JAWA Dandy MJ50 User manual

DANDY MJ50
Operation and Maintenance Manual
Dear friends,
you have become the owners of Dandy 50 motorcycle that was manufactured in MotorJikov, a
joint stock company, in ČeskěBudějovice, Czech Republic.
This late type of two-seat motorcycle has renewed interrupted tradition in manufacturing of
Stadion mopeds that were the top products of Czech motorcycle industry in their time. Besides the
motorcycle production MOTOR JIKOV is renowned company also in the field of Manufacture of
car accessories and small two-stroke and double-stroke engines.
The motorcycle you have chosen has been designed using up-to-date computer art and experience
of leading designers of motorcycles, taking special care of drive safety and driving
characteristics. The materials used for the motorcycle are manufactured according to the latest
knowledge of metallurgy and petrochemical industry, and therefore they guarantee high
reliability and long service life of all its parts.
The operation and maintenance manual includes all basic data of your motorcycle; using the
manual you will be familiarized with service, maintenance and technical data of the motorcycle
in details. There is also a section devoted to troubleshooting of smaller failures in the manual.
Before the first drive read these instructions carefullv. Observing all advices and
instructions, MOTOR JIKOV’s motorcycle will serve you well.
A great deal of plesure in driving your ,,Dandy"!
MOTOR JIKOV
1

2. Table of Contents 8.13. Rear Wheel Brake Check and Adjustment
23
1) Introduction 1
2) Table of Contents 2
3) Technical Data 3-6
3.1. Engine 3
3.2. Undercarriage 3-4
3.3. Electric Equipment 4
3.4. Working Liquids 4-5
3.5. Other Data 5-6
4) Technical Description 7
4.1. Identification Marking 7
5) Familiarization with Motorcycle before Drive
8-12
5.1. Control Elements 8
5.2. Brake Control 9
5.3. Clutch Control 9
5.4. Gear Shifting 9
5.5. Fuel Cock Control 10
5.6. Choke Lever Control 10
5.7. Side Stand 10
5.8. Tool Box 10
5.9. Machine Locking 11
5.10. Working Liquid Refilling 11-12
6) Motorcycle Check before Drive 13
6.1. Brake Check 13
6.2. Clutch Check 13
6.3. Gas Grip Check 13
6.4. Chain Check 13
6.5. Tyre Check 13
6.6. Wheel Check 13
6.7. Electric Installation Check 13
7) Driving the Motorcycle 14-15
7.1. Motorcycle Starting 14
7.2. Motorcycle Setting in Motion 14-15
7.3. Motorcycle Stopping 15
7.4. Engine Running-In 15
8) Adjustment and Maintenance 15-29
8.1. Lubrication and Maintenance Schedule
16-17
8.2. Torques 17
8.3. Table of Lubricants 18
8.4. Gear Oil Level Check 18
8.5. Gear Oil Replacement 18
8.6. Fuel Cock Cleaning 19
8.7. Air Filter Cleaning 19
8.8. Carburetter Check 20
8.9. Sparking Plug Check 20
8.10. Ignition 20
8.11. Clutch Check and Adjustment 21
8.12. Front Wheel Brake Check and Adjustment
22
8.14. Excessive Effect of Brakes 23
8.15. Rear Stop Light Switch 24
8.16. Front Stop Light Switch 24
8.17. Chain Tightening 24
8.18. Chain Cleaning 25
8.19. Front Wheel Mounting and Dismantling
25
8.20. Rear Wheel Mounting and Dismantling
25
8.21. Telescopic Fork 25
8.22. Steering Bearing Clearance Check 26
8.23. Wheel Bearing Check 26
8.24. Side Stand Check 26
8.25. Exhaust Equipment Decarbonization 26
8.26. Headlight Adjustment 26
8.27. Lamp Replacement 27
8.28. Fuse Replacement 27
8.29. Battery Check 28
8.30. Electric Installation Diagram 29
8.31. Table of Failures 28
9) Care of the Motorcycle 30-31
9.1. Motorcycle Cleaning 30
9.2. Motorcycle Storage 30
9.3. Winter Operation and Protection against
Corrosion 30-31
9.4. Fuel Saving 31
9.5. Ecologic information 31
2

3. Technical Data
3.1. Engine
Type SACHS50/5AKF SACHS50S
SACHS 50/5 AKF I *
SACHS 50/5 AKF. **
SACHS 50/5 AKF I. **
Numberofcylinders 1
Cylinder bore/Piston stroke 38 mm/44 mm
Cylindercapacity 49.9ccm
Compression ratio 11.5:1 10:1
Engine max. power 2.6 kW 5,700 rpm 46 kW 8,000 rpm
Max. torque 5.1 N.m / 3,500 rpm 5.8 N.m / 7,500 rpm
Fuel consumption 2.1 l/100 km 2.5 l/100 km
Engine lubrication oil and petrol mixture
Lubrication ratio 1:30 (1:40) See Section 5. 10
*separated lubrication of the engine
Oil tank volume* 1.3
Carburetter BLNG 18/15/101 BNG 21/20/127
dif. Ø 15 mm dif. Ø 19 mm
Mainjet 78 80
Idle-runjet 30 45
Ignition
With light coil
Type contactless contactless
ignition ISKRA ignition VAPE
Light power 12 V/80 W
Sparking plug
Type BOSCHW5BC BOSCHW3A
BRISK N 17 BRISK L N 14
NGK B6 HS NGK B8 HS
CHAMPION L-81 CHAMPION L-78
Electrode spacing 0.5 - 0.6 mm
Gearshift mechanism
a) Primary drive by gears with helical teeth
Ratio 3.21
b) Secondary drive by chain
Ratio 2.71 (3.09)** 2.53
c) Clutch multi-plate.in oil bath
Number of metallic plates 4
Number of friction plates 5
Control mechanical
d) Gearbox
Numberofgears 5
I 4.6gearratio
II 2.73
III 1.95
IV 1.59
V, 1.375
Neutralbetween IandII
3.2 Undercarriage
Type cradle-shaped double frame welded from steel sections (ring, square and rectangular)
Suspension
a) Front fork telescopic, with hydraulic stop
Stroke 170 mm
b) Rear fork swinging, with central springing unit
Stroke 150 mm
3

Wheel dimensions
Frontrim 1.6x17"
Rear rim 1.6x17"
Tyre dimensions
Front tyre MICHELIN 2.75"x17"
METZELER 2.75"x17"
SAVA 2.75 x17”
Rear tyre MICHELIN 3.0"x17"
METZELER 3.0"x17`
SAVA 2.75 x17"
BARUM * 90/90 x 17"
* (only combined with front wheel tyre, e.g. SAVA)
Tyre pressure
Front tyre
a) solo 180 kPa
b) with a pillion rider 230 kPa
Rear tyre
a) solo 230 kPa
b) with a pillion rider 280 kPa
Brakes
a) Front hydraulic disk brake, disk Ø 220 mm
b) Rear drum brake Ø 124 mm
Fuel tank
Capacity/Reserve 6.5 lt / 0.6 1t
3.3 Electric Equipment
Electric equipment voltage 12 V
Main headlight round, (rectangular)
Mainlamp 35/35W
Clearance light lamp (rectangular lamp) (5 W)
Pilotlamps 1.2W
Rear light
Taillightlamp 5W
Stoplightlamp 10W
Direction lights - Lamps 10 W
Horn electric
Fuse 8A
Battery 12V/4.5Ah
3.4 Working Liquids
Engine - Fuel mixture of BA 90-95 mixture of BA 90-95
petrol with oil petrol with oil
It is possible to use leadless petrol
a) Fuel for running in 1:30 (1:40)1
b) Fuel for operation 1:40 (1:50)1
for the type with separated lubrication
oil is poured into the oil tank
Oil Mogul TS
Castrol Super TT1
SHELL Super 2TX1
Gearbox
a) Oil class gear oil, viscosity SAE 8O
b) Oil volume in the gearbox 400 ccm
Front absorbers
a)Oil M3AD
CASTROL TQ Dexron
b) Volume 100 ccm
4

Rear absorber
a)Oil AMG10
b) Volume 100 ccm
Front disk brake
a) Brake fluid Synthol HD-205
Classification DOT 3
b)Volume 40ccm
3.5. Other Data
Dimensions
Length 1,950 mm
Width 700 mm
Height 1,070 mm
Seat height 800 nini
Wheel base 1,320 mm
Ground clearance 240 mm
Weights
Kerbweight 81kg
(with working liquids)
Useful weight 180 kg
Total weight 261 kg
Number of places to sit 2
Maximum speed 65km/h 85km/h
Dimensional Drawing
5

Figure 2 Motorcycle Description
1 - Rear foot rest
2 - Rear light
3 - Oil tank
4 - Rear direction light
5 - Fuel tank
6 - Clutch lever
7 - Rear-view mirrors
8 - Brake lever
9 - Front bonnet
10 - front direction light
11 - Engine
12 - Carburetter
13 - Rear brake lever
14 - Front foot rest
Type. ACS, ACP, SC
15 - Front headlight
16 - Clutch lever
17 - Fuel cock
Type. AKS. AKP. SK
6

4. Technical Description
The motorcycle is designed for operation on roads, but its design also enables to use it in a light terrain.
The 50 ccm engine is carried by the cradle-shaped double frame welded from steel sections (round, square and
rectangular cross sections), which design ensures high overall stiffness of the motorcycle and guarantees safe
drive.
Fixed in the steering head, in front part of the frame there is a telescopic fork that bears the front wheel
equipped with the hydraulic disk brake. Besides the front wheel, there are mudguard and tubular handlebars
with clutch and brake control levers, switch body and gas grip fastened to the fork. There are rear-view mirrors
attached to the handlebars. The headlight and direction lights are fastened onto the frame head in front part
(front part of bonnet - only for SK model). There is a horn fastened onto the frame brace under the steering
head. The 6.5 I fuel tank is fastened to the front part of the frame.
Two-stroke licenced engine SACHS, fastened in front lower part of the frame, is equipped with an oil pump for
separated lubrication of engine for some selected types of the motorcycle.
The engine is equipped with a carburetter according to the particular motorcycle type, which is connected
through the elastic coupling with the intake silencer with replaceable filter element. The motorcycles exhaust
piping with the exhaust silencer is led under the left rear side. Under the engine there are a foot rest holder, rear
brakes, parking stand, and bearing of the rear swinging fork that is mounted on the central springing unit. The
rear part of the frame that bears lockable double-seat, rear mudguard with rear light, and plastic sides with
direction indicators is bolted in the upper section of the front part of the frame. Under the double-seat there is a
room where battery and other mandantory equipment are located.
Transmission of torque is realized from the engine through the multi-plate clutch in oil bath and secondardy
roller chain to the rear wheel gear. The gearbox enables to shift five gears forward.
The electric installation is of 12 V, fed by the battery that is connected to the electrical network through the
regulator after start of the engine.
4.1. Identification Marking
Type Identification:
MJ 50 DANDY AKS
MJ 50 DANDY AKP
MJ 50 DANDY SKS
MJ 50 DANDY ARS
MJ 50 DANDY ARP
MJ 50 DANDY SRS
MJ 50 DANDY ACS
MJ 50 DANDY ACP
MJ 50 DANDY SCS
MJ 50 DANDY AWS
MJ 50 DANDY AWP
MJ 50 DANDY SWS
Frame Identification Number
 It is stamped on the right side of the steering head (Figure 3)
Motorcycle Identification Plate
 It is Iocated on the right side of the frame front part, at the rear swinging fork suspension (Figure 3a)
Identification Plate and Serial Number of the Engine
 Identification plate is fastened on the right side of the engine (Figure 4)
 Engine number is stamped on the right side of the engine (Figure 4)
7

5. Familiarization with motorcycle before Drive
Before first drive it is necessary to familiarize himself with the motorcycle thoroughly and to carry out check of
the whole motorcycle according to Section 6.
5.1 Electric Switch Control
Switch Box
 The switch box controls ignition and lighting
 Position 0 - Electric circuits are opened and it is possible to
withdraw the key.
 Position 1 - The electric circuits are closed, the clearance
lights are on, and it is possible to start the engine.
 Position 2 - The headlight and tail light are on.
Pilot Lamps
 The speedometer lighting - goes on after the start of the engine and indicates the clearance light
function.
 Direction indicator pilot lamp - This lamp is flashing, when the direction light change-over switch is in
the right or left extreme positions.
 Dimmed light pilot lamp - This lamp goes on after start of the engine and switching on the dimmed
lights. and indicates the dimmed light function.
 Distance light pilot lamp -This lamp is on at use of the distance light.
 The pilot lamp of separated lubrication of the engine - This lamp indicates minimum amount of oil
(0.5 lt) in the oil tank for separated lubrication of the engine.
 The light change-over switch - serves for switching
over the dimmed and distance lights. Its individual
positions are shown on Figure 7
 The direction light change-over switch - serves for
indication of turning on the right (extreme right
position) and on the left (exreme left position). Do
not forget to return it to the central position after the
turning is completed.
 The horn - An acoustic signal sounds after pressing
the horn's push-button.
8

5.2. Brake Control
Two independent brakes serve for safe stopping of the motorcycle. The machine is equipped with the disk
brake on the front wheel, and the drum brake on the rear one
1. Front Brake Control
 The front disk brake is operated by right hand. using the lever located on the right side of the
handlebars (See Figure 8).
1. Rear Brake Control
 The rear brake is operated by night foot through the lever under the foot rest on the night side of the
motorcycle (See Figure 9).
 If the engine is running, the rear stop light goes on automatically at pressing the front or rear brakes.
5.3. Clutch Control
The multi-plate oil bath clutch serves for setting the motorcycle into motion and near shifting.
 The clutch is operated by left hand, using the
clutch lever on the left side of the handlebars
(Figure 10). For smooth setting the motorcycle into
motion it is necessary to learn how to handle the
clutch carefully. The clutch must be pressed down
anytime you will shift the gear to eliminate the
damage to the gearbox.
5.4. Gear Shifting
 The motorcycle is equipped with 5-gear
gearbox and neutral between the first and
second gears. The gear shifting is carried
out by left foot, using the gear shift lever
on the left side of the engine. At gear
shifting it is always necessary first to
press down the clutch lever, and then to
shift the selected gear.
 The positions of particular gears are
shown on Figure 11.
 Shift always the neutral after stopping.
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