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WORKSHOP MANUAL
This workshop manual is intended primarily for all repair shops and their
workers concerned with repairs of our model 210 moped. It does not
contain servicing jobs and repairs described in the Rider's Manual but
only repairs for which special assembly tools and jigs are required.
The purpose of this manual is to facilitate the work of the repairmen and
to improve servicing of our products. Any changes and deviations from
standard procedure? will be announced in our Service Bulletins.
CONTENTS
I. Moped specifications
II. General technical data
1. Assembly tools and jigs
2. Moped lubrication — Lubrication Chart
3. List of bearings, scaling rings and bushes
4. Engine torque transmission — diagram and description
III. Engine
1. Removing engine from frame
2. Removing cylinder head, cylinder and piston
3. Grading of cylinders and pistons
4. Clutch dismantling
5. Carburettor
6. Crankshaft
IV. Frame
1. Front, telescopic fork
2. Front, and rear wheel
3. Rear wheel telescopic suspension
V. Electrical equipment
1. Alternator
2. Ignition system
3. Wiring diagram
4. Diagnosing electronic ignition defects
VI. Causes of defects and their removal
www.jawamoped.com
moped model 210
ZVL model 210 Workshop Manual Pages 1 & 2
ZVL concern
Povazske strojarne
Klementa Gottwalda works
sales and technical service
department
jkw
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Summary of Contents for JAWA ZVL 210
- Page 1 www.jawamoped.com WORKSHOP MANUAL moped model 210 This workshop manual is intended primarily for all repair shops and their workers concerned with repairs of our model 210 moped. It does not contain servicing jobs and repairs described in the Rider's Manual but only repairs for which special assembly tools and jigs are required.
- Page 2 www.jawamoped.com I. MOPED SPECIFICATIONS Engine type air cooled, two-stroke single-cylinder unit Swept volume 49 cc Cylinder bore x piston stroke 39 x 41 mm Engine power output 1.75 kW at 5,000 rpm ± 8 % Clutches automatic, dry, centrifugal Gearbox two-speed unit Engine to rear wheel transmission ratio .
- Page 7 www.jawamoped.com 4. Engine Torque Transmission - Diagram (Fig. 4) (C) so that they run at the same speed. The run- and Description ning of the layshaft gears (4) and (5) at different speeds is enabled by the freewheel (D). The gear Gearbox change is effected by the automatic centrifugal The diagram of the two-speed automatic trans-...
- Page 9 www.jawamoped.com III ENGINE Removing engine from frame Removing cylinder head, cylinder and piston a) Remove the engine guards. b) Detach the spark plug cable, the fuel hose, and a) Unscrew the four M6 nuts and lift them off the throttle cable. together with washers from the studs.
- Page 10 www.jawamoped.com 4. Clutch Dismantling After removing two M 5 x 30 screws, lift off the left- hand clutch cover. Using the clutch drum retaining jig No. 928-1000-1.5 retain the starting clutch drum and loosen the nut with the spanner No. 17 (Fig. 8). Pull off the clutch drum using the drag No.
- Page 11 www.jawamoped.com For the removal and refitting of the starting shoes use the jig (hook) No. MN 1100-7.1 (Fig. 12) or flat pliers. Loosen the nut of the drum housing the change gear shoes with the spanner No. 17 while holding the output shaft with the spanner No.
- Page 12 www.jawamoped.com 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.
- Page 13 www.jawamoped.com Reassembling 2nd-speed clutch Observe utmost cleanliness during the clutch re-assembly. Never touch the friction lining and the friction surface of Degrease the drum (large pulley) with a degreasing agent the drum with greasy hands. Place the ,’O’ sealing ring on (e.g.
- Page 14 www.jawamoped.com Checking and adjusting fuel level in float 2. Checking fuel level using the jig illustrated chamber in Fig. 22a Check and adjust the fuel level after every renewal of the fuel float or if the fuel leaks from After having adjusted, the fuel level mechanically the carburettor and the leakage is not due to a it is recommended to check the adjustment defective float or needle.
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