JAWA 210 User Manual

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.
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
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
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 1
st
. speed overall ratio --- 1 : 24.4231
transmission ratio 2
nd
. speed overall ratio --- 1 : 13.7305
Primary transmission indented belt
Secondary transmission link chain
Pedal drive transmission ratio1 : 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 1.8 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 Pages 1, 2 & 3
jkw

JAWA 210 Specifications

General

Cooling System	Air-cooled
Transmission	4-speed manual
Cylinders	1
Fuel System	Carburetor
Front Suspension	Telescopic forks
Front Brake	Drum
Rear Brake	Drum
ABS	No
Engine Type	2-stroke, single cylinder
Brakes	Drum brakes
Engine	2-stroke, single cylinder

Summary

General technical data

Assembly tools and jigs

Lists proprietary tools and their use for engine dismantling, advance adjustment, and sealing ring installation.

Moped lubrication

Details lubrication points, lubricants, and notes for engine, gearbox, wheels, and other moped parts.

List of bearings, sealing rings, and bushes

Provides catalogue numbers, dimensions, and quantities for bearings, sealing rings, and bushes.

Engine torque transmission

Explains torque transmission in the two-speed automatic gearbox, detailing gear mechanism and clutch operation.

Engine

Removing engine from frame

Details the step-by-step procedure for safely removing the engine from the moped frame.

Removing cylinder head, cylinder and piston

Provides instructions for dismantling the cylinder head, cylinder, and piston assembly.

Grading of Cylinders and Pistons

Explains classification tables for cylinder and piston grading based on dimensions.

Clutch dismantling

Step-by-step guide for dismantling the clutch assembly, including specific tools required.

Carburettor

Details the JIKOV 2912 DC carburettor, its parts, adjustments, and routine maintenance procedures.

Crankshaft

Instructions for removing and reinstalling the crankshaft, including assembly groups and classification.

Crankshaft aligning

Details procedure for checking and correcting crankshaft alignment using special jigs and dial indicators.

Frame

Front Telescopic Forks

Instructions for removing and refitting front telescopic forks, including lubrication of sliding parts.

Front and Rear Wheel

Discusses minimum brake-shoe lining dimension and provides exploded views of front and rear wheels.

Rear Telescopic Suspension Units

Describes rear telescopic suspension units, their maintenance, and removal procedure.

Electrical equipment

Alternator

Explains alternator function, output, and how it supplies current to the moped's electrical system.

Ignition system

Details the contactless, thyristorized ignition system, its components, and maintenance.

Moped Wiring Diagram

Reference to the location of the moped's wiring diagram on page 30.

Electronic Ignition Diagnosing Tester

Provides instructions and ohmmeter readings for diagnosing electronic ignition system defects.

Causes of defects and their removal

Engine

Lists common engine defects: failure to start, erratic running, loss of power, poor acceleration.

Transmission

Discusses less frequent transmission defects, focusing on 2nd-speed engaging mechanisms.