www.jawamoped.com WORKSHOP MANUAL …

1 MANUAL moped model 210 This WORKSHOP MANUAL is intended primarilyfor all repair shops and their workersconcerned with repairs of our model 210moped. It does not contain servicing jobsand repairs described in the Rider's Manualbut only repairs for which special assemblytools and jigs are purpose of this MANUAL is to facilitatethe work of the repairmen and to improveservicing of our products. Any changes anddeviations from standard procedures will beannounced in our Service concern, Povazske strojarneKlementa Gottwalda workssales and technical service departmentCONTENTSI.

2 moped specificationsII. General technical data1. Assembly tools and jigs2. moped lubrication Lubrication Chart3. List of bearings, sealing rings and bushes4. Engine torque transmission diagramand descriptionIII. Engine1. Removing engine from frame2. Removing cylinder head, cylinder and piston3. Grading of cylinders and pistons4. Clutch dismantling5. Carburettor6. CrankshaftIV. Frame1. Front, telescopic fork2. Front, and rear wheel3. Rear wheel telescopic suspensionV. Electrical equipment1. Alternator2.

3 Ignition system3. Wiring diagram4. Diagnosing electronic ignition defectsVI. Causes of defects and their removalI. moped SPECIFICATIONSE ngine typeair cooled, two-stroke single-cylinder unitSwept volume49 ccCylinder bore x piston stroke 39 x 41 mmEngine power kW at 5,000 rpm 8 %Clutchesautomatic, dry, centrifugalGearboxtwo-speed unitEngine to rear wheel1st. speed overall ratio --- 1 : transmission ratio2nd. speed overall ratio --- 1 : transmissionindented beltSecondary transmissionlink chainPedal drive transmission ratio 1 : starting gear overall ratio 1.

4 Suspensiontelescopic fork without shock absorbers60 mm strokeRear suspensiontelescopic suspension units without shockAbsorber -- 60 mm strokeBrakesinternal expanding shoe -- brakes controlledby levers on handlebarsBrake dimensions85 x 20 mmTyres2 x 16" (WH1) x 16 Inflation pressures - front tyre196 kPa (2 atm) [ 28 psi ] - rear tyre245 kPa ( atm.) [ 36 psi ] moped dry weight51 kgMoped running weight54 kgRoad speed - sustained35 km/hr. - maximum40 km/hr 5 %Fuel tank filling capacity4 litresFuel reserve0,7 litresMaximum climbable gradientwith rider weighing 75 kg25 %Noise70 decibelsIgnition system6 volt, contactless with semiconductorelementsSpark plugPAL N 7 R [ Champion L89CM L85 L86 ] [ NGK B6HS Bosh W7AC ]Headlamp6 v 21 wTail lamp6 v 5 wSpeedometer lighting6 v 2 wFuel litres/100 km at 27 km/hrLoad capacity, maximum90 kg including 5 kg luggage on carrierNote.

5 When exceeding the load capacity, it is necessary to decrease themaximum speed proportionallyZVL model 210 WORKSHOP MANUAL Pages 1, 2 & Engine Torque Transmission - Diagram (Fig. 4)(C) so that they run at the same speed. The run-and Descriptionning of the layshaft gears (4) and (5) at differentspeeds is enabled by the freewheel (D). The gearGearboxchange is effected by the automatic centrifugalThe diagram of the two-speed automatic trans-clutch (C) provided with two shoes of the leadingmission is shown in Fig.

6 The operation of this clutch is controlled byforce closing between the parts (2'), (6) and (7)The torque is transmitted from the crankshaft(1) to the gears (2 2') over the starting clutch(B) by an indented the output shaft (7), the torque is trans-mitted to the rear wheel by means of secondary1st-speed 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 respectivebetween the gears (4) an(5) on the layshaft. Fromgear depending on the road speed, the drive takenthe gear (6), the torque is transmitted over a forceoff the automatic transmission, the accelerationclosed mechanism to the output shaft (7) andand deceleration, and the rolling resistance ofthe rear wheel by means of the secondary trans-the vehicle in terrainmission gearing:The output shaft (7) with the gear-change me-chanism runs in two ball bearings.

7 The layshaftParts (3), (6), and (7) are coupled with the clutchis supported by two bronze model 210 WORKSHOP MANUAL Page 8 ENGINE1. Removing engine from framea) Remove the engine ) Detach the spark plug cable, the fuel hose, and thethrottle ) Disconnect the leads of the electrical ) Disconnect the chain of the secondary ) Disconnect the exhaust pipe from the ) Remove screws fastening the engine to the frame,and lift off the well the surfaces of the engine, and drain the oilfrom the automatic transmission case.

8 During enginedismantling, clean immediately all the removed partsand put them aside in the order of their removal, so thatthey can be reassembled correctly and in the shortestpossible Removing cylinder head, cylinder and pistona) Unscrew the four M6 nuts and lift them off togetherwith washers from the ) Remove the cylinder ) Remove the cylinder (Fig. 5)d) Remove the circlips securing the gudgeon pin anduse the drift No. (Fig. 6) to drive outthe gudgeon care not to spill the 2 x 8 mm needle rollersof the gudgeon pin (there are altogether twenty five).

9 The maximum permissible ring gap of a worn pistonring is from mm to the dimension for grading the pistons in theindividual classes mm. From the piston base ( )ZVL model 210 WORKSHOP MANUAL Page 10 Clutch DismantlingAfter removing two M 5 x 30 screws, lift off the left-hand clutch the clutch drum retaining jig No. the starting clutch drum and loosen the nut withthe spanner No. 17 (Fig. 8). Pull off the clutch drumusing the drag No.

10 4T 210-2200-01 (Fig. 9). With ascrewdriver remove three circlips from the recesses toloosen the clutch starting shoes (Fig. 10)For re-assembly use the washer No. 4T 210-2100 and clutchdrum drag No. 4T 210-2200-01 and secure the clutch with thecirclips (Fig. 11).After having removed the drum with starting shoes,rotate and gently pull the starting drum with the sma11pulley to remove it together with the indented carefully so as not to damage the needle bearingsand model 210 WORKSHOP MANUAL Page 11 the removal and refitting of the starting shoes usethe jig (hook) No.