u

350JAWA

/56
I

,'

NARODNi PODNIK TYNEC n./sAz.

~i

"

),

1989
'.
,--

ThiS WORKSHOP MANUAL hae bee~ issued

expecielly

for the use of repair

shope

",ith . the purpose of 888istins

ther repairmen in more exteli8ive end more complicaWhen describins

of JAWA motor cycles.

the individusl.repair
use the set of special

procedures
tools

and mechanics

1fbichhave been designed not. contain descriptions

to faci1.itatethe

most complicated

Jobs. This Manual doe.

of repairs end adjustments de~cribed Handbook handed over to every buyer of a JAWA motor cycle.

Sales and Technical Service Department

- 1-

Fig.No. 1 - JAWA 350/634-5,8

Fig.No.

2 - JAWA

350/634-6

-3-

PRE-SALE

INSP1!XJTION OF MACHINE

a) Unpack the motor cycle, remove the protective coating of its parts, and fit in position units and parts of equipment separately packed and delivered with the machine. b) Remove the battery, put it in working condition, charge it, and reinstall it. On the correct electrolyte density and charging depends the service life of the battery. c) Inspect the motor cycle surface finish. Repair any defects charging the repair expenses to the account of the culprit (hauler, sto~e, manufacturer, Touch up scratched or otherwise damaged enamel. d) Check whether the filter e1ement'is in position in the intake silencer and whether the intake silencer is properly cor~ected to the carburettor.
e) Check the oil level in the gearbox - top it up if it doe9 not reach up to the

etc.).

,mark.
f) Check the oil filling of the front fork paying attention to lmy traces of oil leakage (oil sp10tcheo on the rim, tyre, etc.). If there are no indications satisfactory (oil is filled in-in the factory of leakage, the oil filling is

in automatically metered out amounts) but if a defect is ascertained remove it,

drain the

remaining oil, and refill the fork leg (legs) with the recommended nmount of fresh oil. Never top up the oil remaining in the fork leg!

g) Remove transport packings (plugs) from the fork lugs or nuts of fork legs. If you fail to do so, ~n undesirable overpressure builds up during the up and down swing of ~he front fork resulting in the deterioration of riding characteri~fics and shortening of the ssrvice life of seals and, moreover, regarding damaged seals will be recognized. h) Check on all positions of the ignition key in theewitch tail and stop li~t, no claims

box and test the

individual parts of electrical equipment (headlamp, direction indicators, horn, switches on handleba~e). Repair defects, if any.

i) Check tyre pre~sures' and adjust them to the recommended values. . j) .Check the tension of the secondary chain and adjust it as necessary. k) Check the proper tightening of the front ~~d rear wheel spindles and the nut of the rear sprocket (chain wheel). If the machine was delivered with the front wheel removed, first tighten the spindle nut, then push down and release several times the front fork, and finally tighten firmly the clamping bolt of the slider end pieces. Do not forget to lock the nut with 8 cotter pin on machines intended for coupling with a sidecar. 1) Check the 8d~ustment of brakes (dead travel) and adjust the stop swith if nece~sary. m) Pour at least one litrE! of petrol mixed with the recommended oil in the ratio

prescribed for the respective machine model into the fuel tank. n) Start the engine and try the individual positions of the switch box. Switch on all the lights and check at medium engine speed (machine propped up .on its

stand, the speedometer indicates 50 km with the 4th gear engaged wheth~r the engine runs smoothly and regularly and does not stall when disconnecting the battery fuse. In this way you will make sure that the dynamo covers all the electric power demand.

- 5-

List of Tools for P.reTious JAW! Models Usable a180 ~or UndA1 ~3A_A

Pos. No. 1 2 3
'4

Desin8':" nation
8-9 8-10 S-44

Product No. 16-65671-3 16-67585-3 9.71.51578.3 9.71.51559.4

Description
Front 1"ork bush extractor

Quanti ty
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Exhaust pipe nut spanner

extension pieces

5-46 5-48 .5-61

Injection adTance adjusting gauge Dynamo rotor puller Crank mechanism centre bush extractor Crankcase halves separating press with bolts Pawl retaining jig Centering bush drift Cluth pilot plate Tubular wrench w32" for chain wheel nut B~arin8 extractor Packing ring installer Packing ring protector Fork leg puller Tubular wrench for steering

5 6 1 8 9 10 11 12 13 14 15 16 17

9.11.51598.3 9.11.51589.4 9.11.51590.4 9.11.51603.3 9.71.51565.4 9.71.51577-4 9.71.51576.4 9.71.51599.4 16-65776-3 16-19758-3 16-19756-3 new tools:
9.71.52254.3 9.71.52248.4 9.7i.52253.4 9.71.52252.4 9.71.52251.4 9.71.52255.3

sternnut

8-82

Hook spanner

c~;'j 18;~, 19 20 21, 22 23

Ad~~tional,
5-84 5-85 5-86 S-87 5-88 S-89

Exhaust silencer core extraotor Sprocket puller Gudgeon pin drift

1 1 1

Gudgeon pin pres&-ou~ pin, 4is.16 mm 1 Connecting-rod smaliend insert 2 Gate interlock adjusting lever 1

Special 24 25 26

service 5-200 S-201 S-202

tools

for crank mechanism: 9.1l. 72590.1 9.06.55407.3 9.06.55408.2 Pressing fixture attachments Lever Pliers including 1 1
'1

- 8-

14
"0
0 0 0 0
0'
01 1U I

"

8
10

11

9 12 13

15

0 14

16

~~17
Fig.No~3 Service tools

- 9

18

19

~
20 21

.~
22
~

.1/

24

..
.

I ;

- ~
26

25

~
Service tools

~ ~

Fig.No.4

- 10.o'~

.-

LIST OF MAIN BEARINGS AND SEALING RINGS Table No.1

Item
No. 1

Desition
324 163 050 036 (960-630507)

Bearing
Bearing 6305 C 36. Bearing 6306 C 36 Bearing. 6303 . Bearing

Dimension'
62/25xl5

Unite 2

Location
Engine

2 3
4

324 163 060 036 (960-630607) 324 163 030 000

72/30.xl9

Crankshaft mechanisll

47/l7xl3

Gearbox

324 232 050 000

52/25%20.6

1 2 2

Gearbox Crenkshaft
m.echenism
Crenksha1"t.

(961-320500) 5 6 x xx Needle bearing Needle

mechanism 42/l5xl3 2+2 Front and rear wheel

7
9

3?4 163 020 000 (960-630200) 324 914 010 452 (9QO-406350)

Bearing 630;'

Ball

38+1

Frame head Declutching device

(1/4")

324 162 050 000 (960-620500)

Bearing 6205 Sealing

52/25x15

Rear wheel

10

.:{'i<\

">273 521 006 917

25/62/8

Engine

953-025808)
273 521 100 303 (954-008107)
.

ring" gufero"
"gufero" 8/l6Xl 1 Speedometer drive

11

12

273 521 108 603

"gufero"

30/52xl2

Gearbox

only

separate needles and gudgeon pins are supplied - see the "Idst of Spare Parts" .

xx - not supplied. In the case of a defectr replace the complete connecting rod which 1S supplied complete with the b1g and small end bearings and the respective journals .

- 11 ..;.
1

5 2 ~ 10

6' 11

12 4

'!'

Fig.No.5

Layout of bearings and packing rings

- 12 -

;
1ft.... ...re

~ ~ "'-N
...

J!

~
~
=

<

"" '

"-.c a

; ~ .
'"
"""

Cl:! cc ,..

~
>
.0

---

lilt

,..

~ ,..
.0

>

>

.0

."... re

~ ~N

Fig.No.

6 Wiring diagram (single-instrument model)

I
1

-13-

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