SPECIFICATIONS OF JAWA 250 CCM MOTORCYCLE

• Document Type: CREST
• Collection: General CIA Records
• Document Number (FOIA) /ESDN (CREST): CIA-RDP80-00926A000500030010-4
• Release Decision: RIPPUB
• Original Classification: R
• Document Page Count: 30
• Document Creation Date: December 14, 2016
• Document Release Date: April 23, 2001
• Sequence Number: 10
• Publication Date: August 9, 1948
• Content Type: REPORT

(;LH&'II'IUAI IUN
Approved For &W24
. COUNTRY Czechoslovakia
SUBJECT Specifications of JANA 260 cam Motorcycle
PLACE
ACQUIRED
THIS DOCUMENT CONTAINS INFORMATION AFFECTING TILE NATIONAL DEFENSE
OF THE UNITED STATES WITHIN THE OEANING OF THE ESPIONAGE ACT BO
HIBITED BT LAW. REPRODUCTION OF THIS FORM IS PROHIBITED. NOW
EVER INFORMATION CONTAINED IN SOOT OF THE FORM MAT SE UTILIZED
SOURCE
25X1A
DATE DISTR.9 August 1948
NO. OF PAGES 1
NO. OF ENCLS.
(LISTED BELOW)
SUPPLEMENT TO
REPORT NO.
THIS IS UNEVALUATED INFORMATION FOR THE RESEARCH
USE OF TRAINED INTELLIGENCE ANALYSTS
On file in the CIA Library is a copy of a booklet (27 pages) entitled
"Operation and Care of JAWA 260 con Motorcycle,* The booklet was issued
by the Brno Arras Factory, National Corporation, Works Prague-Ausle II,
and it contains full technical specifications as well as detailed instruc-
tions for care and operation*
STATE NAVY ' I I NSRB
RESTRICTED
FE1
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 STATOTHR
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CQ E,ETr i C-t pd,
Operation and care of
JAWA 290 ccm motorcycle.
Brno Arse Factory,
National Colporation,
228723
~ e urn tc (JA s
L U frJJ
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C o n t e n t s
Page
Introduction
Technical Description
Riding
Running Instructions
Cleaning
Lubrication
Pneumatic tyres
Removing front wheal
Removing rear wheel
Adjusting brakes
Driving out bearings
Maintenance and chain adyuatement
Removing covers
Dismantling cylinder head
Removing piston
Decarbonisation
Carburettor
Maintenance of Carburettor
Clutch and its disengagement
Lubrication of clutch
Gearbox
Lubrication of gear box
Dismantling steering head
Handlebars
Forks
Headlight
Rear springing
Fuel tank
Electric control
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These are Directions for using T ur 250 cu-cm. JAWA Motorcycle.
It is a new model, both as re;;ards its design aid capacity,
*hose perfect, up-to-date construction is the result of many
years experience of the designers of our motor cycles industry.
JAWA is a world renowned mark with a great tradition in sport
and in service to motorists. This is proved by an ixtensise
collection of trophies gained by JAWA in international races
-and reliability trials as well as the most valuable trophy,
its good repute and satisfaction of the customers.
We are convinced that your 250 cu.cm.JAWA will comply with
all your requirements. It is a beautiful machine and it deserves
-your attention and a thorough inspection of all its component
parts, their functions and use. This is very important if you
want the machine to serve properly, to last long and become a
permanent source of your satisfaction.
We wish you thousands of nice and joyfull miles.
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Foot starter at the left of the engine; foot operated change
mechanism housed in gearbox.
Frame of steel, rigid, welded of square tubes.
Telesoopis fork with spiral springs and forming headlamp shell.
Wheelg6asily removable, rims 2 1/4 x 19, tyres 3,00" x 19",
Mudguardsi front fixed, rear guard with hinged tail piece.
Internal expanding brakes dia 150 mm, 25 mm wide.
Saddle comfortable, rubber-sprung with frictional shook
absorber. Tension of spring adjustable to the weight of the
rider.
Footrests adjustable.
Telescopic rear springing fully enclosed of very simple design.
Handlebars dia 22 mm, 700 mm wide adjdstable.
Fuel tank, capacity 3 imp.gallons, with 60 mm dia. Filler cap.
Lights 35/351, long distance, dimmed city, parking and rear.
Length over all 2000 am, height 950 am, width 700 mm
1 79 " 37,5" 27,5
Weight of the machine 220 -BAs.
Admissible load; 336 lbs, Maximum speed 65 miles per hour
Fuel consumption at an average speed of 38 miles per hour
....... miles per gallon.
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Riding hints.
l/ It is obviously needless to say that it is necessary to make
'ure before taking a trip whether there is fuel in the
tank. Before starting, therefore, open the filling cap of
the fuel tank by turning the closing cap to the left and
lifting it to asceitiin the level of petrol. Before putting
gasoline in, mix it first with mobiloil D in the proportion
of 1 t 25. Close the tank by putting the cap on and screwing
it down to the right. The small opening in the middle of the
cap should be protected from being clogged by impurities.
A reserve of fuel always :remains in the right hand half
of the tank, which is sufficient for abt. 10 miles.
If need be, the fuel cane be passed, by tilting the machine
to the left, over to the left -.ind half from where it drains
to the carburettor.
2/ Push the key into the switch box. If the battery is in good
condition he red control light will start burning. Ascertain
whether any of the lights indicating that the speeds are
engaged is alight. If the neutral is pushed in correctly, the
bulb "N" will be alight. If the gear is pushed in theAecond
neutral /between the third and fourth gear/ only the control
light of the battery will be alight. In that case change over
to the proper neutral position between the first and second gear.
If the bulb indicating the engaged gear isa alight, change
over always to the neutral. The machine can however be started
up even with the gear engaged by disengaging the clutch by
hand /for instance if the foot control fails/.
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3/Close air intake of the carburettor by turning the cover
of the cleaner, which is to be opened again after the engine
is warmed up.
4/ Open the fuel tap and press down the tickler pin of the
carburettor several times which ensures a rich mixture.
/Do not overflood unless the engine is cold since a warm
engine would get rich mixture and be difficult to start/.
5/ Turn the right twist grip toward you by about a 1/2 turn.
6/ Start the machine up by your right of left foot /whichever
you are most accustomed to/. As soon as the engine starts
running, decrease its speed by turning the gas grip to the
closed position. The carburettor should merely be adjusted
so that the engine, just ticking over with the twist grip
in fully closed position, works at the lowest speed without
stopping. /For adjustment see the paragraph "Carburettor".
7/ When starting running pull the clutch lever with your left
hand, engage the first gear by the point of your left foot,
by moving the lever of the foot control upwards, and release
slowly the clutch lever at the same time opening the throttle.
As soon as the machine is running at a speed of about 10 miles
per hour, reduce gas quickly and simultaneously tread on the
change lever and open throttle quickly again. By doing this
the second gear is engaged quickly and smoothly. When engaging
the further gears, tread the lever downwards always exactly
the same manner. When reversing the gear, pull the gear lever
upwards. The light of the lamp in the switch box indicates
which gear is just engaged at the moment. There are only two
bulbs for four gears, one of them for the first and third gears,
the other one for the second and fourth gears. You must there-
fore, learn to ascertain also by the sense of touch, which is
gained by practice, which gear is engaged.
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8/ When stopping, close throttle, pull the clutch lever, brake
the machine, change the gear to the neutral position between
the first and second gears, and then only, release the clutch
lever. If you stop for a short period /at a road crossing and
the like/ change to the first gear and keep the clutch dis-
engaged. When braking always apply rear brake first and secondly
the front broke, and only in the straight direction of running.
After finishing the ride close the fuel tap, return the key
to the zero position and take it out from the switch box.
9/ When riding at night set the most favourable distance of the
fall of lights from the headlight upon the road, by turning
the adjusting screw on the headlight.
The first six hundred kites should be run carefully since it is
important to run the machine in properly, which has a great in-
fluence upon its output, long life and consumption. Do not ride
at full throttle but at 1/3 maximum. Run the machine in preferably
on ground not too hilly and at a speed not exceeding at the maxi-
mum 30 miles per hour, and do not attempt hills in top gear. Use
the second gear and third gear as rarely as possible and the first
gear when starting only. Give more oil in proportion of 1 s 20
i.e. 1/20 of a gallon of oil per 1 gallon of gasoline i or first
600 miles then 1/25 of a gallon of oil to 1 gallon of gasoline.
Do not leave the engine running for long after starting up since
it is not cooled so well as during riding. When riding without
engine running do not engage gear in order to prevent the gear
wheels of the gear box from getting damaged. It is therefore
advisable to start the engine before engaging the gears. Make sure
occasionally that the connecting screws are not loosed.
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Wash the machine always with orate' since cleaning it dry would
damage the finish. Parts dirtied with oil and dust should be
washed with parrafin. After washing, dry the machine with a
3haadis or soft fiammele while cleaning the machine, be careful
the water does not get into the carburettor /to avoid this close
the cover of the air filter/, head light and the brakes. Water
remaining between the ribs of the cylinder after spraying, can
be removed by running the engine for a short time. The water
evaporates and the cylinder is prevented from getting rusty.
Lubricate all the points provided with grease nipples for
pressure lubrication occasionally. /Preferably after the maschi-
ne is washed, to force out water which might have entered the
bearings/.
For lubrication of the other parts see Paragraphs "Lubrication
of Engine" Gear Box and Clutch. In addition put a few drops of
oil into the bearing of the foot brake pedal rod, the saddle pin,
the stand pin etc. The rear springs should be lubricated after
every 3.000 miles of running.
The machine is pbovided with pneumatic tyres, size 3" x 19".
Make sure always that they are correctly inflated, since this
willprolong their life. At normal load /one rider/ a pressure
17 lbs/square inch for the front tyre and a pressure of 21 1/2
lbs/square inch for the rear tyre is suitable. When riding with
a pillion passenger the rear tyre should be inflated to 25 lbs.
The pressure is measured by a pressure gauge. If air escapes from
the inflated tyre, it may be caused either by leakage in the
valve or there may be a puncture in the tube.
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The leakage of the valve is ascertained by removing protecti$
cap of the valve and moistening its end;if air bubbles form, it is
a sign that the valve leaks. The valve may sometimes.be sealed by
tightening its cone. The other side of the protecting cap with a
slot meant for this purpose, is used for thorough tightening. If
this does not help, replace it by a new one. If the air escapes,
even if the valve is in order, the inner tube is damaged and must
therefore be removed from the wheel and repaired. After removing
the wheel /see paragraphs "Front wheel" "Rear wheel"/, unscrew
the valve cap and let all air out. Screw off the nut fixing the a
valve to the rime Press the edge of the outer cover at a point
opposite the valve into the hollow of the rim and pull the casing
edge near the valve, after lifting by levers, over the edge cover
of the rim. Take the inner tube carefully out and inflate it.
Immerse the inflated tube under water. The puncture is shown at
points where air bubbles escape. Now, dry the tube, let air out
agai4 and patch the opening. If possible, spread some talc Aver
the patched place. Put the inner tube into the outer cover and in-
flate it partly, so as not to squeeze it in the cover when fitting
it in. The outer cover is put on without using the tyre levers.
Push the pneumatic tyre on, preferably by hand and pull the remaining
part over by treading on tyre.. Never pull the cover over the rim
by force and damage the wire in the edge of the cover and thus the
whole pneumatic tyre. Start pushing the cover on the rim at a point
close to the valve.
Maintenance and chassis adiustement.
The front /primary/ chain is entirely enclosed in the chain case.
It requires almost no maintenance since it runs in an oil bath.
When replacing the chain, dismantle the clutch /after removing the
wire, unscrew the 3 screws holding the spring down, take the springs
down, take the springs and discs out/.
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Release the chain wheel of the clutch /unscrew nut M12x1,5/ and
push it out of the grooves by a special wrench. Simultaneously,
after screwing off nut M 18 x 1,5 remove the other chain wheel,
Remove the rear /secondary/ chain by turning the connecting link
of the chain on to th-e rear chain wheel and removing the link by
a wrench after pushing out the spring lock. After undoing the chain
turn the wheel a little and pull the chain out. First of all clean
the chain in gasoline. When dry, place it in /mildly/ heated grease
for about three hours until oil penetrates into the links. Now take,
the chain out, leave the grease to solidity and wipe off the sur-
face of the chain thoroughly. The assembly is carried out in such
a manner that first of all the chain is put &n the chain wheel of
the speed box and thereafter upon the rear chain wheel where the
two ends of the chain are connected by the connecting link. Adjust
the chain after realeasing the axle of the rear wheel and the nut
of the brake drum box, by.uniformly turning the screws in the slits
of the slides. Make sure that the rear sheel follows the trace of the
front wheel. After setting, tighten the screw nuts again.
carburettor.
The carburettor is combotiy set at factory, the jet and the throttle
valve are suitable chosen. No adjustment is therefore necessary
except. occasional cleaning. The fuel is led from the tank by a pipe
into the float chamber. The fuel tank tap is provided with a screen
catching all impurities. The fuel level in the float chamber is
maintained at a constant height by the float and needle. The air is
drawn in streams through the air cleaner at a great rate round the
jet, drawing off the fuel getting out of the jet and spraying it
around. The amount of mixture drawn in by the motor Fiston and thus
also the output and speed are regulated by opening or closing the
throttle valve with the needle connected by bowden wire to the twist
grip on the right hand side of the handlebars. /For starting the
engine see the paragraph "Riding"/.
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If the engine is to start up well, the idling run must first of
all be set correctly. This adjustment is very importatnt and has
a great influence upon the consumption and output of the engine.
It is effected by an adjusting screw of the free coupling. To
attain a lean mixture /when ticking over/ unscrew the screw a little.
A richer mimbure is ensured by sdrewing the screw down. If the mix-
ture is lean the engine can only be started with difficulty, tending
to fire back to the carburettor, gets overheated. and loses its
output. The exhaust pipe squires a blueish tinge.
The rich mixture becomes evident from the heavy run of the
engine and black smoke leaves the exhaust, the interior of the
carburettor becomes black and a reserve reflection of the mixture
takes place. 'Nhk:n idling /tne engine runs even with the Ws grip
entirely closed/. This is adjusted by securing the position of the
slide by a stop screw to prevent it closing altogether. The stop
should never be unscrewed entirely.
Maintenance of carburettor.
The carburettor should be cleaned regularly. It is cleaned best
if its individual parts are dismantled and washed in clean gasoline.
If the jet bloc" is difficult to remove, hammer it out with a wooden
block.Replace at! dammed and worn parts by new ones. The presses
of thefree trip Gear are cleaned best by pRilLng a fine horsehair
through it. kem,ve the air filter trom the carburettor occasienaly
and wash the filter body in clean gasoline.
During assembly make sure that the float chamber is vertical to the
carburettor body so that the floating pis is freely clear of the
opening of the cover.
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The four-speed gear box with gears in permanent engagement
is made in one block with the engine. The mechanisms of the foot
starter is inside the box. Only the starter lever and the foot gear
control lever are outside. The change of speed is described in the
paragraph "Riding".
The oil in the gear box should be maintained at a constant
level and replaced from time to time. The filling opening is in
the left cover of the box closed by a plug. Before unscrewing
the plug its surroundings should be cleaned thorouLtLy. When pou-
ring oil in, unscrew the screw in the cover marked with the in-
scription "oil"' and an altitudinal mark shows the oil level. A
discharge screw placed at the bottom of the left part of the box
is used for discharging the oil. Oil must be changed after 600 miles.
The clutch is intended to interrupt the driving power of the
motor to the rear wheel, which is necessary for effecting the
changes of gear, the stopping, starting and the like. It has a
great number of discs running in oil and is placed on the main
shaft of the transmission E par box and covered with a cap. The
clutch may be disengaged automatically when changing gear by the
foot lever or also by the hand lever with Bowden cable placed on
the left of the handlebars. if the clutch slips, adjust it by
turning the screw passing thi`ough the right lift of the box. When
disengaging by hand remove the right lid of the box and adjust
the lenght of Bowden by a screw. The cork lining of the discs which
wears out eventually should be replaced at your motorcycle service
station.
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The connecting rod of the clutch is lubricated is such
a manner that.thu regulating screw is screwed out, the rod with
the ball is pushed out, a small quantitty of grease is put into
the opening and the disconnecting rod is pushed in again. After
screwing the regulating screw in, adjust the clutch.
After having ridden 1.200 miles the decarbonisation is very
important. The residium of the burnt mixture /carbon/ which has
settled down on the piston, cylinder head and in the exhaust port
is to be scraped off carefully. Simultaneously remove the carbon
from the piston ring grooves so that the rings can move freely. Be
careful not to damage the surfaces of the areas cleaned. After the
carbon iq`removed, it is advisable to polish all the parts smoothly
with fine emery cloth. The exhaust pipes and silencers, after about
6.000 miles are dismantled and cleaned by a wire brush. Do not en-
large the openings in the liners since every change has an influence
upon the output and consuption.
When dismantling the heads and cylinders unscrew first the rear
fixing screws of the fuel ta}ik and release the front scree, close
supply from fuel tank to carburettor, disconnect the sparking plug
cable and lift the tank a little. Unscrew the 4 nuts of the cylinder
head remove the sparking plug, lift the head upend remove it. Before
dismantling the cylinder disconnect the exhausts, move the piston
by the starter lever to its lower position, lift the fuel tank up
and push the cylinder oht.
Cover the opening in the crank case with paper or clean cloth.
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,When pushing the piston with the rings into the cylinder it is
-ddvisablo to proceed as per the illustrated method.
Reulacement of the piston. piston Pi and rings.
Wheh~ removing the piston from the connecting rod of the
crank shaft, take out the spring safety locks holding the pin
on the piston bearing /preferably with pointed pliers/ push
the pin out /by a wooden block or a special device in service
station/ and remove the pin. After dismantling the piston remove
the piston rings by means of three thin sheet iron. strips inserted
between the piston ring and the piston-, one in the middle and two
at the end of the rings. Proceed in the same way when putting the
rings on. If the piston rings are worn too much and if the*r slits
are wider then 1 mm /the correct width is 0.2 am/ they should be
replaced. The width of the slit is ascertained by inserting the
removed ring into the cylinder.
The starting-and gear changing lever is dismantling by
being pushed out of engagement by two screw.'3 drivers or a special
device, after entirely unscrewing the fastening screws. The right
cover of the crank case is removed by screwing off the two screws
and by pushing the lever of the foot brake. The left cover of the
box is removed by screwing off the 8 screws, by simultaneously
lifting it by means of two screw drivers in the gap of the cover.
Before replacing it turn the pedal to its bottom position, by
releasing one of the screws, so that it does not get in the way.
To remove the whole engine from the frame it is necessary to
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unerew the fixing;' screws of the engiut, to take off the right
cover of the box, to disconi et the exhausts, release the top
and bottom covers of the chain, undo the secondary chain,
disconnect the three strand cable from the dynamo and contact for
electric gear indication of the gear engaged. With the fuel tank
lifted up, push the engine in parallel with the front frame carrier
until the boss for the rear screw for the right cover clears the
rear stop of the frame towards the left cover. When inserting the
engine in the frame proceed in reversed order.
The two halves of the boxes are separated from each other
by screwing off the 10 screws and pushing out the crank mechanism
by means of a special device, preferably in service station.
-Prior to that, hcwever, it is necessary to remove the cylinder
with head, the carburettor cover and the carburettor itself inclu-
ding the branch.
When assembling the unit clean all the bearing surfaces
carefully and apply again the packing coumpound "Hermetic"
or other copound.
itelease the screws securing the upper split frame holders.
Unscrew the bottom screw entirely. Push out the axle, grasp the
slide by its lower part and take it out of the engine together
witn the spring and the upper latch. When assembling it again
procced in reversed order.
Handlebars.
The handlebars consist of two parts and are fixed in the steering
head and sedured by adjusting screws. The twist grip of the right
handlebar is remcved by unscrewing the screw through the opening
in the rubber of the grip and casing.
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"Moving the steering head.
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Unscrew the 2 screws securing the steering heed to the headlight
holder and push it out of the grooves by knocking on it. After
unscrewing the head /the screw/, the two nuts from the steering
gear axle and the securing screw of the silencer in the bottom
part of the frame, the whole fork will fail out downwards.
/be careful that the hills do not fall out when the axle is removed/.
Dismantling the Tank.
--------------------
Wh?n removing the tank, unscrew the tour fixing screws, release
the switch box, uisconnsot the cables to the switch box, the cable
to the spark plug and the pipe for the supply of fuel from the cook.
The switch box is released by screwing off the 3 screws fixing it to the
tank. The fuel tank can also be screwed off for the purpose of
gleaning or repairing ?
Removing the front wheel.
-------------------------
Balsams the screw securing the slit end of the fork, screw out the
axle, push out the wire cleat of the front brake from the gap of
the lever and take the wheel oute
Removing the rear wheel.
Release the nut of the rear axle and push it out. Take out the
distance piece between the slide and the wheel. After folding the rear
part of,the mudguard push the wheel out of the grooves of the brake
drug. Take off the brake drum after screwing out the nut froze the slide
bush axle, after first having undone the rear chain.
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16.
Driving out the bearings form the wheel hubs.
-ssmove the safety device securing the bearing and front the opposite
side drive out, by a pipe, the other bearing towards the hub until
the bearing which has been unlocked, falls out. Remove the distance
piece and drive the rest of the bearing out to the other side.
Adjusting the brakes.
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Adjust the rear brake by turning the wing nut at the and of the
brake tension rod.. In the front brake, after releasing the oleat,
pull the wire out a little by a pair of pliers and secure it by retigh-
toning the cleat.
Dismantling the fork.
--------------------
Take the wheel and the aaudgsard out, release the collate securing
the rubber collars, and screw the end boxes with tha steel eprings
out. The sabres are pushed out after releasing the two securing
screws of the carrier and unscrewing the four screws in the rear
rlutoh part of the herd light.
screwing
After sswuksg out the securing screw of the headlight socket,
r.move the galas with toe rim by tilting the bottom-aide up,
disconnect the ccbles from the terminals and the speedometer, by
unscrewing the nut on the speedometer arive. 6crew-out the two
screws connecting the cork holaer to the steering head and drive
the holder out, preferably with a wooden block.
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Electric devices.
Ignitions dynamo-battery. The dynamo is D.C., shuht,
four-pole, 6-Volt, Mark JAWS'.. Output of the dynamo is max. 45 W.
Tensions 6 Volts. An automatic voltage regulator with switch and
o2cuiv breaker which can be turned by about 16? /advanced
ignition regulation/ is connected to the dynamo.
Batrrs. 7 An /14 Ah/ 6 V, leaden, with eleotrolite-diluted
sulphuric acid. The battery is placed in a box at the left og the
machine. Near the battery, in a casing, in a fuse for 8 A to the
6SN 72581 Standard Specifications.
Switch box.
It is situated in the fuel tank and distributes the
current'.from the dynamo or battery to the individual points.
It contains a change-over switch, an ignition coil and control
bulbs.
Current points.
In the head light is a double filament bulb of 6V, 25/25W,
shape B to the LSN Standard Specifications No. 72601, and a par-
king bulb of 6 V, 1,5 W shape H to the 6SN No. 72601. In the
rear lamp is a bulb of 6 V, 3W shape G to the 6SN Standards
No. 72601. The elctric horn of 6V, 3 A is underneath the fuel
tank. The sparking plug with M 14 thread is in the cylinder head.
Its contacts must be kept clean. The beat sparktng is attained
at a distance of the electrodes of 0,5 mm.
Cables,
The connections are made of varnished auto-cables having
a section of 1 sq.mm, From the dynamo to the switch box is a three-
strand cable of 3x1 sq,mm., from the light change-over switch
on the handlebars to the head light is a three-strand cable of
3xl,5 sq.mm. The cable to the sparking plug has a section of
1,5 sq.mm. Inspect the cables carefully to make sure
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 Approved For Release 2001/11/21 : CIA-RDP80-00926A000500030010-4t
that they are not damaged and do ,not caner abort circuits or
bad function of the electric equipment. The ends of the cables
should have brass end-boxes or should be soldered.
i8sintenanoe of tb. 5 free roads/,
4 Parking and rear lamps switched on /parking at night/
Key may be taken out,
5 Ignition and horn out in direotiy from dynamo. iise only if
battery should fail. /Lamps are not bu*ning and starting is
difficult. Push the machine at seco*Q speed.
Marking of terminal board in the bottom part of the
--------- --- --
W1ith-[ Oa blboxi
e of spark plug to tesmimal Of dynamo 1
30 sable of plug-pole of battilg
51 oable of dynamo plus-po10 to dynamo terminal S0
6a oebld to horn
App$~b VfflUb 1FeotrpR~ef9ase l~ /~ RDP80-00926A000500030010-4
 ,Approved For Release 20Q1/11/21 : CIA-RDP80-00926A000500030010-4
"57" cable to parking lamp in headlight
76l" cable of ignition control lamp to dynamo
7587 cable to rear lamp
"1-3-N-2_4" three-strand cable to change-over switch of
electric indicator of the speed out in.
Function of the electric equipment, when starting themoo
and during rjdAp&,_
After pushing An the kep into the switch box and turn-
ing to pdsitton "1-2,3",the red bulb musteburning which means
that the dynamo does not supply current to the consumers which
take the current from the battery. If the neutral is cut in
between first and second gear /which should always be the
case before starting/ the white bulb also will be burning. If
after starting, the speed of the motor rises to more than
1,300 R.p.m. the red bulb will go out, the battery will, not
discharge, the consumers will take current from the dynamo, or
the battery will be charged by the excess of current. If the
red bulb is not burning in the above positions, inspect the fuse
or the battery to see whether it is burnt out or whether the bulb
is damaged. If the fuse and the bulb are in order, but the bulb
is not burning, or if it is burning intermittently during
running /flickering/ it is necessary to inspect the electric
equipment in expert. workshops /fault in the switch/. The broken
or burnt bulb is taken out from the switch box after removing
the lid by pressixg and.turning to the left.
The control lamp and the sflq, lamps indicating the gears
have 8-10Ys0, 8-1W as per the 68N Standard 8pecifikations shape J.
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 Approved For Release 2001/11/21 : CIA-RDP80-00926A000500030010-4
22
ow to locate troubles.
Indication of troubles;
Engine cannot be started - Engine has stopped
Carburettor can be overflooded Carburettor cannot
be overflooded
ignition control lamp Ignition control Spark is at
is burning lamp is not cable end
burnirg
Ascertained trouble ~emedy
No fuel in toe tank Pass fuel from reserve /for abt.
6-9 miles is enough/ and add mix-
ture to tank as quickly as possible
Supply pipe cock closed Open the cock
Cleaner clogged above cock Unscrew cook and clean the cleaner
Pipe or screen in carburettor Remove piping and blow it through,
take out carburettor, dismantle
nozzle and clean it.
Hole in lid of filling opening Clean air opening in lid
of fuel tank clogged
Oiled plug Remove plug and clean it
Damaged insulation of plug Replace plug
Short oinuit between contacts of plug Put contacts apart abt. 0,5 mm
Great distance between plug contacts Put contacts nearer to each other,
abt, 0.5 mm apart
Key not inserted into switch box Put key in and turn in to correct
position
Burnt fuse of battery Replace fuse
Battery discharges Change over switch to position
"5" and start machine by pushing
Get battery charged.
'Defective contacts of breaker
7?lug cable broken or released
Damaged condenser
Damaged insulating of winding
Water in beaker
Clean contacts by cloth soaked
in benzine
Get contacts repaired or replaced
Exchange cable or connect axid in-
sulate with insulating tape and
replace as soon as possible
VIa d cable with insulating tape
and replace soon
nepluce
Get repaired by .TX.7d d's$lar
Blow out water, wipe out carefully
or leave to dry.
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 Approved For Release 2001/11/21 CIA-RDP80-00926A000500030010-4
- 23
Piston ring broken
Piston ring caked
Packing under plug leaking
Remove ring from piston and replace
Remove ring, clean it and put on
Replace packing
It leaps over
Irregular spark
Ascertained trouble
Engine knocks
Correct spark
Remedy
Engine overheated Allow engine to cool down and run at
low speed
Plug contacts glow, bad plug
Much carbon in cylinder head
Brake jaws do not separate frog
drum
Greatly advanced ignition
Water or oil in carburettor
Fuel supply in carburettor al-
most used up
Temporary short circuit
connection to cylinder
Lean mixture
}Badly mixed gasoline and oil
mixture
Unsuitable plug
ail smeared plug Take
reat distance of plug contacts
Dirty breaker contacts
Badly adjusted breaker contacts
poas,7 short-circuitin of
Tom
cable connection to cylinder
Replace sparking plug
Take off head and remove carbon
Inspedt springs of brake jaws and
clean drum
Adjust advanced ignition by turning
carrier of breaker
Take off silencer, dismantle and
clean it
clean carburettor
open fuel cock pass reserve over,
supplement mix4ure,iaspact supply
Wind insulating tape round cable, or
preferably replace it
Adjust carburettor
Stir mixture well before pouring
it into tank
Replace sparking plug
sparking plug out and clean it
Adjust distance of plug contacts
to a-bt.0,5 mm
Clean contacts with cloth soaked in
bentine
Adjust distance of contacts to
abt. 0.35 mm
Wind contact with insulating tape,
or replace it.
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 Approved For Release 2001/11/21 : CIA-RDP80-00926A000500030010-4
Engine running incorrectly Engine cannot be started or it has
stopped
Carburettor can be overflooded
Engine has not sufficient output Esigi.ne has compression
/does not pull/ Plug emits sparks
- - - - - - - - - - - - - -
Temporttily Permanently Carburettor Carburettor
/from time to /all the time/ not in odder is in order
time/
Ascertained trouble Remedy_ _ _
I n s u f f i c i e n t kake sure that oil is always well
lubrication mixed with gasoline in proportion
df 1:25
Bowden cable to carburettor Replace cable
broken
Bad packing between carburettor
and cylinder Replace packing
M u oh carbon settled in cylinder Take off head, cylinder, exhaust
head, exhaust vents and silencers and remove carbon
Fuel supply clogged partly Dismantle piping and clean it
Bad adjustment of ignition Adjust distance of breaker contacts
and advanced ignition
Carburettor-not set /bad mixture/ Adjust free trip, needle position
and clean air cleaner
Exhaust silencers clogged Dismantle silencers and remove carbon
settled therein
Interior of cylinder and piston Regrind cylinder, fit new piston
worn rings, ascertain wear of piston
bearing etc. at service station
Engine draws in air /box halves Separate box halves, clean conic ct
of carburettor branch ate not surfaces, apply packing compound and
packed properly/ assembly firmly. Replace packing
underneath carburettor branch
Nozzle clogged Take out nozzle and clean it
Float leaking Solder float or replace it
Float needle does not close Replace damaged needle or repair it
Fuel supply or cleaner partly Clean supply or cleaner
clogged
Bowden cable or gas jams Lubricate cable or replace
Motor /Eniline/ overheated' Leave engine cool down and maintain
it at low speed
Faulty sparking plug Replace sparking plug.
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 Approved For Release 2001/11/21 : CIA-RDP80-00926A000500030010-4
Toole of lubrication or 200 ou.cm. JAWA
------------------------- ----------------------------------------------
wuneber of Type of
After . ...miles ubrioation point lubricating Lu')rioant Note
points
Rear snringa 2
Saddle 1
Hand brake lever 2
Olutoh 'ever 3
b'ont brake lever 1
tilasilins
Oil a few drop
oil dtto
oil dtto
vaseline
uiaconneoting rod of
clutch 1
oupplementing oil in
speed gear box
Starter lever
Stand
vaseline on pushing
grip out
dtto
oil a few drops
oil ,itto
oil check level'
frequently
vaseline also after
spraying
washing of
machine
1600
Rear idleel
Celt of breaker
breaker oam pin
1
1
1
vu eel ine
dtto
oil a few drops
Brake keys
2
oil dtto
Speedometer drive
r'ront brake oabie
Clutch oaq]e
1
1
1
oil after dismant.
dtto a few drops
Steering gear head
Secondary chain
Gear box
tieplaoement of oil
2
1
1
vaseline after dismantl
as per directions
vaseline dtto
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 Approved For Release 2001/11/21 : CIA-RDP80-00926A000500030010-4
Description of pioturas.
-----------------------
1/ How to use reserve of fusl in reserve tank
lteutra:l engaged, engine runs
lot or brd gear engaged
2nd or 4th gear engaged
5/ Closing of air cleaner of earburetter
6/ Adjusting of headlight
7/ Front wheal
8/ Hear wheel
7a/ Removing front wheel
8a/ Removing rear wheel
9/ Chain adjustment
10/ Gear box dismantled
11/ Dismantling gear control lever
12/ Dismantling kiokrstdrter lever
13/ Removing left cover
14/ Removing right cover
15/ Dismantling cylinder head
id/Dismantling cylinder
17/ Crankshaft and oy inder *ith head
18/ i[xhaust pipes and silencers
19/ Aeplaoement of gudgeon pin
20/ xenleoement of piston ring
21/ Carburettor, float chamber, mixing chamber, air cleanor
E2/ carburettors unassembled
23/ Gear control lever, clutch driving plates, operating rod,
adjusting acrew, automatic gear control can. acaeme o1
automatic declutching.
84/ Clutch adjusting
25/ Clutch complete
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 ,Approved For Release 2001/11/21 : CIA-RDP80-00926A000500030010-4
27/ Scheme or Igears engaged
lot gear, 2nd gear, 3rd gear, 4th gear, orankeuaft
primary chain, gear box in neutral position, clutch,
secondary chain, brake drum, rear wheel.
28/ Gears and starter
29/ control mechanisms
30/ r'illing gear box with oil
31/ Dismounting steering head
32/ rork complete
33/ Dismounting fork
34/ Dismounting head light
35/ Brame complete
o6/ Lismounting rear springing
37/ dtto
38/ Position of electrical equipment. Bead light, switch box,
horn, rear lamp /tail lamp/, plug, dynamo, battery, fuse
39/ Wiring diagram, triple-wire cable, oontaotor, switch box,
over switch, push button, t'use, battery, tail lamp, dynamo,
voltage regulator.
40/ Adjusting pre-ignitio n
41/ Rotor and stator of dynamo
42/ $witoh box scheme, switch box, over switch, wiring, ignititn
key position, machine, standstill, L.riding by day, ll.riding
through the town, Ill.riding by night, IV. parking,
V. riding without oattery.
43/ Tool
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 Approved For Release 2001/11/21 : CIA-RDP80-00926A000500030010-4
25X1A
Approved For Release 2001/11/21 : CIA-RDP80-00926A000500030010-4