1. DL manuals
  2. JAWA
  3. Motorcycle
  4. 350
  5. Workshop Manual

JAWA 350 Workshop Manual

Manual is about: Jawa Motorcycle

Summary of 350

  • Page 1

    Workshop manual jawa 350/638,639,640  jawa moto spol. S r.O. Týnec nad sázavou 2004.

  • Page 2

    2 workshop manual ___________________________________________________________________________ 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 adjusti...

  • Page 3

    3 workshop manual ___________________________________________________________________________ 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 – t...

  • Page 4

    4 workshop manual ___________________________________________________________________________ gearbox type mechanical with gears, double shaft number of gears 4 control by foot lever overall ratio climbing capacity with full load 1.St gear 1 : 14,50 41% 2.Nd gear 1 : 8,60 20% 3.Rd gear 1 : 6,10 14% ...

  • Page 5

    5 workshop manual ___________________________________________________________________________ list of repair tools for type 638, 639, 640 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19.

  • Page 6

    6 workshop manual ___________________________________________________________________________ list of repair tools for type 638, 639, 640 ite m nr. Type desig. Serial nr. Quan tity description 1 s-46 9.71.51559.4 1 feeler gauge for ignition advance adjustment 2 s-97 9.71.880097 1 drag (for rotor) 3 ...

  • Page 7

    7 workshop manual ___________________________________________________________________________ c telescopic front fork mogul super 15w/40 api sd/cb or mogul super stabil api sf/cc 15w/40 sae 15w/40 d accelerator twist grip energrease la2 iso-l-xbceb 2 swinging rear arm energrease la2 iso-l-xbceb 2 e ...

  • Page 8

    8 workshop manual ___________________________________________________________________________ list of main bearings and sealing rings designation name of part pcs. Positin 324 594 043 400 needle bearing ina hn (15x22x12) 1 engine – leftt side 324 163 030 100 bearing 6303 a 1 engine – leftt side 324 ...

  • Page 9

    9 workshop manual ___________________________________________________________________________ piston grading grading d 2 + 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 ...

  • Page 10

    10 workshop manual ___________________________________________________________________________ list of gudgeon-pin bearings connecting rod gudgeon pin needle roller Ø 2 x 13,8 clearance red 19,994+19,998 blue 15,994+15,997 1,994+1,996 1,993+1,995 0,005+0,016 0,007+0,018 red 15,997+16,000 1,994+1,996...

  • Page 11

    11 workshop manual ___________________________________________________________________________ using the torque spanner at the force of 17,6 nm. If the engine is mounted in the frame, first remove seat and tank, separate the exhaust elbows and disconnect the coils, cables and cable shoes. 1.2. Pisto...

  • Page 12

    12 workshop manual ___________________________________________________________________________ piston must have signing l (left side) or p (right side) for the corresponding cylinder and the arrow must be oriented forward to the exhaust ports. Use the press-out pin s-87 to push the piston pins. Make...

  • Page 13

    13 workshop manual ___________________________________________________________________________ 1.3. Primary gear, clutch - dissasebly caution: first drain oil from the gearbox. Take off the starting lever (first move it to the star position) and remove the bolts holding the left engine cover. After ...

  • Page 14

    14 workshop manual ___________________________________________________________________________ 1.4. Clutch - assembly fit the oiled clutch rod with rest in the mainshaft. On the outer drum put one by one the friction and steel discs. If we change the plates, before the assembly, measure their overal...

  • Page 15

    15 workshop manual ___________________________________________________________________________ 1.6. Starter spring (primary gear dismounted) turn the starter shaft to the left and take it out of its mounting take off the starter segment and spring. When remounting the spring, fit its one end on the ...

  • Page 16

    16 workshop manual ___________________________________________________________________________ 1.9. Adjusting of semi-automatic clutch disengagement set • remove the right engine cover • screw home the clutch cable adjusting bolts on bowden (make bowden shorter) to loosen the cable socket on clutch ...

  • Page 17

    17 workshop manual ____________________________________________________________________________ take off the outer cover sprocket, loosen the gear nut and unscrew with nr.32 socket spanner. Pull out the sprocket with inner cover from mounting. It is not necessary to uncouple the chain. Remove the ri...

  • Page 18

    18 workshop manual ___________________________________________________________________________ suggestion: use grease (f.Ex.Pm-nh2, litol 24, castrolease lh-2 ...) to avoid needles falling out of countershaft bearings. 2.3. Gearbox – shifting, crank mechanism with the engine in this dismantled condi...

  • Page 19

    19 workshop manual ___________________________________________________________________________ also after unlocking and driving wheel inside the case. Mounting of all bearing is realised to heated case (100-120°c). Put the bearings into the pre- heated halfs of engine case, getting them inline with ...

  • Page 20

    20 workshop manual ___________________________________________________________________________ set the gear shift gate in one of the centre positions (extreme positions are unsuitable). Then fit the mainshaft with the spacer and gear locked in the position with wireformed ring into the bearing in th...

  • Page 21

    21 workshop manual ___________________________________________________________________________ 2.8. Joining the housing halves heat the right half of engine housing the same way as the left one. Coat the left housing half sealing surface with sealing putty. Coat the gearbox shaft end and the right c...

  • Page 22

    22 workshop manual ___________________________________________________________________________ iii. Crank mechanism dismantling and reassembly 3.1. Crank mechanism dismantling using the nr.12 tubular spanner, unscrew the nuts holding together the two part face plate and separate two halves of the pl...

  • Page 23

    23 workshop manual ___________________________________________________________________________ c) then put the left half of the crank mechanism into the jig and use the s-204 guiding insert to press in the centre pin. Fit the bearing nr. 6206 c 36 (packed with grease) and the distance ring on the ce...

  • Page 24

    24 workshop manual ___________________________________________________________________________ c c r r a a n n k k s s h h a a f f t t m m e e c c h h a a n n i i s s m m c c o o m m p p l l e e t t e e – – d d i i m m e e n n s s i i o o n n s s + + t t o o l l e e r r a a n n c c e e s s.

  • Page 25

    25 workshop manual ___________________________________________________________________________ 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...

  • Page 26

    26 workshop manual ___________________________________________________________________________ iv. Chassis 4.1. Front wheel remove 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 th...

  • Page 27

    27 workshop manual ___________________________________________________________________________ 4.3. Secondary chain proper care and correct tensioning of the chain are decisive for its function and lifetime. It is important for the chain to have necessary slack in every position of swing arm. For ex...

  • Page 28

    28 workshop manual ___________________________________________________________________________ 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...

  • Page 29

    29 workshop manual ___________________________________________________________________________ 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 th...

  • Page 30

    30 workshop manual ___________________________________________________________________________ front fork oil exchange a) loosen the drain screw from the fork. B) for faster draining remove also the top plugs. C) after all oil is drained out, flush the tube with flushing oil. D) chech sealing washer...

  • Page 31

    31 workshop manual ___________________________________________________________________________ 4.9. Removing the rear swingarm (without disconnecting secondary chain) remove the rear wheel from the rear swing arm, detach the brake bowden and remove the rear wheel sprocket with cover while leaving th...

  • Page 32

    32 workshop manual ___________________________________________________________________________ disc brake – put into operation (new or after repair) tighten all pressure tight joints, pour the brake fluid into the reservoir of main brake cylinder. By repeatedly pressing the front brake lever pump th...

  • Page 33

    33 workshop manual ___________________________________________________________________________ check every 50.000 km or 5 years complete dismantling of brake system (master cylinder, caliper). Check functional surfaces, exchange all rubber parts (sealings, dust rings, connecting hoses). Untertake th...

  • Page 34

    34 workshop manual ___________________________________________________________________________ 4.12 exchange the ball bearing of the rear sprocket. After removing of rear wheel, unscrew with 32 mm spanner the nut of sprocket, which we remove from the swing arm also with cover. Detach the sleeves on ...

  • Page 35

    35 workshop manual ___________________________________________________________________________ 4.14. Removing of fuel tank close the fuel cock and detach the fuel hose. Take off the saddle, side cases and unscrew the m6 bolts holding the tank in the rear. After removing the silentblocks pull up the ...

  • Page 36

    36 workshop manual ___________________________________________________________________________ carburettor is for better starting equiped with choke, which is controlled by lever on carburettor body. The choke is „on“ in its upper position, „off“ in lower position. V. Electrical equipement 5.1. List...

  • Page 37

    37 workshop manual ___________________________________________________________________________ adjustment of headlamp and rear suspension load of motorcycle rear suspension setting position ii. Position iii. Position iv. No load 1 - - 1 person 1 - - 2 persons - 2 - 2 persons + baggage - - 2 1 – head...

  • Page 38

    38 workshop manual ___________________________________________________________________________ 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 engi...

  • Page 39

    39 workshop manual ___________________________________________________________________________ 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 t...

  • Page 40

    40 workshop manual ___________________________________________________________________________ notes to individual components : sensor s01 sensor resistance = 200 Ω +- 20%, measured by direct-current ohmmeter. This value is valid when environs temperature reaches 20 c. If this motorcycle component i...

  • Page 41

    41 workshop manual ___________________________________________________________________________ 4. The resistance of secondary winding (measured on vn outlets) = 6k Ω÷ 10%. For first series (7th month of 1996) the coils with resistance of 7k Ω +- 10%- have been used. The measurement is in principle d...

  • Page 42

    42 workshop manual ___________________________________________________________________________ alternator a 67 the stator of alternator contains two types of winding. 1. Charging winding for feeding z67. The resistance of winding = 820 Ω (measured direct- current). In heated state in operation the r...

  • Page 43

    43 workshop manual ___________________________________________________________________________ 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 ba...

  • Page 44

    44 workshop manual ___________________________________________________________________________ the steps detecting defects in circuit of charging of battery and regulator r67 1. Provided that ignition set is operational and motorcycle can start 2. Check-up the winding circuit on a67 (0,5 Ω ) by mean...

  • Page 45

    45 workshop manual ___________________________________________________________________________ 5. By ohmmeter verify resistance of yellow conductor against frame (120 Ω ) at switch z67 ; resistance of red and white conductors and blue conductor has to be > 40k Ω - more details in article conc. Z67 6...

  • Page 46

    46 workshop manual ___________________________________________________________________________ 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 5.6.1. Preparing the battery for operation electrolyte fil...

  • Page 47

    47 workshop manual ___________________________________________________________________________ electrical schema of jawa 350

  • Page 48

    48 workshop manual ___________________________________________________________________________ vi. Oil pump 6.1 description of lubricating system 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 s...

  • Page 49

    49 workshop manual ___________________________________________________________________________ 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 elect...

  • Page 50: Contens

    50 workshop manual ___________________________________________________________________________ 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...

  • Page 51

    51 workshop manual ___________________________________________________________________________ 4.3. Secondary chain 27 4.3.1.Exchange of secondary chain without removing closed chain guard 27 4.4. Steering – replacement of bearing on the lower bearer. 28 4.5. Front fork 29 4.6. Locking of motorcycle...

  • Page 52: Workshop Manual

    52 workshop manual 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 ...