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.
9

5.5. Fuel Cock Control
 The fuel cock has 3 positions - open, closed, and reserve,
and at the same time it cleans the fuel.
OFF - The cock does not let fuel flow through it in this
position (Return always to this position after stopping the
engine).
ON - In this position fuel flows into the carburetter, the
position serves for normal operation.
RES - Use the reserve, when fuel ends during the drive; there
is still 0.6 1 of fuel in the reserve.
5.6. Choke Lever Control
5.6 Choke Lever Control
 The engine requires richer mixture for cold starts.
 The choke is operated by turning the lever located on the left
side of the handlebars (Figure 13).
 Return the lever into its initial position after heating the
engine.
5.7. Side Stand
5.7. Side Stand  The side stand is fastened on the left side of the
motorcycle frame and serves for the motorcycle
parking.
 The stand is drawn down to its lower position, and
the motorcycle is then put on it.
 When the stand is released, it returns back
spontaneously to its initial position.
WARNING!
The motorcycle must not be used for drive with its side
stand in lower position. Should the stand not be return to
its initial position before the drive, it could contact the
road with resulting loss of control over the motorcycle.
5.8. Tool Box
The tool box is accessible after unlocking and taking off the seat.
 To unlock the tool box, insert the key into the lock and turn it to the right. After withdrawal of the lock
it is possible to take off the seat.
 Following basic equipment of the motorcycle is placed in the tool box:
- wrench for sparking plugs, - handle - double-ended wrenches 13/16, 18/21, 8/10
- socket wrench 6 - screwdriver - air pump.
10

5.9. Machine Locking
It is possible to secure the motorcycle against unauthorized use by locking the lock located on the right side of
the steering head (Figure 15).
 Lock the machine by insertion of the key into the lock,
turning the key to the right, insertion of the lock inside,
turning the key to the left and its withdrawal.
 Unlock the machine similarly, but with withdrawal of the
lock, which unlocks the steering beam.
 Store attached copies of the key carefully.
5.10. Working Liquid Refilling
1. Fuel
For motorcycles without separated lubrication of the engine
(engines SACHS 50/5 AKF, AKF S, SACHS 50 S).
Open the fuel tank closure by its turning to the left, and refill the petrol and oil mixture (for better mixing first
pour in oil and then petrol)
Recommended petrol: with minimum octane number 90, including leadless petrols.
Recommended oil: MOGUL TS, CASTROL Super TT, SHELL Super 2TX
Mixing ration table: Oil Type Mixing ratio
for running-in for normal
up to -500 km operation
MOGUL TS 1:30 1:40
CASTROL Super TT
SHELL Super 2TX 1 40 1:50
 The capacity of the whole fuel tank: is 6.5 lt, out of which 0.6 lt is separated as a reserve.
 If you do not tank petrol directly on at a petrol station but prepare the petrol and oil mixture yourselves,
please observe the following procedure:-
• Store petrol and oil only in clean and closed vessels.
• Do not use long stored petrol, it could be contaminated by water or dirty.
• Use only absolutely clean funnels for pouring.
• Do not pour in petrol higher than 1 cm under the upper edge of the tank.
• If you overfill the petrol or pour it over the tank and engine at refuelling, dry carefully the affected
places before starting the engine.
11

For motorcycles with separated lubrication of the engine
(engines SACKS 50/5 AKF I, AKF SI).
 Open the fuel tank closure by its turning to the right and refuel
the tank with the petrol prescribed.
 Open the oil tank closure (for separated lubrication of the engine)
and refill the tank with the oil prescribed.
Oil tank capacity:- approx. 1.3 lt
Recommended oil:- Mogul TS,
CASTROL Super TT,
SHELL Super 2TX
 The capacity of the whole fuel tank is 6.5 lt, out of which 0.6 lt is separated as a reserve.
WARNING!
For the first drive with a new motorcycle fill the fuel tank with 1 litre of the prescribed petrol and oil
mixture in the ratio 1:30 (1:40), see Mixing Ratio Table. After use of this amount of petrol use only petrol
without oil (for the types with separated engine lubrication).
Following warnings apply to all types of motorcycles
WARNING!
It is forbiden to refill petrol on the engine running and in closed and poorly ventilated rooms!
WARNING!
The fuel tank closure ensures its venting and tightness at overtilting, therefore it is forbiden to make any
incompetent action on it!
2. Engine Oil Fill
 Stand the motorcycle on a horizontal surface and
unscrew the oil check plug (Figure 16). If oil does
not flow out, refill the oil tank (See Section 8.4).
 Unscrew the filling hole plug and fill the oil tank
with the prescribed oil (See Section 8.4) until the oil
flows spontaneously out of the check hole. Screw in
the both plugs and tighten them properly.
3. Front Hydraulic Brake Fill
 The brake fluid tank is located on the right side of the
handlebars. The fluid level is maintained within the lower
and upper edge of the check hole.
 Refilling and replacement of the fluid. (See Section 8.12)
12

6. Motorcycle Check Before Drive
6.1. Brake Check
1. Brake Lever and Brake Pedal
 Check correct functions of the front brake lever and rear brake pedal. If the functions are not
acceptable, make necessary adjustments (see Section 8.12, 8.13).
2. Brake Fluid
 Check the amount of the brake fluid in the tank on the right side of the handlebars. In case of need refill
it, and check visually tightness of the braking system.
(See Section 8.12.)
6.2. Clutch Check
 Check the clutch lever clearance and make sure that the lever works properly. If not, make necessarryc
adjustment. (See Section 8.1 1.)
6.3. Gas Grip Check
 Turn the grip a bit and make sure that it returns into its initial position after its release. Ask special
service immediately for the gnp adjustment, if need be.
6.4. Chain Check
 Before each drive check condition and tightening of the chain. In case of need adjust and grease it (see
Section 8.17.)
6.5. Tyre Check
 Check the pressure in the tyres. The tyre pressure must be adapted to the motorcycle load as follows:
- load up to 90 kg front tyre 180 kPa 26 psi
rear tyre 230 kPa 33 psi
- load above 90 kg front tyre 230 kPa 33 psi
rear tyre 280 kPa 41 psi
 Check condition of the tyres. If the depth of pattern on the tyre centre is less than 1 mm or if the tyre
side is cracked or otherwise damaged, replace the tyre, best of all in the special service.
Use only the tyres approved for this type of motorcycle. Other tyres change characteristics of the
machine control, and in that case manufacturer is not responsible for any damage due to use of these
tyres.
Front tyre: Reartyre:
MICHELIN 2.75" x 17" MICHELIN 3.00" x 17"
SAVA 2.5" x 17" SAVA 2.75" x 17"
METZELER 2.75" X 17" METZELER 3.00" x 17"
BARUM* 90/90 x 17"
(* only combined with the tyre SAVA on the front wheel)
6.6. Wheel Check
 Always check the wheels before drive, and in case of any failure contact the special service.
Do not try to make any repair on the wheel. If the wheel is cracked or deformed, it must be replaced by a
new one.
 The wheel should be balanced after each mounting of the tyre. Unbalanced wheel causes bad
controllability of the machine and shortens service life of tyres.
6.7. Electric Installation Check
 Check correct functions of headlight, rear and stop lights, direction indicators, and all pilot lamps.
13

7. Driving the Motorcycle
 The driver must own a licence for driving small motorcycles and meet all requirements according to
valid regulations and the highway code.
 When driving it is unconditionally necessary for the driver and pillion-rider to use protective crash
helmets.
 Before drive you are obliged to check readiness and technical condition of your motorcycle to make
sure that it meets relevant highway code (see Section 6.).
7.1. Motorcycle Starting
 Turn the fuel cock into the ON position.
 Lift up the side stand.
 Turn the key into the first position and engage the neutral (Figure 18).
Cold Start
 Open the choke fully and let the gas grip in the zero position. Start the engine by quick, smooth
stepping on the starting lever of the engine. The starting lever returns automatically by a return spring.
 After start of the engine and its heating to the working temperature return the choke into its original
position (Figure 19).
Hot Start
 You need not use the choke to start the hot engine.
WARNING!
Never start the engine or let it run in a closed room. Exhaust gases are poisonous and may cause loss of
consiousness or even death in a very short time.
Always lift up the side stand before any drive. If it is not fully up, it can cause serious accident at turning.
7.2. Motorcycle Setting into Motion
 Turn the switch box key into the second
position (the lights are on).
 Press the clutch lever, engage the first gear
(put your foot down on the gear lever until its
lower extreme position) Figure 20.
 Increase the engine speed by the gas grip
partly and simultaneously begin to release
slowly the clutch lever (see Section 5.3 )
 Approximately in the last third of the lever
travel the clutch is engaging, and after its full
release the motorcycle begins to move.
 When the motorcycle is moving, its speed is
controlled by the gas grip and by changing
other gears (see Section 5.4.).
14

Correct placing of loads on your motorcycle is important for its control, braking, and other manoevring,
and it can affect the safety of drive. Do not transport freely attached things that could move during drive
and change the balance suddenly.
Never overload the motorcycle; take care that the overall weight of the load, driver, and pillion-rider,
equipment (aerodynamic elements, seat bag, if approved for this type of motorcycle) does not exceed the
maximum permissible load of the motorcycle.
7.3. Motorcycle Stopping
 Release the gas grip, press down the clutch lever, and brake using one or both brakes according to the
relevant conditions until the motorcycle stops.
 Engage the neutral and release the clutch lever. If you also want to stop the engine, turn the key in the
switch box to the first position.
 Close the fuel cock - position OFF.
 When parking, always withdraw the key from the switch box and lock the motorcycle.
7.4. Engine Running-In
The engine running-in influences its output and life significantly. Therefore you are asked to study the
following data carefully.
 Use the fuel mixture prescribed by the manufacture for the engine running-in (see Section 5.10.).
0 to 500 km
 After each hour of drive stop the engine and let it cool down for approx. 10 minutes.
 Do not accelerate quickly, nor load the motorcycle engine with full output; use only 1/2 turn of the gas
grip.
 Do not maintain the drive speed constant long, change it to change the speed of engine.
500 to 1,000 km
 Do not drive long with more than 3/4 tum of the gas grip.
WARNING!
Do not forget to replace the gear oil after completion of 1,000 km!
over 1,000 km
 The motorcycle can be used with its full power after 1,000 km.
WARNING!
In case of any failure of the engine during its running-in contact the special service immediately!
8. Adjustment and Maintenance
To maintain the motorcycle in safe and proper technical condition, it is necessary to check, adjust, and lubricate
it regularly. The lubrication and maintenance table serves as a basic instruction for the regular maintenance.
The maintenance must also take into account the method of use, and therefore it is necessary to schedule the
regular maintenance intervals with regard to it.
On following pages you will find the most important data related to the regular check of the motorcycle.
If you have not special knowledge of motorcycles, you are recommended to have all the work made by a
special service.
15

8.1. Lubrication and Maintenance Schedule
Work Description and Scope
Before
Putting
into
Operation
After
every
1,000 km 3,000 km 6,000 km In Case o
f
Need
Screws and nuts
Tighten all screws and nuts (See Section 8.2.) x x
Driving chain
Check tightening of the chain. Clean and grease it by
the spray for chains. (See Section 8.17. & 8.18. ) x
Brake adjustment
Brake lining - Check the brake lining.
(take care of minimum thickness of the lining) x
When the brakes work incorrectly, check the
function of hand/foot brake and make required
adjustment. Grease joints and cables. x
Replace worn out, mechanically damaged or
oiled lining. x
Brake fluid
Check of the state of the break fluid and its
replacement, if need be. (See Section 8.12_, 8.13)
x
Every x 2 years
Rear wheel swinging fork
Check its bearing - without clearances x
Gear oil
Check the amount of oil and refill it, if need be x
Oil Replacement
400 ccm of gear oil (See Section 8.4., 8.5.) x
Sparking plug
Check of the electrodes spacing and overall condition
of the plug. Replace it, if need be. (See Section 8.9.) x x
Exhaust silencer and paper filter
Clean the intake paper filter. Replace it, when to
dirty. (See Section 8.7.) x x
Speedometer drive
Grease the speedometer drive (on the wheel axis)
SHELL RETLNAX-A x
Bowden cables
Lubncate the cables with thin oil x
Fuel screen in the carburetter
Clean the fuel screen by petrol and blow it through by
pressure air. In case of damage replace by a new one. x x
Fuel cock
Clean the fuel cock screen and blow it through by
pressure air. (See Section 8.6.) x
Carburetter
Clean individual parts of the carburetter
(See Section 8.6.) x x
Exhaust silencer decarbonization
Remove the oil carbon from the exhaust piping end.
(See Section 8.25.) x
Ignition check
Have the check made in a special service.
(See Section 3.10.) x
16

Work Description and Scope
Before
Putting
into
Operation
After
every
1,000 kni 3,000 km 6,000 km In Case o
f
Need
Clutch and its adjustment
Check its function and adjust or replace it, if need be.
(See Section 3.11.) x
Telescopic fork
Functional check or replacement, if need be.
(See Section. 8.21.) x
Steering bearings
Check and replacement, if need be.
(See Section 8.22.) x
Wheel bearings
They require no maintenance. If there is a clearance
in the bearings, replace them. Have them replaced
in a special service. (See Section 8.23.)
x
8.2. Torques
Use a torque wrench for tightening the screws and nuts. It is recommended to make occassionaly the check of
tightening, especially before a long drive. Check always torques at mounting or dismantling individual parts.
Torque Tables
Screw Torque
M 6 mm 8-12 N.m
M 8 mm 18-28 N.m
M 10 mm 40-60 N.m
M 12 mm 70-100 N.m
M 14 nun 110-160 N. m
M 16 mm 170-250 N.m
Engine drain plug 20-25 N.m Rear brake lever screw 6-10 N.m
Sparking plug 15-20 N.m Central springing unit
Front wheel axle nut 35-40 N.m screws 35-40 N.m
Front wheel axle socket screw 15-20 N.m Brake braket screws
Rear wheel axle nuts 50-60 N.m upper 20-25 N.m
Swinging fork axle nut 30-35 N.m lower 14-15 N.m
Lower beam screw 20-25 N.m Handlebars Yoke screws 15-20 N.m
Upper beam screws 15-20 N.m Brake hose screws 17-18 N.m
Engine bearing Cylinder head nuts 10-12 N.m
Socket screw M8x53 10-15 N.m Exhaust flange bolts 10-15 N.m
Socket screw - M8x100 25-30 N.m Screws for plastic 3.5 - 4 N.m
17

8.3. Table of Lubricants Used
Oil
(Viscosity Class) Grease
Gear box SAE 80 W
API GL-4 MOGUL TRANS 80 TRYSK GYROL 80W/90
MADIT PP 80
CASTROL EP 80
SHELL Spirax EP (MA)
Bowden cables MOGUL TS
Lever pins SAE 80 W
API GL-4 MOGUL TRANS 80 TRYSK GYROL 8OW/90
MADIT PP 80
CASTROL EP 80
SHELL Spirax EP (MA)
Speedometer drive
Gas grip MOGUL LA 2 SHELL Retinax A
AGIP GREASE 30
Front fork SAE I0W-30 M 3 ADX
CASTROL TQ Dexron
Rear springing unit AMG 10
CASTROL HYSIN AWS 10
Secondary chain CASTROL Super Ketten spray
TEXACO Ketten spray
Engine lubrication TSC-1 MOGUL TS
CASTROL Super TT
SHELL Super 2TX
8.4. Gear Oil Level Check
 Stand the motorcycle vertically so that it is not
deflected to one side.
Its deflection will cause incorrect measurement.
 Unscrew the oil check plug (1), and check if the oil
reaches minimally up to the lower edge of the
check hole.
 If the level is lower, refill the relevant oil.
8.5. Gear Oil Replacement
 Start the engine and let it heat up for 1 to 2 minutes.
 Place an oil vessel under the engine.
 Unscrew the filling plug (1), check plug (2), and
drain plug (3), and let the oil get out (Figure 22).
 Screw in the drain plug and tighten it. The torque is
20 N.m
 Refill 0.4 1t of recommended gear oil into the
filling hole.
 After refilling the gear box check, if oil does not
leak out of the drain plug or oil level check plug.
18

8.6. Fuel Cock Cleaning
The fuel cock has a built-in filter element that cleans fuel before the carburetter inlet. If it would have been
clogged, the fuel could not get into the engine in required amount.
Type: Bonneted design
 Disconnect the electric installation from the front direction lights, and dismantle the lights by releasing
and unscrewing the fastening nuts.
 Withdraw the split pin from the connecting shaft of the fuel cock and disconnect the connecting shaft.
 Dismantle the front bonnet by unscrewing of four screws. Unlock and take off the double seat and
dismantle rear „L" and „R" sides. Then unscrew the tank cap and unscrew 2 nuts that fasten the tank
cover to the frame, and after it remove the cover from the tank.
Type: Classic
 Disconnect the electric installation from the front direction lights, and dismantle the li hts by releasing
and unscrewing two nuts.
 Withdraw the split pin from the connecting shaft of the fuel cock and disconnect the connecting shaft.
 Unlock and take off the double seat and dismantle rear „L" and „R" sides. Then unscrew the tank cap
and unscrew 2 nuts that fasten the tank cover to the frame, and after it remove the cover from the tank.
Note: Following operations are identical for both types
 Discharge fuel from the tank.
 Dismantle the fuel cock out of the tank in the following way:-
Set the cock control to ON
Unscrew the screws M6 with the control pull rod bracket
Remove the fuel cock
 Clean the fuel cock by petrol in various positions of its setting
and blow it through by pressure air.
 Mount the fuel cock in reverse order.
Check the packing, and replace it, if need be.
8.7. Air Filter Cleaning
 Disconnect electric installation from the rear direction lights and dismantle the lights by unscrewing
two nuts with following removal of the lights. Take off the rear cover.
 Dismantle the right rear side by releasing the nuts which fasten it to the front bonnet, and then
disconnect the side from the bolt and withdraw it backwards.
 Dismantle the filter cover, remove the filter element and clean it by pressure air. If it is too dirty,
replace it by a new one.
 Install the filter element back in such a way that contact surfaces fit properly to ensure their tightness.
 Clean the air filter in the intervals recommended by the motorcycle's manufacturer. At operation in a
dusty environment shorten these intervals.
 Perform assembly in the reverse order.
WARNING!
Never operate the engine without the air filter
19