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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.
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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.
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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
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18 19~
20 21
.~ ~22
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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
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Fig.No.
6Wiringdiagram(single-instrumentmodel)
A-black,
B-white,
C-blue,
D-green,
E-yellow,
F-red,
G-grey,
H-brown
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