jet (Ekonostat) 50
Choke jet 85
Idle jet 40
Auxiliary idle jet (at idling orifice) 80
Idle screw 1 ± 0,5 ot.
Needle position 1st Notch from top
Needle valve Ø2
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Legend
1 – Sleeve valve, complete
2 – Needle valve, Ø 2 complete
3 – Idle jet (40)
4 – Jet of auxiliary system (72)
5 – Main jet (640 - 100)
6 – Fuel metering needle
7 – Needle securing clip
V. ELECTRICAL EQUIPEMENT
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Make type
BRISK NR15C, N15C
CHAMPION L78
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Set of source and ignition system Vape (technical description for service purposes)
The set contains :
- electronic switch Z67 - ignition coil with two high voltage outlets for two plugs of two
stroke engine, controlling element of performance which governs primary coil winding
- regulator R67 - electronically controlled semiconduct power - rectifier , which maintains
the central value of direct-current voltage=14 V in electrical network and on battery of 12 V.
The controlling and performance circuit is built in alluminium cover serving as a cooler of
power-rectifier.
- sensor S01 - induct. sensor containing permanent magnet and coil with winding. The
voltage puls induce itself into coil at the moment when projection placed on outer circuit of
rotor jacket is passing the sensor core.
- alternator A67 - alternator is composed of stator and rotor. On stator (star-shaped form) is
placed one black coil (feeding ignition coil Z67) , 10 source coils (serving as chargers of
battery - through regulator R67 - and of lighting of motorcycle. Rotor contains 12 pcs of
permanent magnets, there are two projections on circuit determining together with sensor S01
the moment of spark flashover. The spark is generated twice to one engine revolution 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 existing system
Vape Z04 where the energy source was the
battery 12V.
As there is no connection between
ignition coil Z67 and battery 12V (with
exception to the connection through
motorcycle frame), the spark will be generated
even if the battery is not mounted on
motorcycle. As regards the placement of Z67,
there is still valid the requirement of the same
building-up as for former Z04. It means to
place coil into cooling air flow and to move it
maximum away from emitted heat of cylinders
head. The advantage of coil Z67 is the
decreased heating-up when idling engine
revolutions.
Coil Z67 collaborating with rotor A67 does not enable to start up the engine on opposite
side than wished following to marked projection on outer circuit of rotor jacket and input
circuits in coil Z67.
The using of sensor S01 is very similar to that of system Z04. For the correct function it´ s
obligatory to keep the prescribed space between S01 and projection on rotor. The correct
setting-up oscillates between 0,4 - 0,5 mm. If it is not possible to maintain this spacing, we
chose as priority lower spacing (0,3 mm) than higher one.
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On testing machine it´ s not recommended to let turn alternator A67 to opposite side than the
engine operation is prescribed, i.e to more than 1.300 engine revolutions/min . During this
working operation the voltage on condenser is getting increased over 400V. When opposite
side of alternator working, the coil Z67 will only run on 2.000 revolut./min. approx.
Controlling on testing machine we can notice when sudden change of revolutions, e.g. from
1.000 rev./min.to the right instantly to 1.000 rev./min. to the left, following situation :
immediately after the changement of revolut.direction, the coil Z67 sparkles even when
opposite (lefthand) run and approx. within 0,5 sec. this effect is disappearing ( the switch
doesn´ 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 alternator
A67:
- two wires - one red and one white charging condensor in coil Z67
- two black wires charging the battery 12V via regulator R67 and providing current for
lighting
The voltage induced to coils on stator is always alternating. According to the need it has to be
rectified using regulator R67
The principle of regulation : the load (of battery, lamp) is connected and disconnected to
winding on stator in such a way to keep the middle value of direct-current voltage = 14V on
battery. The over energy from alternator A67 is therefore not utilized that means there is
lower coil heating-up on stator A67.
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Sensor S01
Sensor resistance = 200Ω +- 20%, measured by direct-current ohmmeter. This value is valid
when environs temperature reaches 20 C. If this motorcycle component is heated over the
named temperature, the resistance will be increased on 250Ω approx. On the other side when
freezing,, the resistance value is inferior to reach approx. 160Ω.
The measured resistance values (at temperature 20 C) inferior to 150Ω and superior to
250Ω indicate the defect (e.g. temporary winding short-circuit, event. winding breakage).
The short-circuited sensor S01 ( resistance < 10 Ω ) represents on outlet weak signal and Z67
cannot generate the spark. The totally open circuit S01 can under some circumstances
generate puls voltage, which synchronizes coil Z67 and generates the spark. In this case it is
possible to increase the starting revolutions by signalization. The increased starting
revolutions can also be caused by partial short-circuit.
Puls voltage generated S01 is increasing together with rotor revolutions and is lowest
when starting-up. Its loss is from these reasons most apparent.
The eventual short-circuit of outlet conductor from sensor S01 on frame doesn´ t lead
to its dammage.
The switch of the sensor outlet on + battery pole doesn´ t damage sensor, if this
wrong switching on is repaired within 5minutes approx.. On the contrary the switching on
S01 to alternator circuit (e.g. through 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 the damage can be caused by
connection to another sources of electrical voltage.
Coil Z67
The source of energy is the charging (black) coil on stator. It is connected by means of
two conductors (red and white). The blue conductor serves to switching off the engine and
can be short-circuited on motorcycle frame only(= coil center Z67). The yellow conductor is
connected to sensor S01.
On high-voltage outlets one can read as far as 35 kV voltage . One spark is always
positive and the second one always negative. One spark is always in advance 2,5 mm in front
of the top dead center and second one always in the engine exhaust phase. After the revolution
of engine of 18 the situation interchanges. The cylinder in "exhaust" is in front of the top
dead center etc. The coil center becomes thus the frame point of Z67.
Diagnosis :
1. The resistance between yellow conductor and frame = 120Ω ( direct-current)
2.The resistance between blue conductor and frame is very high(> 50 kΩ ). This indication is
informative only and can be influenced by type of testing machine. Practically speaking it is
the information very unreliable for control.
3. The resistance between red and white conductor mutually or against frame is very high,
too (> 40 kΩ ). This information is also very unreliable and the same statement as ad 2) is
valid.
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4. The resistance of secondary winding (measured on Vn outlets) = 6kΩ÷10%. For first series
(7th month of 1996) the coils with resistance of 7kΩ +- 10%- have been used. The
measurement is in principle direct-current (PU 120 etc.)
Attention !! There cannot be in any case red, white a blue conductors Z67 connected to
battery (even for short period). These conductors cannot be connected to source winding of
alternator (for charging of the battery), neither. This winding on A67 and battery produce high
current (> 5 A) , that usually damages the performance element inside Z67. Subsequently Z67
is definitively out of use.
The big short-circuited currents flowing through coil and its circuits signal different
"burls" on surface of coil casing. This place was affected by local overheating of some part.
When functionning normally, the winding charge in stator is not capable to provide this
damaging performance.
Short-circuit of Vn outlet on frame or short-circuit between Vn outlets mutually do not
menace the coil itself, but the motorcycle stops.
The supplied performance will damage quickly (approx.within 10 sec.) the entry parts 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 conductor, one can use from necessity :
a) disconnection of red and white conductors
b) short-circuit of red and white conductors between them
c) short-circuit of yellow conductor on frame
d) disconnection of yellow conductor from S01
All four variants of how to switch off engine can be used when idling only (i.e. up to 2000
rev./min.) with the exception of point d) which can be used even when revolutions exceed
2000 rev./min.
In all the case the frame S01 and frame of coil must be perfectly connected electrically,
otherwise there is a danger of increased starting revolutions , eventually the spark in wrong
advance. If the spark is getting weak it´s possible that Vn coil is in partial short-circuit. We
shall find it by measuring of secondary winding resistance. (Note : Coil heated in operation
presents resistance of approx. 7kΩ and coil out of operation with environ´s temperature 20 C
presents resistance of 6 kΩ). Measured resistance bellow 5 kΩ signals partial short-circuit on
coil winding , when winding disconnected (resistance > 20 kΩ) the spark can get weaker.
The other possibility of weakening of the spark is the leakage of red conductor on
frame. This matter is connected with alternator A67, too.
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Alternator A 67
Attention !
Stators A30, A49 and A67 are not in any case interchangeable. The same with rotors A30,
A49 and A67. Rotor A30 doesn´t allow to suppress the left-hand engine run.
2. The source winding presents small resistance approx. 0,4Ω - 0,5Ω. The battery source
winding generates alternating voltage to amplitude 100V. During operation the alternator is
getting warmed up to temperatures near to 100 C. When testing separately from motorcycle it
is necessary always to connect the switch Z67 with charging coils. Not loaded charging
winding provides voltage 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-circuit between windings mutually (black and copper coils), either
decrease of lighting performance and warming of regulator R67 takes place or decrease of
spark performance takes place, because one end of winding for coil Z67 will be framed.
Only 50% of energy will get into Z67. It´s very dangerous to connect circuit of charging coils
(black) and source coils (copper) on stator A67. Under higher revolutions (> 2.000 rev./min)
Z67 will be dammaged.
Rotor of alternator contains 12 permanent magnets. Any of two adjoining magnets have
always to have opposite orientation of magnetic field.
Regulator R67
It is monophasic and is connected to source winding on alternator A67 (by means of black
conductors). All needed connections are led through two two-pole and one single-pole
terminal boards.
Two of them (black) represent entries from alternator A67. Both are interchangeable and
equivalent as on A49 as on R30.
Red conductor is connected to + battery pole
White conductor on terminal board is frame. The alluminium cover is conductively connected
to frame by negative pole.
Green-red conductor serves for charging control
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Regulator R67 is warmed up during operation the more the higher performance it is providing
to bulbs and battery. It has to be cooled by air circulation. When motorcycle is on stand,
slight current from battery flows through regulator to frame. This current represents less than
0,5 mA. If the regulator is warmed up, the current is higher (even several mA ). After cooling
of R67, current is decreasing. No need to disconnect battery from regulator when motorcycle
is out of operation.
The most important when in operation is the proper connection of all the resp. parts. The
eventual loss on transitory resistances is influencing intensity of regulated voltage.
The battery cannot be connected with regulator in opposite way. The resulting damage cannot
be repaired. The battery cannot also be changed with some entry terminal connector(from
alternator).
Regulator is set-up on 14,2 to 14,4V with battery charged and without attached" load". If
there are other consumers joint, e.g. 63W (3 x 21W) under 4.000 rev./min., the voltage
decreases to approx.14 V. After warming up R67, the U(REG) is 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 blades 6,3 on
terminal board , event. against frame can be considered as informative, only. The framed
blade has to have short-circuit on A1 cover R67. Other contacts represent high resistance (50
kΩ and plus). If somewhere the resistance is inferior to 1 kΩ event. if short-circuit appears,
this is the question of defect.
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The steps detecting defects in circuit of charging of battery and regulator R67
Note : Both windings are to be perfectly insulated from each other. If the windings on stator
and resistance S01 are O.K., stator A67 itself is O.K.,too
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5. By ohmmeter verify resistance of yellow conductor against frame (120Ω) at switch Z67 ;
resistance of red and white conductors and blue conductor has to be > 40kΩ - more details
in article conc. Z67
6. Measure Vn coil - resistance = 6kΩ±10%
7. Verify whether blue conductor is not by coincidence constantly short-circuited on frame by
fault in cabelling
8. Check-up whether frame S01 is connected to frame Z67
Note : Various bulges and bumps on surface of Z67 signal overheating of Z67. It´s necessary
to check-up cabelling and eventual short-circuit into 12V distribution circuit
If all these values are correct and it´s not still possible to start-up the motorcycle, try on
removing plug if some spark even exists when starting-up
Accumulator is supplied in precharged condition. It fulfills Czech state norms ČSN 36 4316,
ČSN 364318.and the international ones, too.
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Dimensions of accumulator :
height 130 mm
length 121 mm
width 61 mm
net weight of accumulator 1,7 kg
gross weight of filled in accumulator 2,07 kg
Charging
The accumulator which is activated after 6 months period from the date of 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 changing any longer.
Note
Charging period depends on state and capacity of accumulator. During the charging it´s
necessary to follow temperature of accumulator which should not exceed 40 C. After
exceeding the mentioned temperature the accumulator has to be cooled (e.g. by running
water).
When higher density of electrolyte we keep filling up the level by distilled water , only.- The
voltage of fully charged accumulator is 12,6 V, i.e. 2,1 V per cell. From the structural reason
the voltage of individual cells of this type cannot be measured.
When operating the motorcycle the terminal connectors have to be permanently connected
with battery when engine is running. It´s not even permissible "trial" disconnecting of
accumulator when engine is running ! We draw also attention to the following situation :
during arc welding the terminal connectors of regulator have always to be disconnected
together with terminal connectors of rectifier (eventually even earth connection eye on
regulator casing).
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Oil pump
Motorcycles equipped with oil pump are from now on greased with fuel mixture but not in
proportion given and mixed beforhand, which is changing subject to revolutions and to travel
of slide valve and oil is taken from separate reservoir.
The used oil pump MIKUNI IM 137-22 is adjusted from producer to basic optimum supplied
quantity of oil for motorcycles JAWA 350 and it cannot be replaced with any other type or
execution without preceding authorization of JAWA MOTO.
The oil pump, powered directly by crankshaft, is placed in left engine cover. The admission to
it can be reached when removing the cap fixed with two bolts. It is fixed to left cover with
two nuts and the sealing is executed with "O" ring No. OS/16″ (supplied by MIKUNI).
Oil tank
Oil tank made of transparent plastic material is placed in rear part of underseat space ,
accessible after removing of the seat. It is equipped with filler and withdrawable cap and in
lower part with outlet. The oil tank has the capacity of 1,5 l. In its front part there is mark
indicating minimum oil level.
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e) The basic setting of segment for engines 638 (pump type 22) is 15° and is executed as
follows : - insert gauge 638( No.of prod.9.71.87536.4,
width 3,5mm) between segment and attachment stop
- use electric pen to mark new gauge line(B)
(determinating basic setting of oil pump) facing gauge
line on attachment
f) Adjusting of bowden of carburettor . The slide gate has
to be in lowest position
g) When freewheel slide gate position is changed , it´s
necessary to adjust oil pump bowden following point e)
h) If air vent of oil pump occurs, release the deaeration
screw on face of pump ( above regulating segment) .
After filling the pump with oil tighten the screw and with
slightly increased revolutions we turn over by hand
the segment into maximum position. This procedure
accelerates the deaeration of piping into engine.
To pic
1 – segment A - original gauge MIKUNI X - space for gauge
2 – attachment B - new gauge JAWA
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 lower part of
tank replace by a new one equipped with sieve (prod.No.451964039013)
2. Flush also the feeding transparent pipe of bigger diameter and proceed following point 2b)
3. Dismantle feeding oil tube to engine from inlet suction branch valve and clean the valve
with compressed air in the direction of oil flow
4. Drain fully the fuel tank and pour in 1 liter of mixture (fuel/oil) 1: 50
5. Cover in a adequate manner the inlet of securing valve, start up the engine and wait until
some 50cm3 of original soiled oil flows out
6. Switch off the engine, loosen securing valve and connect the whole system
7. After refilling the fuel tank and assemby of oil pump on motorcycle, we proceed following
point 2a. Deaerate the oil pump according point 2h.
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CONTENS
Presale service 3
Technical data 3
List of special tools 5
Lubricants 6
Maintenance plan 7
List of main bearings and sealing rings 8
Piston grading 8
Cylinder grading 9
List of gudgeon pin bearings 10
I. ENGINE
1.1 Removing and refitting cylinder heads and cylinders 10
1.2. Pistons – removing and refitting 11
1.3. Primary gear, clutch dismantling 13
1.3.1Reassembly 13
1.4. Clutch reassembly 14
1.5. Speedometer drive and sealing 14
1.6. Kickstarter spring 15
1.7. Gearshaft with carrier, gear shift pawls 15
1.8. Removing semi automatic clutch 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
IV. CHASSIS
4.1. Removing the front wheel 26
4.2. Removing the rear wheel 26
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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 37
5.6. Battery 12V 5Ah 45
5.6.1.Preparing the battery 46
Electric diagram 47
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JAWA 350/638,639,640
II. edition 2004
Taking over the text and illustrative 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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