Table of Contents
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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 procedures will be
announced in our Service Bulletins.
ZVL concern, Povazske strojarne
Klementa Gottwalda works
sales and technical service department
CONTENTS
I. Moped specifications
II. General technical data
1. Assembly tools and jigs
2. Moped lubrication - Lubrication Chart
3. List of bearings, sealing rings and bushes
3. Grading of cylinders and pistons
IV. Frame
1. Front, telescopic fork
2. Front, and rear wheel
3. Rear wheel telescopic suspension
2. Ignition system
4. Diagnosing electronic ignition defects
WORKSHOP MANUAL
moped model 210
I. MOPED SPECIFICATIONS
Engine type
Swept volume
Cylinder bore x piston stroke 39 x 41 mm
Engine power output
Clutches
Gearbox
Engine to rear wheel
transmission ratio
Primary transmission
Secondary transmission
Pedal drive transmission ratio1 : 0.692
Pedal-actuated starting gear overall ratio 1 : 0.0504
Front suspension
Rear suspension
Brakes
Brake dimensions
Tyres
Wheels
Inflation pressures - front tyre
Moped dry weight
Moped running weight
Road speed - sustained
Fuel tank filling capacity
Fuel reserve
Maximum climbable gradient
with rider weighing 75 kg
Noise
Ignition system
Spark plug
Headlamp
Tail lamp
Speedometer lighting
Fuel consumption
Load capacity, maximum
Note:
When exceeding the load capacity, it is necessary to decrease the
maximum speed proportionally
ZVL model 210 Workshop Manual Pages 1, 2 & 3
air cooled, two-stroke single-cylinder unit
49 cc
1.75 kW at 5,000 rpm ± 8 %
automatic, dry, centrifugal
two-speed unit
st
1
. speed overall ratio --- 1 : 24.4231
nd
2
. speed overall ratio --- 1 : 13.7305
indented belt
link chain
telescopic fork without shock absorbers
60 mm stroke
telescopic suspension units without shock
Absorber -- 60 mm stroke
internal expanding shoe -- brakes controlled
by levers on handlebars
85 x 20 mm
2¼ x 16"
1.60" (WH1) x 16"
196 kPa
- rear tyre
245 kPa
51 kg
54 kg
35 km/hr.
- maximum
40 km/hr ± 5 %
4 litres
0,7 litres
25 %
70 decibels
6 volt, contactless with semiconductor
elements
PAL N 7 R
[ Champion L89CM L85 L86 ]
[ NGK B6HS
6 v 21 w
6 v 5 w
6 v 2 w
1.8 litres/100 km at 27 km/hr
90 kg including 5 kg luggage on carrier
www.jawamoped.com
(2 atm)
[ 28 psi ]
(2.5 atm.)
[ 36 psi ]
Bosh W7AC ]
jkw
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Table of Contents
Related Manuals for JAWA 210
Summary of Contents for JAWA 210
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Page 1: Table Of Contents
When exceeding the load capacity, it is necessary to decrease the 2. Ignition system maximum speed proportionally 3. Wiring diagram 4. Diagnosing electronic ignition defects VI. Causes of defects and their removal ZVL model 210 Workshop Manual Pages 1, 2 & 3... -
Page 6: Engine Torque Transmission - Diagram
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... -
Page 8: Engine
Check the dimension for grading the pistons in the possible time. individual classes 34.5 mm. From the piston base (Fig. ZVL model 210 Workshop Manual Page 10... -
Page 9: Clutch Dismantling
(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. -
Page 10: Www.jawamoped.com
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. -
Page 11: Www.jawamoped.com
Reassemble and reinstall the transmission, If any of the parts are worn beyond the acceptable c) Press on the left-hand half of the crankcase. (warmed up to about 70 to 80°C) measure, replace them with new ones. ZVL model 210 Workshop Manual Page 13... -
Page 12: Carburettor
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. ZVL model 210 Workshop Manual Page 14... -
Page 13: Www.jawamoped.com
Floats adjusted in this way fitted on the engine. should maintain the fuel in the float chamber at the correct level. ZVL model 210 Workshop Manual Page 15... -
Page 16: Crankshaft
7. press the flywheels together – observe the previously 3. Assemble the connecting rod, the crankpin and the made index lines. cage with needle rollers according to the classification 8. After reassembly, it is necessary to centre the table. crankshaft. ZVL model 210 Workshop Manual Page 17... - Page 17 Check the alignment of crankpins as illustrated in Fig this work requires great skill, it should be done by a 23. If the crankshaft halves are mutually set off, remove highly qualified fitter. the crankshaft from the centres, Fig. 23 ZVL model 210 Workshop Manual Page 18...
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Page 21: Electrical Equipment
,,E" and recheck the advance. from interfering with the ignition system in any way. In the case of a defect, have the repair done by a skilled electrician. 3. Moped Wiring Diagram (is placed on page 30) ZVL model 210 Workshop Manual Page 22... - Page 23 Defects of the ignition coil are rare and therefore it is recommended to check before its renewal the condition of the connecting leads and terminals. Replace the H.T. coil only with an original coil, Part No. 443 212 210 800 — 4 V. ZVL model 210 Workshop Manual Page 24...
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Page 24: Causes Of Defects And Their Removal
3. Partly obstructed fuel supply or choked main jet another one with a different number of teeth. 4. Leaky crankcase. 5. Faulty cable terminal. 6. Faulty ignition. 7. Imperfectly vented fuel tank. ZVL model 210 Workshop Manual Page 25... -
Page 25: Www.jawamoped.com
2. Oil or grease on regulating driver and 2. Degrease shoe contact areas. Light vibration might occur in final stages of 2 gear engagement. ZVL model 210 Workshop Manual Page 26 & 27... - Page 26 According to speedometer readings, the moped should attain about 24 km/hr. in 1 gear at full throttle and the change to the 2 gear should be completed at a speed of about 28 km/hr. ZVL model 210 Workshop Manual Page 28 & 29...