640Work L 9.9 - Jawa Moto

1 workshop MANUALJAWA 350/638,639,640 JAWA Moto spol. s T nec nad S zavou20042 workshop MANUAL_____The purpose of this Manual, intended primary for specialized Jawa repair shops, is tofacilitate all jobs connected with repairs of Jawa 350 motorcycles. All the describeddismantling, refitting and adjusting procedures have been elaborated under the assumption,that the reccomended tools and special jigs and fixtures will be used for them. Allinformation, illustrations and technical data contained in this manual are based on the latestknowledge gained in and during manufacture. The Jawa Moto spol. s reserves the right tochange its products any time without a previous notice. Any changes and or deviations fromthe standard version for certain territories will be published in the form of Supplements to thisManual.

2 It is not permited to reproduce this workshop manual or its parts in any formwhatsoever without written MANUAL_____PRE-SALE SERVICE1. Unpack the motorcycle, free it from preservation grease, assemble the separatelydelivered units and parts of accessories /control of completeness/.2. Check engine and frame numbers to be conform with the Take out the accumulator charging forming, Control the oil level in the gearbox Control all the functions of electrical Basic adjustment of the headlight /page 50 operating instructions/ and vertification ofheadlight Check ignition spacing between catcher and Adjustment of 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 theengine.

3 (Motos without Oil-master) By motorcycles with Oil-master filling in oil,deaerate whole syst m, filling in petrol and Adjusting the idle run on warm engine, retightening of cylinderheads and Control of bolted Instructions about attendance of machine and handing over to the DATADIMENSIONS OF MOTORCYCLE Length2100 +/- 30 mmWidth780 +/- 15 mmHeight 1160 +/- 30 mmClearance120 +/- 10 mmSeat height 820+/- 15mmAxle base1370 +/- 25 mmMin. turn radius3,5 +/- 0,4 mMASS AND LOADP roper mass149 +/- 3 kgRunning mass162 +/- 3 kgOverall mass342 +/- 3 kgPayload180 kgNr. of seats2 Trailer mass50 kg overallSidecar mass172 kg overallENGINEC ategorytwo-stroke, air-cooledNr. of cylinders2 Cylinder capacity343,5 ccmBore58 mmStroke65 mmCompression ratio9,8 + 0,7 :1 - 0,3 :1 Max / 1 minMax output17 kW 10% -5250/1 min +/- 3%Max torque32 Nm 6% - 4750/1 min +/- 5%CARBURETORC lassJikov 28-29 CE horizontalSlide typeCLUTCHT ypemultiple-disc in oil bath4 workshop MANUAL_____GEARBOXT ypemechanical with gears,double shaftNumber of gears4 Control by foot leverOverall ratioclimbing capacity with full gear1 : 14,5041% gear1 : 8,6020% gear1 : 6,1014% gear1.

4 4,969,5 %primary chain2 x 9,525 x 4,7766 linkssecondary chain1 x 12,7 x 7,75126 links+1 conectSUSPENSIONF ronttelescopic fork, steel spiralspringsStroke150 mm wheel axle 134 mmRearswing arm, spiral springsStroke80 mm whell axle 90 mmFront shock absorberhydraulicTypetelescopic in fork s armsRear shock absorberhydraulicType telescopic in suspension unitsRIMSF ront wheel steel, deepened profileDimensions2,15 B x 18 Rear wheelsteel, deepened profileDimensions2,15 B x 18 BRAKESF rontdisc type, hydraulic controlDimensions 265 mmReardrum, mechanic controlDimensions 165 mmELECTRIC OUTFITI gnition magneto VAPE A67 contactlessOutput12 V, 180 WBatterylead type, 12 V, 6 AhHeadlampasymmetrical, rectangular,adjustable12 V 60/55 W12 V 4 W BA 9sDip switchsliding typeIndicators switchlever typeTail lampgroup typeIndicators locationheadlamp bracketrear frameFUEL AND LUBRICANTSFuel tank capacity17 l, 2,8 l reserveGearbox oil charge1+0,1 lSuspension oil chargeFront200 ccm per armRear47 ccm per absorberpermanent chargeFront brakebrake fluid DOT 4 to max.

5 (upper edge of window)FRAMET ypetubular, double, closed5 workshop MANUAL_____ LIST OF REPAIR TOOLS FOR TYPE 638, 639, 640123456789101112131415161718196 workshop MANUAL_____LIST OF REPAIR TOOLS FOR TYPE 638, 639, gauge for ignition advance (for rotor) , centering for driving out for driving home sealing rings7S-8116-19758-41 Tubular spaNner steering , removing primary for gudgeon pin preSsing dia. 16 in and bush, connecting rod small end12S-9028-86-7631 Jig with bolts for separating crankcase clutch plate14S-9228-86-7651 Drift15S-9328-86-7661 Fork leg extractor16S-9428-86-8141 Primar chain jig with accessoriesList of lubricants recommended for motorcycle JAWA 350 Use of oil type of oil in the Czech rep. Viscosity ClassnotesA gearboxMogul Trans 90 API GL 4temperature over 0 Cbrake lever pinsGyrol 90 SAE 90clutch lever pinsbrake cams Mogul Trans 80W/90 API GL 4whole yearstand pinsbowden cablesByrol 80W/90 SAE 80W/90B engine lubricationB1lubricated petrolMixture ratio 1:60 after running in, 1.

6 50 during running inFor whole year riding use oil of viscosity class SAE 30-40 for two stroke engines andwith classification according to API with Oil master systemFor whole year riding use prediluted or synteticoil for two stroke engines according to recommendation of individual oil riding in temperatures over 0 C can be used oil for two strokes engines ofviscosity class SAE 30-40 and with classification according to MANUAL_____CTelescopic front fork Mogul Super 15W/40 API SD/CB orMogul Super stabilAPI SF/CC15W/40 SAE 15W/40D accelerator twist gripenergrease LA2 ISO-L-XBCEB 2 Swinging rear armenergrease LA2 ISO-L-XBCEB 2 Erear sprocket bearingsenergrease LA2 ISO-L-XBCEB 2 Fwheel bearingsenergrease LA2 ISO-L-XBCEB 2 Gsecondary chainspecial spray Castrol Mo S2, Gleitmo 582.

7 OPERATING LIQUIDSTYPE OF LIQUID IN CZCLASSIFICATIONA brake fluidSyntol HD 260 DOT 4 Maintenance plankm5001500250050001000015000200002500 030000 Transmission oil*VVKVKVKVC lutch*KKKKKKKVKC arburettorSAir filter**KKKVKKVS teering headKKMKKMRear suspensionVKSecondary chainKKKMKVMKVW heels and rear suspension bearingsMMMB rakes brake liningKKKB owden cables**KKKKKKB atteryKKKKKKKKVA lternatorKKIgnition spacing - between rotor and catcherSKKKSKSKSS park plugsCVVF ront fork oil exchange**VVVVVVVW heels spokes stretchingKBrake lever pins, joints, stop switches, accelerator twist grip*KKKKKKKKP iston, piston rings, transfer portsKKBrake plateKKKVKKVS crews, nuts and packings**KKKKKKKKK*check as often as necessary K checking, cleaning, adjusting or eventually replacement**check every 1000 km Ccleaning** check every 2500 km S adjustment** check every 5000 km MlubricationV replacement D decarbonizationAfter running of:25 000 kmprimary chain replacement30 000 kmcheck or exchange of connecting rod bearings, steering head bearings, shaft type gasket ringswith the crankshaft as well as wheel with hub, wear of cylinder (event.)

8 Re-bore)50 000 kmcomplete dismantling of brake system8 workshop MANUAL_____List of main bearings and sealing ringsDesignationname of 594 043 400needle bearing INA HN (15x22x12)1engine leftt side324 163 030 100 bearing 6303 A1engine leftt side324 163 059 566bearing 6305 A1engine leftt side324 594 049 200needle bearing INA BN (16x22x12)1engine right side324 232 050 000bearing 32051engine right side324 232 050 003 bearing 3205 C 31engine right side324 162 069 566bearing 62062ckrankshaft273 521 008 617sealing ring (30x52x10)1engine right side273 521 106 807sealing ring (25x52x7)1engine right side273 521 006 917sealing ring (25x62x8)1engine leftt side273 521 100 417sealing ring (8x16x7)1speedometer drive324 914 010 452ball ( 6,35)1+36frame head, clutch release324 163 020 100bearing 6302 A2+2front and rear wheel324 162 050 100bearing 6205 A1rear wheel sprocket9 workshop MANUAL_____Piston gradingGradingD 2+ 0,000 - 0,010 StandardA57,972B57,982C57,9921.

9 Re-boreA58,222B58,232C58,2422. re-boreA58,472B58,482C58,4923. re-boreA58,722B58,732C58,7424. re-boreA58,972B58,982C58,992 Cylinder gradingNote: The manufacturer delivers spare cylinders exclusively with the basic /standard other dimensions given in the table are guides for cylinder reboring. As it is very difficultto rebore the cylinders accurately within the tolerance limits of hundredths of millimeters, it isnecessary to check the bore of the rebored cylinder by measuring it at several points, and touse a piston of grading corresponding to the measured dimension. The grading mark on thetop face of the cylinder has to be changed the engines (new or rebored) the right-hand and left-hand may be of a different grading class (but not ofdifferent rebore grading).

10 In the case of cylinders withrebores in between of two grading groups, it is possibleto use a piston of B or C group. With the B piston isrunning in quicker, with C piston nocking is likely oncold engine (after start). ,01+0,0158,01+0,0158,01+0,02B58,02+0,015 8,02+0,0158,02+0,02C58,03+0,0158,03+0,01 58,03+0,02D58,04+0,0158,04+0,0158,04+0,0 2+0,25+0,5+0,75+1,0010 workshop MANUAL_____List of gudgeon-pin bearingsConnecting rodGudgeon pinNeedle roller 2 x 13,8 ClearanceRed19,994+19,998 Blue15,994+15,9971,994+1,9961,993+1,9950 ,005+0,0160,007+0,018 Red15,997+16,0001,994+1,9961,993+1,9950, 006+0,0170,008+0,019 Blue19,998+20,002 Blue15,994+15,9971,996+1,9981,995+1,9970 ,005+0,0160,007+0,018 Blue15,997+16,0001,996+1,9981,995+1,9970 ,006+0,0170,008+0,019 White20,002+20,006 Blue15,994+15,9971,998+2,0001,997+1,9990 ,005+0,0160,007+0,018 Yellow20,006+20,010 Red15,997+16,0001,998+2,0001,997+1,9990, 006+0,0170,008+0,019I.