JAWA B Bedienungsanleitung

Specification and

Operator's Manual

WITH SPECIAL REFERENCE TO SERVICING AND

ROUTINE MAINTENANCE OF MOTORCYCLES

YEZDI 250 cc MODEL ‘B’

JAWA 250 cc MODEL 353/04

Manufacturers

IDEAL JAWA (INDIA) PRIVATE LTD.,

MYSORE 570 002, SOUTH INDIA

INDEX

I SPECIFICATION AND OPERATOR'S MANUAL Page

1. Technical data 7

2. Description of motorcycle 10

3. Electrical equipment description 13

4. Running a new motorcycle 18

5. Servicing instructions 20

6. What should be avoided 23

II MAINTENANCE

1. Cleaning the motorcycle 24

2. Lubricating the motorcycle 25

3. Adjusting the brakes 30

4. Tyres 30

5. Adjusting the chain 33

6. Adjusting the clutch 34

7. Carburettor 35

8. Electrical equipment maintenance 38

9. Decarbonisation 41

III DISMANTLING AND ASSEMBLING WITHOUT THE AID OF SPECIAL TOOLS

1. Removing the front wheel 43

2. Removing the rear wheel 44

3. Removing the chaincase and the chain 45

4. Removing the rear chainwheel 45

5. Replacing the wheel ball bearings 45

6. Removing the cylinder head and barrel 49

7. Replacing the piston rings 50

8. Removing the carburettor 50

9. Dismantling the clutch 51

10. Dismantling the headlamp 51

11. Dismantling the steering head and fork legs 53

12. Handlebars --- twist grip 55

13. Removing the dual seat 55

14. Removing the fuel tank 55

15. Removing the cowls 55

16. Dismantling the rear suspension 56

17. Pivoted Fork 57

18. Removing the battery 58

19. Dismantling the switch box 58

20. Removing the engine from frame 59

21. Removing the R.H. and L.H. engine covers 59

IV DEFECTS, CAUSES AND REMEDIES 60

Two-stroke engine operation 63

LIST OF ILLUSTRATIONS

1. JAWA 250 c.c. ... model 353/04 24. Removing the front wheel

1a. Yezdi Model 'B’ 25. Taking out the rear wheel spindle

2. Engine 250 c.c - sectional view 26. Dismantling the chaincase

3. Plan of the Motorcycle 27. Rear wheel brake drum ...

exploded view

4. Induction silencer - sectional view 28. Front wheel ... sectional view

5. Electric wiring diagram 29. Rear wheel ... sectional view

6. Stop switch 30. Disconnection the exhaust pipes

7. Oil filling and inspection hole 31. Removing the cylinder head

8. Fuel tap positions 32. Removing the cylinder barrel

9. Butterfly air valve 33. Fitting the piston rings

10.Lubrication chart - L.H. side 34. Front fork -- sectional view

11.Lubrication chart - R.H. side 35. Lubricating the steering head

bearing balls

12.Draining the gearbox oil 36. Lubricating the steering head

bearing balls

11.Removing the chain 37. Adjusting the twist grips

connecting link 38. Removing the dual seat

14.Adjusting the brake 39. Disconnecting the rear suspension

damper top bracket

15.Rim and tyre - sectional view 40. Pivoted rear fork bushing -- sectional

--fitting the tyre cover 41. Removing the battery

16.Correct tyre fitting 42. Two-stroke engine operation diagram

17.Adjusting the chain

18.Chaincase lid

19.Clutch operation diagram

20.Adjusting the clutch

21.Carburetter, flange type

22. Removing the fuse

23.Exhaust silencer - sectional view

TECHNICAL DATA

1. TECHNICAL DATA 250 c.c Model 353/04

------------------------------------------------------------------------------------------------

Engine Two-stroke, air-cooled

Number of cylinders One

Bore 65 mm

Stroke 75 mm

Cylinder capacity 248.5 c.c.

Compression ratio 7.2 to 1 (YEZDI - 7.6 to 1)

Engine output 12 BHP (YEZDI - 13 BHP)

Fuel consumption at steady 60 km.p.h 3 litres/100 km

(37 m.p.h) (93 m.p.gallon)

Fuel tank capacity 13.5 litres (Jawa); 14.5 litres (Yezdi)

Maximum speed 105 km.p.h

(65 m.p.h)

Maximum climbing ability (fully laden) 45%

Dimensions of motorcycle --length 1980 mm

--height 1025 mm

--width 670 mm

Weight of motorcycle --dry 128 kg (Jawa); 131 kg (Yezdi)

--inc. fuel 140 kg (Jawa); 144 kg (Yezdi)

Carrying capacity (payload) 160 kg

Front wheel spindle maximum load 85 kg

Rear wheel spindle maximum load 214 kg

Primary drive of 3/8 x 3/8 in. chain 60 links

Final driver by 1/2 x 5/16 in. chain 120 links

Primary and final drive ratios:

Primary 45/22 T

Final 46/19 T

Bottom gear 24/12 x 19/12

Second gear 20/16 x 19/12

Third gear 17/19 x 19/12

Top gear 1/1 direct

Overall gear ratios:

Bottom gear 15.675 to 1

Third gear 9.800 to 1

Second gear 7.013 to 1

Top gear 4.952 to 1

Overall kickstarter ratio 3.41 to 1

Speedometer drive ratio 5/11 T

internal expanding brakes dia 165/35 mm

Braking distances from 40 km.p.h

(25 m.p.h) front wheel brake 30.8 m. (101.05 ft.)

rear wheel brake 30.8 m. (101.05 ft.)

both brakes applied 12.5 m. (41.01 ft.)

Front fork maximum stroke 130 mm (51/3 in.)

Pivoted rear fork maximum stroke 100 mm (3 15/16 in.)

Carburettor 2926 SBD

wheels Interchangeable

size of rims 1.85 B x 16 in.

size of front tyres 3.00 or 3.25 x 16 in.

size of rear tyres 3.25 x 16 in.

Fig. 2. Engine 250 c. c.- sectional view

Fig .3. Plan of the Motorcycle

2. DESCRIPTION OF MOTORCYCLE

The 250 c.c is a solo motorcycle suitable for carrying one or two persons.

The power unit is a two-stroke, air-cooled petrol engine with inverted scavenging.

The engine has a quiet run, well balanced within its extent of revolutions, without

vibration and is capable of lively acceleration.

The clutch is a five-plate friction clutch, fitted with cork lined steel plates running

in an oil bath. Clutch control by hand lever fitted on L. H. side of the handlebars.

The gearbox is of the four-speed type, forming with the crankcase a monoblock

engine unit.

The gear shifting is foot operated by means of a lever located on the L. H. side of

the engine. When changing gear, the declutching is automatic.

Fig. 4 Induction silencer - sectional view

1. Induction silencer cover 5. Clamp

2. Air cleaner 6. Rubber sleeve

3. insert 7. Butterfly air-valve

4. Silencer body 8. Fastening strap

The starting of the engine is foot operated by means of the same lever as gear

shifting and is effected by depressing the shaft and rotating the lever into the

starting vertical position. As soon

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