N-zeta 501/01 Instruction manual

orkshop

anual

This manual covers all Cezeta and N-Zeta models

- 1 -

INTRODUCTION.....................................................................................................- 4 -

CARBURETTOR CLEANING AND MAINTENANCE .............................................- 5 -

Jikov 2924 M 13 carburettor........................................................................................................................- 6 -

To Dismantle The Float Chamber:.........................................................................................................- 6 -

To Set The Carburettor According To The Manufacturers Specifications:.................................- 7 -

Jikov 2924 S 11 Carburettor for the 501/03 to /05 models;..................................................................- 9 -

Jikov 2924 S 13 Carburettor for the 502/00 to /01 model.....................................................................- 9 -

To Dismantle The Choke Device:...........................................................................................................- 9 -

To Set The Carburettor According To The Manufacturers Specifications:...............................- 10 -

Induction Silencer Maintenance and Cleaning.....................................................................................- 12 -

For the 501/01 –03 –05 models...........................................................................................................- 12 -

E N G I N E ...........................................................................................................- 13 -

Cylinder Head and Cylinder Barrel Removal. .......................................................................................- 13 -

Piston..............................................................................................................................................................- 14 -

Piston Grading According To Diameter D2 –Model 502....................................................................- 15 -

Piston Grading According To Diameter D2 –Model 501....................................................................- 15 -

Cylinder ..........................................................................................................................................................- 16 -

Assembly Table For Models 501/01, 03, 05...........................................................................................- 16 -

Assembly Table For Models 502/00, 01..................................................................................................- 16 -

Gudgeon Pin Bush For Models 501/01, 03, 05......................................................................................- 17 -

For Models 502/01, 00.................................................................................................................................- 17 -

Fitting The Piston.........................................................................................................................................- 17 -

Fitting The Cylinder Barrel And Cylinder Head....................................................................................- 18 -

Cooling Fan...................................................................................................................................................- 18 -

Setting The Ignition Advance....................................................................................................................- 21 -

Removal Of The Dynastarter.....................................................................................................................- 21 -

To Dismantle The Clutch Operating Bracket........................................................................................- 22 -

Removal Of The Gearbox Sprocket.........................................................................................................- 23 -

To Dismantle The Clutch And Primary Drive........................................................................................- 23 -

To Remove The Kick Starter Quadrant. .................................................................................................- 25 -

To Dismantle The Gear Change Shaft ....................................................................................................- 25 -

To Replace The Crankshaft and Gearbox Output Shaft Seals .........................................................- 26 -

To Remove The Engine From The Frame..............................................................................................- 26 -

- 2 -

To Dismantle The Gearbox And Crankshaft Mechanism...................................................................- 27 -

Dismantling The Crankshaft Assembly..................................................................................................- 28 -

Connecting Rod For The 501 Model –356-12-230 ...........................................................................- 31 -

502 Model –450-12-230 ..............................................................................................................................- 31 -

Assembling The Engine .............................................................................................................................- 32 -

C Y C L E P A R T ...............................................................................................- 36 -

Model 501 Removal Of The Rear Sprocket............................................................................................- 36 -

Model 502 - Removal Of The Rear Sprocket .........................................................................................- 36 -

Model 501 - Removing The Rear Drive Chain.......................................................................................- 36 -

Model 502 - Removing The Rear Drive Chain.......................................................................................- 37 -

Chain Maintenance......................................................................................................................................- 37 -

Front Fork Removal.....................................................................................................................................- 38 -

Model 501-Removal Of The Suspension Damper................................................................................- 39 -

Model 502 –Dismantling The Rear And Front Suspension Units ...................................................- 39 -

Chain Case Removal...................................................................................................................................- 39 -

To Dismantle The Pivoted Rear Arm.......................................................................................................- 40 -

Model 502 –Dismantling The Pivoted Rear Fork.................................................................................- 40 -

Dismantling The Headlamp .......................................................................................................................- 41 -

To Dismantle The Fuel Tank .....................................................................................................................- 41 -

Luggage Compartment Removal.............................................................................................................- 41 -

Removing The Bodywork And Its Accessories....................................................................................- 41 -

To Dismantle The Choke Device..............................................................................................................- 42 -

Dismantling The Fuel Tap Control...........................................................................................................- 42 -

To Dismantle The Gear Change Pedal....................................................................................................- 42 -

E L E C T R I C A L E Q U I P M E N T ...............................................................- 44 -

Dynamo...........................................................................................................................................................- 44 -

PAL Voltage Regulator 6 V .......................................................................................................................- 45 -

PAL Dynastarter ...........................................................................................................................................- 46 -

PAL 12V Regulator With Contactor.........................................................................................................- 46 -

Operation Of The Dynastart With The Regulator And Contactor ....................................................- 47 -

- 3 -

PAL 02-9421.04 Regulator With Contactor –Technical Data And Setting.....................................- 48 -

Regulator With Contactor - Mechanical Checking ..........................................................................- 49 -

Operation Checking.................................................................................................................................- 49 -

PAL 02-9490.60 Dynastart –Technical Data..........................................................................................- 50 -

Dynastart –Mechanical Checking .......................................................................................................- 50 -

Operation Checking.................................................................................................................................- 50 -

Lights..............................................................................................................................................................- 51 -

Electric Horn..................................................................................................................................................- 51 -

Leads...............................................................................................................................................................- 51 -

- 4 -

N Z E T A S c o o t e r R e p a i rM a n u a l

Introduction

This book represents the Repair Manual for owners of NZETA scooters made by the

world famous CZ Motorcycle Works in Strakonice Czechoslovakia then assembled

and finished by Jawa New Zealand. The reliability of this machine is well known to be

exceptional, its owner having nothing more to do than normal servicing according to

the Owner Handbook supplied with every machine. This Manual is intended for

Service Repair Shops and for those of the NZETA owners who prefer to carry out

repairs on their machines after many years of service. That is why the necessary

information for the repairs of the crankshaft and connecting rod mechanism and

electrical equipment is provided. Because the maintenance and repairs of the cycle

part are, due to the NZETA scooter monocoque bodywork, restricted to the minimum

and are well described in the Owner Handbook, only the most essential matters shall

be discussed here. It is necessary to warn NZETA scooter owners that, they should

consider their mechanical abilities carefully and to only undertake jobs which they are

able to complete successfully. It may be preferable a seek help in service

workshops. When describing individual repair jobs reference will be made to the

special tools supplied by the manufacturers, nevertheless the design of the NZETA

scooter makes it possible for most jobs to be done with normal tools or, where

necessary, a with universal pullers found in the equipment of every service repair

shop

- 5 -

Carburettor Cleaning and Maintenance

On most occasions, carburettor faults are due to impurities entering with the

petrol or air. The time for regular carburettor cleaning will depend on the manner in

which the machine is used. It is not recommended to carry out any carburettor

repairs apart from washing it in clean petrol and setting according to the maker’s

instructions. Any departure from the basic carburettor setting may be carried out with

a view to the condition of the scooter, its use in varying climatic conditions, or the fuel

used. In these cases, keep within narrow limits keeping a careful check of the fuel

consumption and performance after the differing setting has been carried out.

Other carburettor defects which may occur in operation should be remedied

by repairing or, replacing of its parts. This applies to the throttle valve which, in case

of excessive play in the mixing chamber, should be replaced with a new one or in the

case of seizure should be repaired using fine emery cloth or sharpening stone. One

should never omit, to wash the throttle valve in petrol after it has been repaired, to

remove the fine emery which might cause wear of the mixing chamber.

Another carburettor trouble is its constant flooding. This may be due to a leaky

float or lack of tightness of the float needle / dirt under the needle. To repair the float,

it has to be soldered after drying out or replaced. Lack of tightness of the float needle

in its seat in the float chamber top will be removed by grinding using lapping paste or

by replacing the parts. In case of damage to the throttle valve needle the needle has

to be replaced.

- 6 -

All these jobs are done without removing the carburettor from the crankcase,

the carburettor being accessible after opening the side door. The main jet is also

accessible through the side door. To clean it, fine horse hair should be employed

and not a piece of wire or any other hard object. Removal of the jet will be described

for each carburettor separately. To clean the carburettor, it is necessary to first

remove it from the crankcase through the side door.

Jikov 2924 M 13 carburettor Fig.1

This model has been employed in the 501/01 and 501/03 scooter models. It is a

monoblock type carburettor. The main jet #19 is located in the float chamber. It is

accessible after removal of the float chamber top #20

To Dismantle The Float Chamber, Proceed As Follows:

Close the fuel tap first and remove the fuel supply pipe. After unscrewing the

four screws #32, remove the float chamber top together with the gasket #21 and float

#31. To assemble, proceed in the reverse manner.

The throttle valve needle #7 is located in the middle of the throttle valve #4

and is accessible after its removal from the mixing chamber after unscrewing the

mixing chamber top #8. After compressing the spring #5, free the control cable from

the throttle valve notches #4 and thereby the spring resting against the needle circlip

#6 and throttle valve. The circlip #6 secures the correct position of the needle #7. To

assemble, proceed in the reverse manner.

- 7 -

The idling jet #17, the pilot, air screw #18 and the throttle valve stop screw

#15 are located on the R. H. side of the carburettor and are accessible through the

bodywork side door. When repairing the float, push out the float spindle #31a first

thus freeing the float #31. Repair the float or replace it and assemble proceeding in

reverse manner. The float spindle is secured against working free by two screws #32

which fasten the float chamber top #20. In case of loss of any of these four screws, it

is necessary that the float chamber top should be always fastened with two screws

on the sides of the spindle. Dismantling or assembling the float chamber top with

float it is always necessary to handle carefully these parts in order not to damage

the, float stop which would alter the fuel level.

To Set The Carburettor According To The Manufacturers Specifications,

Proceed As Follows:

First check the throttle valve needle position / how to assemble the throttle

valve has been described in the preceding paragraph / slacken the lock nut #10,

screw the cable guide #9 into the mixing chamber top #8 thus freeing the throttle

valve #4. After removing the float chamber top, unscrew the main jet #19 and check

its value.

The pilot air screw #18 serves to set the idling speed. Tighten the pilot air

screw first /clockwise/ and then slacken it /anticlockwise/ by the value prescribed for

setting. With the engine running, its idle speed is set by means of the throttle valve

stop screw #15. By unscrewing the cable guide, the throttle cable slack can be taken

up and the cable guide is then secured with the lock nut #10.

- 8 -

The carburettor is set in the Works for running in, and it has to be reset after the first

2000 km / 1200miles to the following values:

Main Jet 100 to 102 to Solex

Idling Jet 55 to Solex

Needle position 3rd notch from the top

Pilot air screw slacken by ¾ of a turn from tight /anticlockwise/

Fig. 1

- 9 -

Jikov 2924 S 11 Carburettor for the 501/03 to /05 models;

Jikov 2924 S 13 Carburettor for the 502/00 to /01 model Fig.2

These are monoblock type carburettors. They are also equipped with a choke device

for making the mixture rich to assist in starting the engine when cold. The main jet

#24 is located in the jet carrier #23 and is accessible after being unscrewed. The

throttle valve needle #4 is eccentrically located in the throttle valve #3 and is

accessible after the removal of the valve from the mixing chamber when the mixing

chamber top #7 has been first removed.

After compressing the spring #6, free the control cable from the throttle valve

#3 notch and thereby the spring resting against the needle circlip #5 and the throttle

valve. The circlip #5 secures the correct position of the needle #4. To assemble,

proceed in the reverse manner. The idling jet #26, the pilot air screw #27 and the

throttle stop screw #29 are located on the RH side of the carburettor and are

accessible through the bodywork side door.

To Dismantle The Choke Device, Proceed As Follows:

Having unscrewed the choke screw #16, remove the slide #13 suspended on

the cable. Unscrewing the cable screw #14 and the slide #13, will free the cable. To

assemble, proceed in the reverse manner.

This manual suits for next models

Table of contents

Popular Scooter manuals by other brands

Segway Robotics

Segway Robotics Loomo Product information guide

HL Corp

HL Corp ESX3 instruction manual

F-Wheel

F-Wheel DYU S1 instructions

Handicare

Handicare Fortress 2000 SERIES owner's manual

HYOSUNG

HYOSUNG SF 50 B manual

HOMCOM

HOMCOM 371-004 Assembly instruction

Kinroad

Kinroad XT125T-10 instruction manual

PLAYTIVE

PLAYTIVE AS-2448 Instructions for use

Ebinger

Ebinger DONKEY XL User instructions

Flyer

Flyer Mountain Original instruction manual

BackCountry eBikes

BackCountry eBikes Storm owner's manual

Pride

Pride Boxter owner's manual

equipmed

equipmed FreeRoam II user manual

WESTHILL BIKES

WESTHILL BIKES LINK user manual

BAnff

BAnff eProdigy series Assembly manual

Winther

Winther 475 Assembly instruction

Jetson

Jetson JBZL17 user manual

Carrera

Carrera impel manual

N-Zeta 501/01 Instruction manual

Popular Scooter manuals by other brands