JAWA ZVL 210 Service Manual - page 11

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Removing gears

a) Removing driving gear (28 teeth) from output

shaft

— see Fig. 14.

b) Removing coaster pinion — see Fig. 15.

c) Removing driven gear — see Fig. 16.

Removing driver assembly

a) Using a screwdriver, loosen the circlip and

pull the

washer, the volute spring and the complete driver off the

output shaft (Fig. 17)

b) Using circlip pliers, loosen the circlip and

pull the

washer, the cap, and the sprocket off

the shaft (Fig. 18).

c) After loosening the circlip, press the output

shaft out

of the case.

When reassembling the output shaft, use the

sealing

ring installer (Fig. 19) to protect the shaft

sealing rings

from damage,

Removing alternator

a) Use a screwdriver to loosen the alternator

cover

retaining spring, and remove the cover

Then unscrew

the M5 x 25 screw holding down the rotor.

b) Using the rotor drag No. 928-6000-1.1 pull of

 the

rotor (Fig. 20) and the loosen the lock pin.

c) Remove two M4 x 22 screws fastening the

stator, and

pull the stator out of the crankcase right-hand half

together with the leads.

After having removed the transmission clutch and the

alternator, use a hand press to press the crankshaft out

of the crankcase.

 Engine re-assembly

To re-assemble the engine, reverse the procedure for its

dismantling

a) Warm up the right-hand of the crankcase

to about 70

to 80 °C and press in the crankshaft

b) Reassemble and reinstall the transmission,

c) Press on the left-hand half of the crankcase.

(warmed

up to about 70 to 80°C)

d) Reassemble and reinstall the clutch.

e) Reinstall the reassembled alternator and the

assembled driver (engine drive engaging and

disengaging device)

f) Reinstall the piston, the cylinder, and the cylinder

head.

(The arrow on the piston crown points down, towards

the exhaust port.)

If any of the parts are worn beyond the acceptable

measure, replace them with new ones.

ZVL model 210   Workshop Manual   Page 13                    

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