JAWA ZVL 210, 210 Workshop Manual

www.jawamoped.com

WORKSHOP MANUAL

moped model 210

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

ZVL model 210 Workshop Manual Pages 1 & 2

jkw

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.

ZVL concern
Povazske strojarne
Klementa Gottwalda works

sales and technical service
department

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 1st. speed overall ratio

----- 1 : 24.4231
2nd. speed overall ratio

----- 1 : 13.7305
Primary transmission indented belt
Secondary transmission link chain
Pedal drive transmission ratio 1 : 0.692
Pedal-actuated starting gear overall ratio 1 : 0.0504
Front suspension telescopic fork without shock absorbers -- 60 mm stroke
Rear suspension telescopic suspension units without shock absorber

-- 60 mm stroke
Brakes internal expanding shoe -- brakes controlled by

levers on handlebars
Brake dimensions 85 x 20 mm
Tyres 2¼ x 16"

Wheels 1.60” (WH1) x 16”

Inflation pressures ------ front tyre 196 kPa (2 atm) [ 28 psi ]

------ rear tyre 245 kPa (2.5 atm.) [ 36 psi ]
Moped dry weight 51 kg
Moped running weight 54 kg
Road speed --- sustained 35 km/hr.

--- maximum 40 km/hr ± 5 %
Fuel tank filling capacity 4 litres
Fuel reserve 0,7 litres
Maximum climbable gradient
with rider weighing 75 kg 25 %
Noise 70 decibels
Ignition system 6 volt, contactless with semiconductor elements
Spark plug PAL N 7 R [ Champion L89CM L85 L86 ]

[ NGK B6HS Bosh W7AC ]

Headlamp 6 v 21 w
Tail lamp 6 v 5 w
Speedometer lighting 6 v 2 w
Fuel consumption 1 3 litres/100 km at 27 km/hr
Load capacity, maximum 90 kg including 5 kg luggage on carrier

Note:

When exceeding the load capacity, it is necessary to decrease the maximum speed proportionally.

ZVL model 210 Workshop Manual Page 3

jkw

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- clutch (C) provided with two shoes of the leading
mission is shown in Fig. 4. type. The operation of this clutch is controlled by

force closing between the parts (2'), (6) and (7)
The torque is transmitted from the crankshaft
(1) to the gears (2—2') over the starting clutch
(B) by an indented belt. From the output shaft (7), the torque is trans-

mitted to the rear wheel by means of secondary
1st-speed gearing: transmission.

It is formed by two pairs of involute spur gears
(3, 4, 5 and 6) meshing with the freewheel (D) The force-closed clutch engages the respective
between the gears (4) an(5) on the layshaft. From gear depending on the road speed, the drive taken
the gear (6), the torque is transmitted over a force off the automatic transmission, the acceleration
closed mechanism to the output shaft (7) and and deceleration, and the rolling resistance of
the rear wheel by means of the secondary trans- the vehicle in terrain
mission chain.

2nd-speed gearing: The output shaft (7) with the gear-change me-

chanism runs in two ball bearings. The layshaft
Parts (3), (6), and (7) are coupled with the clutch is supported by two bronze bushes.

ZVL model 210 Workshop Manual Page 8

jkw

www.jawamoped.com

III ENGINE

1. Removing engine from frame

a) Remove the engine guards.
b) Detach the spark plug cable, the fuel hose, and

the throttle cable.

c) Disconnect the leads of the electrical

equipment.

d) Disconnect the chain of the secondary

transmission.
e) Disconnect the exhaust pipe from the engine.
f) Remove screws fastening the engine to the

frame, and lift off the engine.

Clean well the surfaces of the engine, and drain the
oil from the automatic transmission case. During
engine dismantling, clean immediately all the
removed parts and put them aside in the order of
their removal, so that they can be reassembled
correctly and in the shortest possible time.

2. Removing cylinder head, cylinder and piston

a) Unscrew the four M6 nuts and lift them off

together with washers from the studs.
b) Remove the cylinder head.
c) Remove the cylinder (Fig. 5)
d) Remove the circlips securing the gudgeon pin

and use the drift No. 50-12000-1.1 (Fig. 6) to

drive out the gudgeon pin.

Take care not to spill the dia.. 2 x 8 mm. Needle
rollers of the gudgeon pin (there are altogether
twenty five). The maximum permissible ring gap of
a worn piston ring is from 0.6 mm to 0.8 mm.

Check the dimension for grading the pistons in the
individual classes 34.5 mm. From the piston base
(Fig. 7)

ZVL model 210 Workshop Manual Page 10

jkw

www.jawamoped.com

4. Clutch Dismantling

After removing two M 5 x 30 screws, lift off the left­hand 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. 4T 210-2200-01 (Fig. 9). With a
screwdriver remove three circlips

from the recesses to

loosen the clutch starting shoes (Fig. 10)

For re-assembly use the washer No. 4T 210-2100 and clutch
drum drag No. 4T 210-2200-01 and secure the clutch with
the circlips (Fig. 11).

After having removed the drum with starting shoes,
rotate and gently pull the starting drum with the
sma11 pulley to remove it together with the indented
belt.
Work carefully so as not to damage the needle
bearings and washers.

ZVL model 210 Workshop Manual Page 11

jkw

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. 10 on the side of
the drive (power take-off) gear to prevent its
rotation. It is recommended to put the engine on the
work bench with the ignition side down to prevent
the oil from getting into the 2nd-speed clutch drum.

After unscrewing the nut and lifting off the cover,
remove the circular packing piece and pull out the
change-gear shoes together with their carrier
(backing plate) using two thin screwdrivers braced
against the inner edge of the drum. Insert the tips of
the screwdrivers under the top arms of the shoe near
the pivots and opposite each other. By carefully
pushing the screwdriver handles downward you will
lift the carrier with the shoes out of the drum.

Wipe the oil off the parts immediately and put the
parts in a clean place. If the drum or the shoe linings
are stained with oil, they have to be degreased
thoroughly. Finally remove the drum of the change­gear clutch.

When removing and refitting the shoe carrier, take
care not to damage or lose the distance piece and the
sealing ring (19 x 15).

Separating crankcase halves

a) Unscrew and remove ten M6 x 45 screws from
the left-hand crankcase half.
b) Fit the jig (crankcase halves separator) No.3T
210-10 000-14.5 on the studs and fasten it by two
screws on the left-hand half of the crankcase.
c) Pull off the left-hand crankcase half (Fig. 13).

ZVL model 210 Workshop Manual Page 12

jkw

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. 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

jkw

www.jawamoped.com

ZVL model 210 Workshop Manual Page 14

jkw

Reassembling 2nd-speed clutch

Observe utmost cleanliness during the clutch re-assembly.
Degrease the drum (large pulley) with a degreasing agent
(e.g. alcohol, acetone, clean petrol, etc) and wipe it dry
with a clean cloth. The roughness of the drum working
(friction) surface must be at least 0.8, i.e. the surface must
be polished with fine emery paper. A rougher surface has
an unfavourable effect on the service life of the friction
lining.
Make sure that the GUFERO sealing ring (15 x 24 x 7) in
the drum is not damaged. Put the shoe carrier (base plate),
with the two 2nd-speed shoes mounted in position together
with the regulating driver located between them into the
drum. All parts must be dry, without any traces of oil.

If oil has got between the joint faces during the
dismantling, remove the 2nd-speed shoes and dip the
carrier in a solvent (degreasing agent). Then dry the carrier
thoroughly.
The hard chrome-plated lands of the regulating driver
which touch the brass friction layer on the shoes must be
bright, clean and dry. Rotate the shoe carrier together with
the regulating driver anticlockwise and fit the parts in their
position by a slight pressure of the hand.

Routine maintenance of the carburettor includes its
removal, flushing and swilling with clean petrol, and
blowing through with compressed air. Clean the jets only
with petrol (or acetone) and compressed air, never with
lengths of wire or other hard objects which are apt to
damage the calibrated holes.

To give the carburettor a thorough overhaul, proceed as
follows:

1. Remove the carburettor from the engine, take it apart,
and clean its parts thoroughly.

2. Discard worn parts and replace them with new ones.

3. Check the flatness of the flange and true it up if
necessary on an abrasive cloth stretched on a flat board.

4. After trueing up the flange clean the carburettor body
thoroughly once again.

5. Check the jets and adjustments for compliance with the
recommended values.

6. Adjust the needle and the fast-idling screw as
recommended and reassemble the carburettor.

7. Refit the carburettor on the engine. Start the engine,
warm it up, and adjust the richness of the mixture by
means of the air-correction screw. Then adjust the idling
speed (from 1,600 to 1,800 r.p.m.) by means of the stop
screw, and the needle valve and the free movement of the
twistgrip by means of the throttle cable guide.

Never touch the friction lining and the friction surface of
the drum with greasy hands. Place the ,’O’ sealing ring on
the recess (clean and undamaged) of the carrier hub and
locate the metal bush on the ,’O’ ring. Then apply a tube
of sufficient length and the same diameter as the bush on
the bush, and by rotating and pressing down the tube,
press the bush through the ‘O’ ring inside the hub. Then
install the inside driver which ensures that the regulating
driver controls both shoes at the same time. For this
reason, the holes must be perfectly clean and the parts
must have a certain clearance along the circumference
with the exception of the contact areas.

Locate the circular sheet-metal washer and the clutch
cover, and then screw down and tighten well the M10 x

1.25 nut

5. Carburettor (Fig. 21)

The moped is fitted with the JIKOV 2912 DC carburettor
with the following parts and adjustments :

Main jet 63
Idling jet 35
Needle valve

- needle position 2nd notch from top

Fast-idling screw 540º (1 to 1½ turns)

www.jawamoped.com

ZVL model 210 Workshop Manual Page 15

jkw

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. Fuel level adjusting pro- with the help of the jig which you can make
cedure:-. of plexiglass (Perspex) according to the drawing.

Screw the jig on to the float chamber (bottom

1. Rough (mechanical) adjustment -- see Fig. 22 drain screw) and admit fuel into the carburettor.

Its level should reach the centre index line with
With the carburettor removed from the engine, a tolerance of ± 1 mm. If this is not the case, ad­remove the float chamber cover. Turn the carbu- just the floats by bending the arms upward
rettor so that the floats are directed upwards, or downward as necessary. The fuel level adjusted
Check that the floats move freely on the spindle in this way complies with the manufacturer's
and that they are perpendicular to the carburettor requirements. When checking the fuel level in the
centre line. Check also their height which must carburettor removed from the engine, it is necessary
reach the level of the venturi tube top edge. If to observe the same height of the pressure column
this is not the case, adjust the height of both floats as exists between the fuel tank and the carburettor
by bending the arms. Floats adjusted in this way fitted on the engine.
should maintain the fuel in the float chamber
at the correct level.