I

,,'

~i!),'";~

u

350- /56I I

JAWA NARODNi PODNIK TYNEC n./sAz.

MADE IN CZECHOSLOVAKIA

1989'.

,--

ThiS WORKSHOPMANUALhae bee~ issued expecielly for the use of repair shope",ith . the purpose of 888istins ther repairmen in more exteli8ive end more complica-ted repairs of JAWAmotor cycles. When describins the individusl.repair procedureswe assum& that the repairmen and mechanics will use the set of special tools

1fbichhave been designed to faci1.itatethe mostcomplicated Jobs. This Manual doe.not. contain descriptions of repairs end adjustments de~cribed in the Rider's

Handbook handed over to every buyer of a JAWAmotor 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, etc.).

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

,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

of leakage, the oil filling is satisfactory (oil is filled in-in the factory

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 charac-

teri~fics and shortening of the ssrvice life of seals and, moreover, no claimsregarding damaged seals will be recognized.

i"I

if

t

Ij

'

~

'j

I

if

;",

li'l

i!i

i

[

1

,

I

"i"i"'I

II'~

h) Check on all positions of the ignition key in theewitch box and test the

individual parts of electrical equipment (headlamp, direction indicators, horn,

tail and stop li~t, 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 inten-

ded for coupling with a sidecar.

1) Check the 8d~ustment of brakes (dead travel) and adjust the stop swith if

nece~sary.

I

I!

r!

r

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 .onits

stand, the speedometer indicates 50 km with the 4th gear engaged wheth~r theengine 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 -

I

I'

List of Tools for P.reTious JAW! Models

Usable a180 ~or UndA1 ~3A_A

Pos.No.

'4

56

89

1011

1213141516

17

Desin8':"nation

Product No.

12

3

16-65671-316-67585-39.71.51578.3

9.71.51559.4

8-9

8-10

S-44

5-46

5-48.5-61

9.71.51568.4

9.71.51561.4

1 8-62 9.11.51598.3

9.11.51589.49.11.51590.49.11.51603.39.71.51565.4

S-63

S-64

S-66

S-68

8-71

S-72

8-738-80S-81

9.71.51577-49.71.51576.49.71.51599.416-65776-316-19758-3

8-82 16-19756-3

Ad~~tional, new tools:c~;'j

18;~,

19

20

21,

22

23"

5-845-855-86

S-875-88

S-89

9.71.52254.3

9.71.52248.49.7i.52253.49.71.52252.4

9.71.52251.49.71.52255.3

Description Quanti ty

Front 1"ork bush extractor

Exhaust pipe nut spanner

Gudgeon pin extractor withextension pieces .

Injection adTance adjustinggauge

Dynamo rotor puller

Crank mechanism centre bushextractor

Crankcase halves separatingpress with bolts

Pawl retaining jig

Centering bush drift

Cluth pilot plate

Tubular wrench w32" for chainwheel nut

B~arin8 extractor

Packing ring installer

Packing ring protector

Fork leg puller

Tubular wrench for steeringsternnut .

Hook spanner

11

1

11

1

1

11

1

1

11

11

1

1

Exhaust silencer core extraotor 1

Sprocket puller 1

Gudgeon pin drift 1

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

Special service tools for crank mechanism:

- 8 -

24 5-200 9.1l. 72590.1 Pressing fixture includingattachments 1

25 S-201 9.06.55407.3 Lever 126 S-202 9.06.55408.2 Pliers '1

8

9

12

13

0

~~17

14

Fig.No~3 Service tools

-9 -

10 11

15

16

j

2 3

14"0

I" 6

00000'01 1- U I § 5

,!

,j

I1

11

j

II

~i;

o'~

18 19~

20 21

.~ ~22

~ .1/

~

24 ...

~ - ~ 25~

26 ~ ~~

Fig.No.4 Service tools

- 10.-

.-

LIST OF MAIN BEARINGS AND SEALING RINGS

Table No.1

x - only separate needles and gudgeon pins are supplied - see the "Idst ofSpare Parts" .

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

1

- 11 ..;.

Item Desition Bearing Dimension' Unite LocationNo.

1 324 163 050 036 Bearing 62/25xl5 2 Engine

(960-630507) 6305 C 36.

2 324 163 060 036 Bearing 72/30.xl9 1 Crankshaft

(960-630607) 6306 C 36 mechanisll

3 324 163 030 000 Bearing. 47/l7xl3 1 Gearbox

(9'60-630300) 6303 .

4 324 232 050 000 Bearing .52/25%20.6 1 Gearbox(961-320500)

5 x Needle - 2 Crenkshaft

bearing m.echenism

6 xx Needle - 2 Crenksha1"t.

bearing mechanism

7 3?4 163 020 000 Bearing 42/l5xl3 2+2 Front and

(960-630200) 630;' rear wheel

9 324 914 010 452 Ball 0 dia 6,35 38+1 Frame head

(9QO-406350) (1/4") Declutching

device

8 324 162 050 000 Bearing 52/25x15 1 Rear wheel

(960-620500) 6205

10 ">273521 006 917 Sealing 25/62/8 2 Engine.:{'i<\

« 953-025808) ring" gufero"

11 273 521 100 303 "gufero" 8/l6Xl 1 Speedometer

(954-008107) . drive

12 273 521 108 603 "gufero" 30/52xl2 I 1 Gearbox(953-030410)

1

6'-11

Fig.No.5 Layout of bearings and packing rings

- 12 -

5

2

~

10

12'!'

4

;~1ft....

...re

~

u

"--.ca;

'"~lilt.

---

~."...re

~

~,..>.0

"""-

~"'--N~

J!...

<=

""'

u

Cl:!cc

~,..>.0

~,..>.0

~~N~

Fig.No.

6Wiringdiagram(single-instrumentmodel)

A-black,

B-white,

C-blue,

D-green,

E-yellow,

F-red,

G-grey,

H-brown

I1

-13-

-.1

t'iJ > :=E.I I foI.

C4 0" ~I-' I-' foI.I-' li)1:!

I~()q.. .. 0.

foI.'>iI IJj !1)

, '.!. ()q'1 c ~I-' ~::r!1).,. 0. foI. Ei. .. <+i~

0"I

(Jq 0~ I~ 0"C4 I-'.. J::.~..I0" t:::1~. I

; ~:::s !11

~.::s

'>iIfoI.(Jq.12:0.

6V 21W

;F

T

634/5/6/8

6V2W

21W6V 15

~VI5W

IA u---

=-

~ ~~WA 6V21W

15

451963460008