HOME
GAZ 69
POLISH ARMY BIKES
THE POLISH SOLDIER
SHOWS AND EVENTS
LINKS AND CONTACT

 

Instruction manual of the K-750W motorcycle by the Polish Ministry of Defence of 1966 translated to English.

Fig. 1. Left view of the K-750W motorcycle.

  1. Engine
  2. Gearbox
  3. Final-drive gear
  4. Frame
  5. Front suspension
  7. Headlight with ignition switch
  8. Fuel tank
  9. Driver saddle
10. Passenger saddle
12. Side-car body
13. Metal case
14. Bracket for special equipment

Fig. 2. Right view of the K-750W motorcycle

  6. Handlebar
11. Side-car frame
Other numbers – see Fig. 1.

Fig. 3. Controls

  1. Main switch
  2. Warning light
  3. Ignition timing adjuster lever
  4. Clutch lever
  5. Horn button
  6. Light switch
  7. Foot gear change lever
  8. Kick-start lever
  9. Hand gear change lever
10. Foot brake lever
11. Throttle twistgrip
12. Hand brake lever
13. Steering damper
14. Speedometer

 
 
TECHNICAL SPECIFICATION

Dimensions and weights

Length – with side-car
Length – without side-car

2400 mm (94 ½ in)
2200 mm (86 ½ in)

Width – with side-car
Width – without side-car

1650 mm (65 in)
820 mm (32 in)

Height

1060 mm (41 ¾ in)

Wheel base

1450 mm (57 in)

Track (with side-car)

1110 mm (43 ¾ in)

Turning radius with side-car
- right, measured at the front wheel footprint
- left, measured at the side-car wheel footprint

 
2150 mm (84 ½ in)
3050 mm (120 in)

Total permitted load with side-car (including load and 3 passengers)

 
300 kg (661 Lb)

Curb weight (with side-car, including fuel, oils, tools and all standard equipment)

 
370 kg (816 Lb)

Top speed, consumption and range

Top speed with side-car, fully loaded on tarmac road

90 km/h
(56 mph)

Fuel consumption on the road (summer)

6 l / 100 km
(47 mpg)

Oil consumption

0,250 l / 100 km
(282 mpqt)

Range on tarmac road

300 km (186 miles)

Engine

Type

Four stroke,
petrol,
side valve

Model

K-750

Number of cylinders

2

Layout

Horizontal,
opposite

Capacity

746 cc

Bore

78 mm

Stroke

78 mm

Compression ratio

6,0 +0,1 -0,3

Power output at 4600 - 4900 rpm

26 h.p.

Torque at 2600 - 3200 rpm

30.38 lbf.ft.

Idle speed

600 – 750 rpm

 

 
 
 

Fuel system

Carburettors (type)

K-37A

Number of carburettors

2

Fuel filter

Mesh in the fuel filler and fuel tank decanter

Air filter

Combined – centrifugal and inertial-wet (oil) two stage

Fuel tank capacity

22 l (5 ¾ gal)

Fuel

Petrol LO 70 - 76

Engine lubrication

System

Combined – wet sump and pressure

Capacity

2 l (.88 qt)

Oil grade

 

   - summer

Engine oil
Lux-10 or S-17

   - winter

Engine oil
Lux-5 (Lux-7z)

Ignition

System

Battery 6V

Ignition coil (single type)

B-2B or B2-B2

   - with automatic centrifugal ignition timing PM-11 (dual)

B-201

Ignition distributor

PM-05

   - with automatic centrifugal ignition timing PM-11 and B-201 ignition coil

 
PM-11

Sparking plugs

A8U

Transmission

Clutch

Double plate, dry

Gearbox

Four speed, constant-mesh

Gear change

Double system with hand and foot lever

Gear ratio

 

   - first gear

3,6

   - second gear

2,28

   - third gear

1,7

 

 
 

   - fourth gear

1,3

Lubrication

 

   - summer

Engine oil
Lux-10 or S-17

   - winter

Engine oil
Lux-5 (Lux-7z)

Capacity

0,8 l (.7 qt)

Drive system between gearbox and differential

Propeller shaft

Final drive gear

 

   - type

Straight bevel

   - gear ratio

4,62

Lubrication

 

   - summer

Summer gear oil

   - winter

Winter gear oil

Capacity

.01 qt

Total gear ratio

 

   - first gear

16,65

   - second gear

10,56

   - third gear

7,85

   - fourth gear

6,0

Chassis

Frame

Double, tubular, welded

Rear suspension

Swing arm with coil springs and hydraulic double-action shock absorbers

Front fork

Two short swing arms with two hydraulic double-action shock absorbers

 

 
 

Oil for front, rear and side-car shock absorbers

Shock absorber fluid

Front fork fluid capacity

.19 qt

Rear and side-car shock absorber fluid capacity (single)

.06 qt

Wheels

Interchangeable with adjustable bearings

Tyres

 

   - size

3,75" - 19,0"

Side-car

Single seat with luggage compartment behind the back of the seat. mountings and brackets for special equipment and tool box.

Suspension

Swing arm with coil spring and hydraulic double-action shock absorber

Side-car body mount

Two rubber bushes

Electrical system

Battery

3-MT-14
(6V, 14 Ah)

Generator

G-11-A (6V, 45W)
or
G-414 (6V, 65W)

Regulator

RR-31-A
or RR-302
with G-414 generator

Horn

S-37-A

Head light

FG-6 or FG-116

Electrical system

Single wire

 

Fig. 4. K-750 engine and gearbox.

1. Engine
2. Gearbox
3. Air filter
4. Air pipe
5. Left carburettor
6. Generator
7. Ignition lead

 
 

1.   Engine head;
2.   Sparking plug;
3.   Cylinder;
4.   Camshaft chamber bolt;
5.   Camshaft chamber cover;
6.   Generator mounting;
7.   Push rod;
8.   Push rod guide;
9.   Push rod adjustment bolt and       nut;
10. Collets;
11. Valve spring collar;
12. Valve;
13. Valve spring;
14. Valve spring plate;
15. Valve spring thermo insulation       washer;
16. Cylinder head bolt;
17. Cylinder head gasket;
18. Piston;
19. Compression piston ring;
20. Oil control piston ring;
21. Gudgeon pin;
22. Small end;
23. Connecting rod;
24. Cylinder gasket;
25. Oil pipe;
26. Connecting rod bearing;
27. Breather pipe;

28. Crankshaft;
29. Washer;
30. Flywheel;
31. Generator bracket;
32. Flinger;
33. Camshaft;
34. Camshaft bearing;
35. Timing valve sprockets cover;
36. Generator;
37. Generator sprocket;

38. Generator spacer;
39. Camshaft sprocket;
40. Breather;
41. Front cover;
42. Camshaft seal;
43. Crankshaft sprocket;
44. Crankshaft front bearing cover;
45. Bearing cover;
46. Seal washer;
47. Oil sump;
48. Washer;
49. Crankshaft rear bearing cover;
50. Seal washer;
51. Seal;
52. Oil sump plug;
53. Oil pump cover;
54. Oil pump sprocket (gear);
55. Oil sump;
56. Oil pump filter;
57. Oil pump case;
58. Washer;
59. Connector sleeve;
60. Oil fill-up plug with dipstick;
61. Shaft,
62. Oil pump gear sleeve;
63. Oil pump gear sprocket;
64. Sprocket cover;
65. Camshaft chamber cover gasket;
66. Flywheel bolt;
67. Sump plug washer;
68. Oil fill-up plug washer;
69. Front crankshaft bearing;
70. Rear crankshaft bearing;
71. Oil pipe;
72. Gearbox bolt mount hole;
73. Ignition distributor;
74. Spring washer;
75. Flinger;

 


Fig
. 5. Engine (cross-section)
Part
A
 
Parts seen on this illustration are printed bold.

 
 

1.   Engine head;
2.   Sparking plug;
3.   Cylinder;
4.   Camshaft chamber bolt;
5.   Camshaft chamber cover;
6.   Generator mounting;
7.   Push rod;
8.   Push rod guide;
9.   Push rod adjustment bolt and nut;
10. Collets;
11. Valve spring collar;
12. Valve;
13. Valve spring;
14. Valve spring plate;
15. Valve spring thermo insulation       washer;
16. Cylinder head bolt;
17. Cylinder head gasket;
18. Piston;
19. Compression piston ring;
20. Oil control piston ring;
21. Gudgeon pin;
22. Small end;
23. Connecting rod;
24. Cylinder gasket;
25. Oil pipe;
26. Connecting rod bearing;
27. Breather pipe;
28. Crankshaft;
29. Washer;
30. Flywheel;
31. Generator bracket;
32. Flinger;
33. Camshaft;
34. Camshaft bearing;
35. Valve timing sprockets cover;
36. Generator;
37. Generator sprocket;

38. Generator spacer;
39. Camshaft sprocket;
40. Breather;
41. Front cover;
42. Camshaft seal;
43. Crankshaft sprocket;
44. Crankshaft front bearing cover;
45. Bearing cover;
46. Seal washer;
47. Oil sump;
48. Washer;
49. Crankshaft rear bearing cover;
50. Seal washer;
51. Seal;
52. Oil sump plug;
53. Oil pump cover;
54. Oil pump sprocket (gear);
55. Oil sump;
56. Oil pump filter;
57. Oil pump case;
58. Washer;
59. Connector sleeve;
60. Oil fill-up plug with dipstick;
61. Shaft,
62. Oil pump gear sleeve;
63. Oil pump gear sprocket;
64. Sprocket cover;

65. Camshaft chamber cover gasket;
66. Flywheel bolt;
67. Sump plug washer;
68. Oil fill-up plug washer;
69. Front crankshaft bearing;
70. Rear crankshaft bearing;
71. Oil pipe;
72. Gearbox bolt mount hole;
73. Ignition distributor;
74. Spring washer;
75. Flinger;

 


Fig
. 5. Engine (cross-section)
Part
B
 
Parts seen on this illustration are printed bold.

 
 

1.   Engine head;
2.   Sparking plug;
3.   Cylinder;
4.   Camshaft chamber bolt;
5.   Camshaft chamber cover;
6.   Generator mounting;
7.   Push rod;
8.   Push rod sleeve;
9.   Push rod adjustment bolt and nut;
10. Collets;
11. Valve spring collar;
12. Valve;
13. Valve spring;
14. Valve spring plate;
15. Valve spring thermo insulation       washer;
16. Cylinder head bolt;
17. Cylinder head gasket;
18. Piston;
19. Compression piston ring;
20. Oil control piston ring;
21. Gudgeon;
22. Small end;
23. Connecting rod;
24. Cylinder gasket;
25. Oil pipe;
26. Connecting rod bearing;
27. Breather pipe;
28. Crankshaft;
29. Washer;
30. Flywheel;
31. Generator bracket;
32. Flinger;
33. Camshaft;
34. Camshaft bearing;
35. Valve timing sprockets cover;
36. Generator;
37. Generator sprocket;

38. Generator spacer;
39. Camshaft sprocket;
40. Breather;
41. Front cover;
42. Camshaft seal;
43. Crankshaft sprocket;
44. Crankshaft front bearing cover;
45. Bearing cover;
46. Seal washer;
47. Oil sump;
48. Washer;
49. Crankshaft rear bearing cover;
50. Seal washer;
51. Seal;
52. Oil sump plug;

53. Oil pump cover;
54. Oil pump sprocket (gear);
55. Oil sump;
56. Oil pump filter;
57. Oil pump case;
58. Washer;
59. Connector sleeve;
60. Oil fill-up plug with dipstick;
61. Shaft,
62. Oil pump gear sleeve;
63. Oil pump gear sprocket;
64. Sprocket cover;
65. Camshaft chamber cover gasket;
66. Flywheel bolt;
67. Sump plug washer;

68. Oil fill-up plug washer;
69. Front crankshaft bearing;
70. Rear crankshaft bearing;
71. Oil pipe;

72. Gearbox bolt mount hole;
73. Ignition distributor;
74. Spring washer;
75. Flinger;

 


Fig
. 5. Engine (cross-section)
Part
C
 
Parts seen on this illustration are printed bold.

Fig. 6. Engine crankcase with covers and oil sump.

  1. Front cover;
  2. Camshaft seal;
  3. Valve timing gear cover;
  4. Seal washer;
  5. Crankshaft front bearing case       washer;
  6. Crankshaft front bearing;
  7. Bearing case;
  8. Oil froth reducer plates
  9. Cylinder seat;
10. Crankshaft rear bearing hole;
11. Valve timing gear chamber and       crankcase connecting hole;
12. Valve timing gear chamber drain
      hole (into crankcase);
13. Crankshaft rear bearing hole;
14. Camshaft rear bearing sleeve;
15. Camshaft bearing hole;
16. Valve timing gear chamber;
17. Generator bearing hole;
18. Crankcase;
19. Top engine mounting bracket;
20. Generator mounting;
21. Generator mounting bolt;
22. Valve timing gear cover gasket;
23. Valve timing gear cover;

24. Plug;
25. Oil pump sprocket sleeve;
26. Generator bracket;
27. Generator bracket bolt;
28. Oil pump sprocket hole;
29. Push rod sleeve hole;
30. Gearbox mount bolt;
31. Valve chamber;
32. Cylinder mounting bolt;
33. Dipstick washer;
34. Dipstick;
35. Crankshaft bearing;
36. Crankshaft rear bearing gasket;
37. Crankshaft rear bearing case;
38. Flywheel seal;
39. Oil passage hole;
40. Fill-up oil hole;
41. Bottom rear engine mounting;
42. Bottom front engine mounting;
43. Bottom front engine mounting stud;
44. Oil sump gasket;
45. Oil sump;
46. Sump plug washer;
47. Sump plug;
48. Oil sump bolt;
49. Oil pipe;



Fig. 7. Crankshaft

  1. Balance weight
  2. Web
  3. Connecting rod
  4. Valve timing sprocket
  5. Flinger
  6. Front main journal
  7. Bearing
  8. Connecting rod
  9. Small end bush
10. Big end
11. Crankpin
12. Flinger bolt
13. Flinger
14. Rear main journal

Fig. 8. Piston and piston rings
  1. Piston
      a. Crown
      b. Skirt
      c. Gudgeon pin holes
      d. Thermal slot
      e. Ring belt
      f. Ring belt
  2. Compression rings
  3. Oil control rings
  4. Gudgeon
  5. Gudgeon circlip

Fig. 9. Cylinders and cylinder heads

  1. Cylinder head
  2. Cylinder head gasket
  3. Cylinder
  4. Carburettor mounting bolt
  5. Carburettor gasket
  6. Washer
  7. Nut
  8. Cylinder mounting nut
  9. Cylinder mounting nut
10. Washer
11. Cylinder head bolt
12. Cylinder gaskets
13. Exhaust port
14. Inlet port
15. Valve chamber
16. Left cylinder oilway
17. Left cylinder lubrication hole
18. Combustion chamber (in the cylinder)
19. Combustion chamber (in the cylinder head)
20. Aligning notch
21. Sparking plug hole

Fig. 10. Cylinder head (Updated)

  1. Top cooling fins
  2. Base
  3. Main cooling fins
  4. Sparking plug hole

Fig. 11. Crankcase breather

  1. Camshaft sprocket
  2. Breather crosshead
  3. Breather
  4. Camshaft
  5. Seal
  6. Seal case
  7. Ventilation pipe
  8. Valve timing gear cover
  9. Vent channel
10. Breather hole
11. Breather collar holes
12. Crosshead hole in breather collar

Fig. 12. Breather timing

Fig. 13. Valve arrangement

  1. Breather crosshead;
  2. Sprocket;
  3. Bolt;
  4. Retaining washer;
  5. Bearing;
  6. Key;
  7. Camshaft;
  8. Push rod;
  9. Push rod gidr;
10. Nut;
11. Adjustment bolt;
12. Push rod guide washer;
13. Spring washer;
14. Nut;
15. Collett;
16. Spring collar;
17. Spring;
18. Spring top washer;
19. Spring thermo-insulation washer;
20. Valve;

Fig. 14. Valve timing

  1. Valve chamber cover
  2. Camshaft
  3. Camshaft sprocket
  4. Breather crosshead
  5. Breather
  6. Seal case
  7. Seal
  8. Camshaft mounting collar
  9. Push rod
10.Push rod guide
11. Lock-nut
12. Adjusting bolt
13. Valve collar
14. Colletts

15. Valve spring
16. Exhaust port
17. Valve washer
18. Exhaust valve
19. Spring thermo-insulation washer
20. Inlet valve
21. Inlet channel
22. Nut
23. Push rod guide plate
24. Bolt
25. Oil pump sprocket
26. Camshaft rear bearing
27. Oil pump sprocket
28. Valve chamber gasket


Fig. 15. Camshaft gear

1. Generator sprocket
2. Breather crosshead
3. Crankshaft sprocket
4. Camshaft sprocket
5. Timing marks
6. Cover
7. Breather pipe

Fig. 16. Valve arrangement

  1. Valve
  2. Valve spring
  3. Valve collar
  4. Collets
  5. Lock-nut
  6. Push rod guide
  7. Push rod
  8. Cover gasket
  9. Cover bolt
10. Cover
11. Adjusting bolt

Fig. 17. Valve timing (clockwise from top left: intake valve opens; exhaust valve closes; exhaust valve opens; intake valve closes; ZZ = TDC)

Fig. 18. Engine lubrication system

  1. Oil pump case;
  2. Oil pump sprocket;
  3. Oil pump sprocket;
  4. Oil pump filter;
  5. Oil sump;
  6. Oil froth reducer plates;
  7. Crankshaft journal;
  8. Flinger;
  9. Oil sump;
10. Oilway;
11. Connector;
12. Valve timing chamber hole;
13. Left cylinder oilway;
14. Oil control ring;
15. Small end bush;
16. Oil filler cap;
17. Left cylinder oilway;
18. Oil pump gasket;
19. Oil sump drain plug;
20. Oil pump sprocket;
21. Oil pump sprocket;
22. Connector sleeve;

23. Oil pump hole;
24. Crankshaft bearing oilway;
25. Crankshaft rear seal oil drain       channel;
26. Crankshaft seal;
27. Rear bearing case (cover);
28. Oil pump inlet hole;
29. Crankshaft lubrication oilways;
30. Rear crankshaft ball bearing;
31. Flywheel hub;
32. Oil pump sprocket oilway;
33. Oil pump case cover;
34. Drain plug washer;
35. Oil pipe;
36. Crankshaft front ball bearing;
37. Flinger oilway;
38. Flinger oilway;
39. Valve timing chamber draining hole;
40. Oil pipe;
41. Bearing case lubrication holes;
42. Channel;
43. Oilway;


Fig. 19. Lubrication system

  1. Flinger collar
  2. Oilway
  3. Calibrated hole
  4. Vertical channel
  5. Oil pump
  6. Crankshaft journal hole
  7. Crankshaft journal oilway
  8. Oil froth reducer plate
  9. Oil pipe
10. Draining hole
11. Flinger
12. Oilway blanking plug
13. Oilway
14. Left cylinder oilway
15. Oil pipe
16. Oilway
17. Camshaft seal
18. Ignition distributor case
19. Valve timing chamber draining hole
20. Camshaft rear bearing lubrication channel
21. Oil control ring
22. Flywheel seal
23. Oil filler cap and dipstick
24. Draining plug

Fig. 20. Fuel supply and exhaust system

  1. Carburettors cables
  2. Fuel pipe
  3. Carburettor
  4. Air intake pipe
  5. Exhaust pipe
  6. Exhaust silencer
  7. Silencer mesh
  8. Divider
  9. Rubber pad
10. Connecting pipe
11. Exhaust pipe
12. Air filter
13. Choke lever
14. Air intake pipe
15. Carburettor
16. Fuel pipes
17. Fuel valve
18. Filter
19. Fuel tank
20. Fuel filler cap
21. Throttle twistgrip case
22. Throttle twistgrip case cover
23. Crosshead
24. Throttle twistgrip
25. Exhaust pipes brackets
26. Exhaust silencers brackets

Fig. 21. Fuel tank

  1. Front mounting bolt
  2. Washer
  3. Fuel tank (right side)
  4. Filler hole
  5. Filter
  6. Tool compartment cover hinge pin
  7. Filler cap
  8. Seal
  9. Tool compartment cover lock
10. Lock retainer
11. Key
12. Tool compartment cover
13. Tool compartment cover hinge pin
14. Rubber pad
15. Pad mounting
16. Pipes
17. Pipe connecting both sides of the tank
18. Rubber bushes
19. Washer
20. Rear mounting bolt
21. Fuel pipe
22. Fuel tank (left side)
23. Valve washer (gasket)
24. Fuel pipe
25. Fuel valve
26. Fuel tank (bottom)

Fig. 22. Fuel tank valve

  1. Valve ceasing
  2. Lever
  3. Rod
  4. Washer (gasket)
  5. Decanter
  6. Filter
  7. Spring
  8. Filter mesh
  9. Decanter gasket
10. Valve gasket
11. Connector to the fuel tank
12. Fuel reserve pipe
13. Fuel pipe
14. Washer
15. Decanter nut

Fig. 23. Carburettor K-37A

  1. Lock-nut;
  2. Cable;
  3. Adjusting bolt;
  4. Slide throttle spring;
  5. Float button;
  6. Float button spring;
  7. Connector pipe;
  8. Slide throttle;
  9. Float chamber cover;
10. Needle valve;
11. Float;
12. Slide throttle needle;
13. Side air-duct;
14. Air-duct;
15. Air filter;
16. Atomizer sleeve;
17. Atomizer;
18. Filter;
19. Connector;
20. Main jet;
21. Main jet seal;

22. Podkładka króćca;
23. Idle jet;
24. Throttle screw;
25. Air screw;
26. Lock-nut;
27. Carburettor body;
28. Pin;
29. Gasket washer;
30. Cover nut;
31. Cover;
32. Throttle screw;
33. Idling passage;
34. Air filter;
35. Filter screw;
36. Air holes;
37. Gasket;
38. Service plug;
39. Jet hole;
40. Breathing hole;
41. Float rod;
42. Clip;


Fig. 24. Carburettor diagram
  a) at starting and idling
  b) at half open throttle
  c) at full open throttle
  8. Throttle
12. Needle
13. Air correction passage
14. Air passage
15. Air passage
17. Jet
20. Main jet
23. Idle jet
24. Slow-running adjusting screw
43. Chamber
44. Jet hole

Fig. 25. Air filter

  1. Mesh
  2. Spring
  3. Stop plate
  4. Ring
  5. Oil cover
  6. Air pipe
  7. Gasket
  8. Throat
  9. Filter elements
10. Mesh plate
11. Seal

12. Air throttle pipe
13. Air throttle
14. Shackle
15. Rubber pipe
16. Air pipe
17. Air throttle lever
18. Screw
19. Filter body
20. Cover catch
21. Cover


Fig. 26. Oil level in the air filter

Fig. 27. Exhaust
1. Right exhaust pipe
2. Left exhaust pipe
3. Clamps
4. Joining pipe
5. Clamps
6. Silencers

Fig. 28. Ignition system with manual timing advance adjustment diagram
  1. Sparking plug
  2. Rotor arm
  3. Contact breaker
  4. Ignition coil primary winding
  5. Ignition coil secondary winding
  6. Contact breaker moving plate
  7. Breaker cam (on the camshaft)
  8. Contact breaker fixed plate
  9. Condenser
10. Distributor
11. Battery
12. Headlight
13. Ignition key
14. Ignition switch contacts
15. Ignition coil

Fig. 29. Ignition coil
1. Primary winding terminals
2. Cover
3. Core
4. Secondary winding
5. Ceramic insulator
6. Insulators
7. Primary winding
8. Casing
9. Secondary winding terminal

Fig. 30. Distributor model PM-05

  1. Condenser
  2. Cable adjusting screw
  3. Breaker moving plate insulator
  4. Contact breaker moving contact
  5. Spring
  6. Casing
  7. Distributor spring
  8. Breaker moving plate securing screw
  9. Insulator
10. Breaker eccentric adjusting screw
11. Contact breaker fixed contact
12. Breaker fixed plate screw
13. Plate

14. Contacts
15. Adjusting screw
16. Pin
17. Terminal
18. Distributor plate
19. Distributor main contact
20. Distributor side contact
21. Distributor cap
22. Cap main contact
23. Cap side contact
24. Spring
25. Seal


Fig. 31. Sparking plug and high tension-lead
  1. Cap
  2. Clip
  3. Sparking plug body
  4. Resistor
  5. Spring
  6. Screw
  7. Rubber cap
  8. High-tension lead
  9. Insulator
10. Terminal cap
11. Sleeve
12. Rubber bush
13. Earth electrode
14. Centre electrode
15. Ceramic insulator
16. Terminal

Fig. 32. Ignition system with automatic timing advance adjuster and dual ignition coil diagram
  1. Sparking plugs
  2. High-tension leads
  3. Ignition coil
  4. Ignition coil secondary windings terminals
  5. Ignition coil primary winding terminals
  6. Ignition coil to ignition switch wire
  7. Ignition coil to contact breaker wire
  8. Ignition coil primary winding
  9. Ignition coil secondary winding
10. Contact breaker
11. Contact breaker moving contact
12. Contact breaker fixed contact
13. Condenser
14. Insulator
15. Battery

Fig. 33. Model PM-11A distributor with centrifugal advance mechanism
  1. Casing
  2. Breaker fixed contact
  3. Breaker moving contact spring
  4. Breaker moving contact
  5. Breaker moving plate axis
  6. Adjusting screw
  7. Flyweight spring
  8. Advance mechanism securing screw
  9. Flyweight
10. Condenser mounting spring
11. Cover
12. Condenser
13. Advance mechanism plate
14. Breaker cam
15. Terminal screw
16. Terminal insulator

Fig. 34. Dual ignition coil model B-201
  1. Secondary winding terminals
  2. Insulation
  3. Secondary winding terminal case
  4. Covers
  5. Two secondary windings
  6. Insulator (paper)
  7. Core
  8. Primary winding terminals
  9. Primary winding
10. Casing
11. Secondary winding insulator
12. Insulator (paper)

Fig. 35. Drive diagram
  1. Engine
  2. Clutch
  3. Gearbox
  4. Propeller shaft
  5. Final drive gear
  6. Drive wheel

Fig. 36. Clutch
  1. Flywheel
  2. Driving studs
  3. Clutch spring
  4. Pressure plate
  5. Clutch plate
  6. Clutch plate hub
  7. Clutch plate lining
  8. Pressure plate
  9. Clutch plate
10. Flinger
11. Plate
12. Screw
13. Shaft
14. Seal
15. Shaft connector
16. Release bearing
17. Crosshead
18. Seal
19. Clutch lever
20. Bracket
21. Lever axis
22. Adjusting bolt

Fig. 37. Gearbox

  1. Front bearing cover
  2. Washer
  3. Front casing
  4. Casing
  5. Bearing
  6. Flinger
  7. 4
th speed gear
  8. Main shaft
  9. Slide bearing
10. 3
rd and 4th gear dog clutch
11. Thrust washer
12. Slide bearing
13. 3
rd speed gear
14. 2
nd gear sprocket
15. Hub
16. 1
st and 2nd gear dog clutch
17. 1
st speed gear
18. Slide bearing
19. Flinger

20. Seal
21. Washer
22. Washer
23. Propeller shaft hub
24. Nut
25. Bearing
26. Flinger
27. 4th speed gear
28. Layshaft
29. Flinger
  a) Layshaft gear
  b) Layshaft gear
  c) Layshaft gear
30. Bearing
31. Rear bearing cover
 K) Seal cover
 S) Seal
 A) Oilway



Fig. 38. Gearbox (numbers – see fig. 37 and 39)
46. Adjusting bolt
47. Lock-nut
58. Drain plugs
61. Washer
62. Seal

Fig. 39. Gear selector and starter gear
             (numbers – see fig. 37 and 38)

32. 3rd and 4th gear fork
33. Crosshead
34. 1st and 2nd gear fork
35. Gear change slide and rod
36. Plunger
37. Foot gear change lever
38. Hand gear change lever
39. Catch (pawl) lever
40. Lever
41. Catch
42. Catch
43. Catch gear
44. Spring
45. Plunger
48. Starter gear shaft
49. Starter gear sprocket
50. Starter gear plunger
51. Axis

52. Plunger and spring
53. Starter gear lever
54. Return spring
55. Plunger release
56. Stop
57. Stop spring
59. Left cover
60. Right cover
63. Spring
64. Stop plug
65. Starter gear shaft sleeve
66. Starter gear front bearing
67. Starter gear sprocket sleeve
68. Nut
69. Bolt
  g) Return spring stop (in left cover)
  b) Return spring stop



Rys. 40. Gearbox

 

  1. Gasket;
  2. Front cover;
  3. Bearing;
  4. Seal;
  5. Seal cover;
  6. Lay shaft;
  7. Washer;
  8. Cover;
  9. Flinger;
10. Bearing;
11. Casing;
12. Right cover;
13. 4
th speed gear;
14. Dog clutch;
15. 3
rd and 4th gear fork;
16. Dog clutch;
17. 3
rd speed gear;
18. 2
nd speed gear;
19. 1
st and 2nd gear fork;
20. 1
st speed gear;
21. Rod spring;
22. Hand gear selector lever;

23. Flinger;
24. Bearing;
25. Speedometer gear sprocket;
26. Seal;
27. Washer;
28. Nut;
29. Main shaft;
30. Propeller shaft hub;
31. Crosshead ring;
32. Clutch crosshead;
33. Clutch lever;
34. Shaft connector;
35. Release bearing;
36. Clutch release rod;
37. Clutch lever bracket;
38. Lay shaft rear bearing cover;
39. Bearing;
40. Gear selector rod;
41. Starter gear sprocket;
42. Seal;
43. Starter gear spring;

 

Fig. 41. Gear change diagram
  1. First gear engaged
  2. Neutral
  3. Second gear engaged
  4. Third gear engaged
  5. Fourth gear engaged

Fig. 42. Gear change mechanism adjustment
  1. Foot gear change lever
  2. Hand gear change lever
  3. Adjusting bolt
  4. Lock-nut
  5. Lock-nut
  6. Adjusting bolt

Fig. 43. Propeller shaft and final drive gear

  1. Fill-up plug
  2. Drain plug
  3. Casing
  4. Crown wheel slide bearing (from       1962 – needle bearing)
  5. Crown wheel hub
  6. Seal cover
  7. Seal
  8. Needle bearing
  9. Adjusting washer
10. Nut
11. Seal
12. Pinion bearing pin
13. Trunnion block needle bearing
14. Joint
15. Nipple
16. Joint

17. Joint hub
18. Propeller shaft
19. Seal
20. Rubber cover
21. Yoke
22. Gasket
23. Pinion bearing
24. Pinion
25. Crown wheel bearing
26. Cover
27. Adjusting washer
28. Adjusting washer
29.Crown wheel
30. Washer
31. Seal
32. Bearing outer ring
33. Seal


Fig. 44. Frame and rear suspension
  1. Head tube
  2. Vertical traverse
  3. Bush
  4. Swing arm
  5. Shock absorber
  6. Suspension bracket
  7. Rear suspension pivot
  8. Rear suspension pivot
  9. Bush
10. Washer
11. Washer
12. Cover
13. Bolt
14. Battery mounting
15. Shock absorber bottom pivot
16. Shock absorber top pivot
17. Mudguard
18. Bracket
19. Mudguard (movable part)
20. Driver seat bracket
21. Driver seat pivot
22. Battery carrier
23. Fuel tank bracket
24. Fuel tank mounting
25. Engine bracket
26. Engine mounting
27. Side-car bracket
28. Engine mounting bolts
29. Side-car pivot bracket
30. Side-car rear mounting
31. Rear footrest
32. Front footrest
33. Brake lever bracket
34. Stand bracket
35. Stand

Fig. 45. Frame
  1. Head tube
  2. Vertical traverse
  3. Bush
  4. Swing arm
  5. Shock absorber
  6. Suspension bracket
  7. Rear suspension pivot
  8. Rear suspension pivot
  9. Bush
10. Washer
11. Washer
12. Cover
13. Bolt
14. Battery mounting
15. Shock absorber bottom pivot
16. Shock absorber top pivot
17. Mudguard
18. Bracket
19. Mudguard (movable part)
20. Driver seat bracket
21. Driver seat pivot
22. Battery carrier
23. Fuel tank bracket
24. Fuel tank mounting
25. Engine bracket
26. Engine mounting
27. Side-car bracket
28. Engine mounting bolts
29. Side-car pivot bracket
30. Side-car rear mounting
31. Rear footrest
32. Front footrest
33. Brake lever bracket
34. Stand bracket
35. Stand

Fig. 46. Shock absorber
  1. Bush
  2. Rod
  3. Cover
  4. Ring
  5. Coil spring
  6. Bump stop
  7. Seal
  8. Nut
  9. Washer
10. Seal
11. Bearing
12. Outer cover
13. Inner cover
14. Casing
15. Ring
16. Valve
17. Piston
18. Nut
19. Cylinder
20. Bump valve
21. Valve
22. Base valve
23. Valve
24. Seal

Fig. 47. Leading link type front suspension
  1. Yoke
  2. Traverse
  3. Stanchion
  4. Arm
  5. Slider
  6. Leading link
  7. Hydraulic shock absorber
  8. Wheel spindle
  9. Mudguard

Fig. 48. Steering damper
31. Cap
32. Traverse
33. Yoke
34. Stanchion
35. Head lamp bracket
36. Handwheel
37. Bush
38. Steering damper spring
39. Steering damper friction washer
40. Top washer
41. Lever
42. Bearing
43. Nut
44. Nut

Fig. 49b. Front fork shock absorber
  1. Spring seat
  2. Leading tube
  3. Coil spring
  4. Wheel spindle bolt
  5. Cap
  6. Gasket
  7. Lever
  8. Rubber stop
  9. Piston (left)
10. Retaining screw
11. Piston (right)
12. Casing
13. Two-stage valve
14. Return spring
15. Cap
     Shock absorber valve
26. Valve
27. Valve
28. Spring
29. Spring
30. Casing

Fig. 49a. Front fork shock absorber
16. Plug
17. Rod
18. Needle bearing
19. Washer
20. Washer
21. Needle bearing
22. Seal
23. Arm
24. Stop bumps
25. Lever

Rys. 50. Front fork (telescopic)

  1. Clamp nut;
  2. Washer;
  3. Yoke;
  4. Seal;
  5. Lock-nut;
  6. Spring top seat;
  7. Nut;
  8. Spring;
  9. Bottom yoke,
10. Guide sleeve;
11. Osłona rury widełek-,
12. Mudguard bracket;
13. Seal nut;
14. Seal ring;
15. Seal ring washer;
16. Seal ring collar;
17. Seal ring spring;
18. Seal casing;
19. Zewnętrzna tuleja rury widełek-,
20. Wewnętrzna tuleja rury widełek-,
21. Stop sleeve;
22. Stop collar;
23. Shock absorber sleeve;
24. Nasadka rury widełek-,
25. Stożek obudowy;
26. Podkładka;
27. Śruba mocująca stożek-,
28. Obsada nasadki rury widełek-,
29. Nakrętka śruby ściągającej;

30. Śruba ściągająca lewej nasadki;
31. Kołek ustalający;
32. Przeciwnakrętka;
33. Bottom guide sleeve;
34. Piston;
35. Kołek
36. Screw;
37. Washer;
38. Nakrętka rury amortyzatora;
39. Rod;
40. Nut;
41. Bolt;
42. Steering damper handwheel;
43. Nut;
44. Lock washer;
45. Bearing nut;
46. Bearing protectve nut;
47. Seal;
48. Bearing;
49. Head lamp bracket;
50. Bottom seal;
51. Seal shackle;
52. Top washer;
53. Friction washer;
54. Washer with lug;
55. Bottom washer;
56. Spring;
57. Nut;
58. Pin;


Fig. 51. Wheel
  1. Rim
  2. Spoke nut
  3. Spoke
  4. Hub
  5. Grease nipple
  6. Round nut
  7. Hub nut
  8.
  9.
10. Bearing
11.
12. Washer

Fig. 52 Tyre
  1. Rim
  2. Tyre tube valve
  3. Valve collar
  4. Nut
  5. Valve spring
  6. Needle
  7. Valve
  8. Seal
  9. Dust cap
10. Bead wires
11. Casing
12. Cap
13. Tread
14. Tyre tube
15. Tube protector

Fig. 53. Front brake
  1.
  2.
  3. Bushing
  4. Lever
  5. Push rod
  6. Adjusting cone
  7. Spring
  8. Brake shoe
  9. Back plate
10. Bolt
11. Cam
12. Bush
13.
14. Equalizer

Fig. 54. Driver seat
  1. Rubber cover
  2. Bow
  3. Hoop
  4. Frame
  5. Rubber bush
  6. Support
  7. Bolt
  8. Bolt
  9. Bush

Fig. 55. Passenger saddle
  1. Rubber cover
  2. Bow
  3. Hoop
  4. Frame
  5. Rubber bush
  6. Support
  7. Bolt
  8. Bolt
  9. Bush
10. Bracket
11. Bolt
12. Elastic handle

Fig. 56. Sidecar frame
  1. Front tube
  2. Suspension arm
  3. Suspension arm hub
  4.
  5.
  6.
  7.
  8.
  9.
10.
11.
12.
13.
14.
15.

Fig. 57. Sidecar body front mounting
  1. Sidecar floor
  2. Frame front tube
  3.
  4. Rubber bush
  5. Bolt and nut

Fig. 58.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.

Fig. 59. Sidecar
  1. Armament rear bracket
  2. Spare wheel bracket
  3. Canvas hook
  4. Armament and gear bracket
  5. Armament and gear bracket
  6. Removable metal case
  7. Canvas hook
  8. Case lock
  9. Case lock
10. Armament front bracket
11. Floor mat
12. Axe bracket
13. Axe bracket
14. Shovel bracket
15. Shovel bracket
16. Luggage compartment lock

Fig. 60. Luggage compartment lock
  1. Casing
  2. Latch
  3. Lock
  4. Spring
  5. Plug

Fig. 61. Connection between the sidecar and motorcycle
  1. Adjustable front rod
  2. Adjustable middle rod
  3. Adjustable rear clamp
  4. Front mounting

Fig. 62. Sidecar mounting clamp
1.
2.
3.
4.
5.

Fig. 63. Alignment diagram

Fig. 64. Front brake adjustment
  1. Bolt
  2. Lock-nut

Fig. 65. Rear brake adjustment
  1. Footrest
  2. Lever
  3. Pin
  4. Washer
  5. Split pin

Rys. 66. Handlebar and controls
  1. Clutch cable bracket
  2. Clutch lever bracket
  3. Bracket wedge
  4. Bracket bolt
  5. Clutch lever
  6. Left grip
  7. Ignition adjusting lever
  8. Ignition adjusting cable
  9. Handlebar
10. Handlebar bracket
11. Handlebar bolt
12. Throttle cable
13. Cover
14. Casing
15. Lubricating nipple
16. Screw
17. Front brake cable
18. Twistgrip
19. Front brake lever
20. Lever axis
21. Lever bracket
22. Bracket wedge
23. Bracket bolt
24. Clutch cable
25. Light cable
26. Horn lead

Fig. 67. Manual ignition adjusting unit
  1. Lever
  2. Bolt
  3. Bush
  4. Spring washer
  5. Casing
  6. Light switch
  7. Light switch lever
  8. Horn switch cover
  9. Horn button
10. Spring
11. Contact
12. Contact base

Fig. 68. Speedometer SP-102
  1. Dial
  2. Needle
  3. Odometer
  4. Cable connector
  5. Bolt
  6. Casing
  7. Glass
  8. Trim
  9. Seal
10. Seal

Fig. 69. Wiring diagram

  1. Headlamp bulb
  2. Key
  3. Fuse
  4. Headlamp
  5. Main switch
  6. Earth lead
  7. High tension lead
  8. Sparking plugs
  9. High tension lead
10. Ignition coil
11. Sidecar front sidelamp
12. Horn
13. Sidecar front sidelamp wire
14. Sidecar tail lamp
15. Motorcycle tail lamp
16. Stop light switch
17. Regulator
18. Dynamo
19. Battery
20. Wire
21. Battery earth lead
22. Contact breaker
23. Distributor
24. High tension lead
25. High tension lead
26. Horn switch
27. Horn wire
28. Manual ignition advance mechanism lever
29. Light switch cable
30. Light switch
31. Warning lamp
32. Sidelight bulb
33. Spedometer light bulb
34. Connector
35. Sidecar tail lamp wire
36. Stop light wire
37. Number plate lamp wire

Fig. 70. Wiring diagram of the version equipped with the automatic ignition advance mechanism PM-16 and 65W dynamo

  1. Headlight bulb
  2. Key
  3. Fuse
  4. Headlight
  5. Main switch
  6. Earth wire
  7. High tension lead
  8. Sparking plugs
  9. Dual ignition coil
10. Contact breaker
11. Sidecar front sidelight
12. Horn
13. Sidecar front sidelight wire
14. Connector
15. Motorcycle tail lamp wire
16. Sidecar tail lamp
17. Sidecar tail lamp wire
18. Motorcycle tail lamp
19. Stop lamp wire
20. Stop lamp switch
21. Regulator
22. Dynamo
23. Battery
24. Wire
25. Battery ground lead
26. Horn switch
27. Horn wire
28. Light switch
29. Warning lamp
30. Front sidelight bulb
31. Speedometer light bulb

Fig. 71. Battery Z-MT-14

  1.
  2. Negative terminal
  3. Plug
  4. Connecting rod
  5. Sediment trap
  6. Negative plates
  7. Wooden separators
  8. Fibre glass separator

  9. Positive plates
10. Container
11. Negative plates
12. Barrier
13. Cover
14. Connecting strips
15. Positive terminal
16. Cover


Fig. 72. Dynamo G-11-A

  1. Sprocket
  2. Seals
  3. Armature winding
  4. Drive end bracket
  5. Casing
  6. Wooden insulator
  7. Armature
  8. Field magnet
  9. Winding
10. Brush

11. Brush spring
12. Terminals
13. Bearing
14. Bearing cover
15. Bolt
16. Armature shaft
17. Brush plate
18. Commutator
19. Commutator end bracket
20. Cover


Fig. 73. Regulator

  1. Terminals
  2. Cut-out core
  3.Cut-out
  4. Contact
  5. Frame
  6. Ground terminal
  7. Casing
  8. Washer
  9. Plate
10. Contact plate
11. Contact plate

12. Regulator core
13. Voltage regulator
14. Cover
15. Shunt winding
16. Frame
17. Spring
18. Adjusting nut
19. Resistor
20. Resistor
21. Spring
22. Rubber cover


Fig. 74. Principle of regulator (part c)
  c) Dynamo generating voltage 6.5 – 7 V
  1. Cut-out
  2. Shunt winding
  3. Series winding
  4. Resistor
  5. Resistor
  6. Voltage regulator
  7. Series winding
  8. Shunt winding
  9. Series winding
10. Warning lamp
11. Battery
12. Ignition switch
13. Generator armature
14. Generator
15. Field winding

Fig. 74 (parts a and b)
  a) Dynamo generating voltage below 6.5 V
  b) Dynamo generating voltage between 6.2 – 6.8 V

Fig. 75. Regulator RR-302
  1. Cover
  2. Cut-out core
  3. Cut-out frame
  4. Voltage regulator core
  5. Voltage regulator frame
  6. Terminal 'SZ'
  7. Terminal 'JA'
  8. Terminal 'B'
  9. Terminal '-'

Fig. 76. RR-302 regulator diagram
  1. Ground terminal
  2. Armature
  3. Winding
  4. Generator field magnet
  5. Generator armature
  6. Cut-out winding
  7. Winding
  8. Contact

Fig. 77. Headlamp FG-116
  1. Main switch
  2. Speedometer
  3. Casing
  4. Headlight fuse
  5. Speedometer cable
  6. Loom
  7. Loom
  8. Sidelight fuse
  9. Sidelight
10. Headlamp lens
11. Headlight bulb
12. Reflector
13. Outer rim

Fig. 78. Headlamp adjusting diagram

Fig. 79. Horn

  1. Screw
  2. Spring washer
  3. Cover
  4. Casing
  5. Spring
  6. Spring
  7. Buzzer frame
  8. Plate with contact
  9. Electromagnet core
10. Electromagnet winding
11. Electromagnet bracket
12. Wiring

13. Membrane washers
14. Core
15. Adjustment washers
16. Membrane
17. Nut
18. Washer
19. Spring washer
20. Resonator
21. Bracket
22. Terminal screw
23. Terminal


Fig. 80. Tail lamp FP-66
  1. Housing
  2. Stop lamp lens
  3. Sidelight lens
  4. Number plate lens

Fig. 81. Stop lamp switch
  1. Rod
  2. Housing
  3. Collar
  4. Spring
  5. Connectors

Fig. 82. Stop lamp switch
  1. Rod
  2. Lock-nut
  3. Rubber cover
  4. Cam

Fig. 83. Sidecar front lamp PF-200
  1. Screws
  2. Seal
  3. Bulb
  4. Connector

Fig. 84. Headlamp dip switch
  1. B & D – connectors
  2. Contact
  3. Slider
  4. Base
  5. Lock-nut
  6. Leading sleeve
  7. Spring
  8. Contacts
  9. Cable
10. Returning spring
11. Housing
  a) Main beam on
  b) Dip beam on

Fig. 85. Ignition switch
  1. Base
  2. Cover
  3. Ignition key
  4. Contact
  5. Terminal

Fig. 86. Head lamp electric diagram
B – Battery and regulator
LC – Speedometer lamp bulb
F – Head lamp
JA – Generator amarment
9 – Switch
SS – Sidelight
ZC – Ignition and horn

Tyre pressure (atm.)

Load

Front wheel

Rear wheel

Sidecar wheel

Rider and one passenger

1,4

2,0

1,6

Rider and two passengers

1,6

2.0

1,8

Rider, two passengers and full load

1,8

2,5

2,0


Fig. 87. Lubrication diagram

  1. Steering greasing nipples
  2. Speedometer cable
  3. Ignition breaker (contact breaker axis and felt)
  4. Generator rear bearing
  5. Engine oil filler
  6. Gearbox oil filler;
  7. Foot gear change lever axis
  8. Final drive gear oil filler
  9. Rear and front brake expander cam axis
10. Sidecar mounting clamps
11. Propeller shaft nipple
12. Rear brake lever axis
13. Clutch lever axis
14. Front fork oil filler
15. Wheel hubs nipple
16. Throttle twistgrip
17. Hydraulic rear and side shock absorbers

 
Service schedule

 

 
Before riding and during stops and breaks (time: 15-20 min):

Check the levels of the fuel and oil and any fuel or oil leaks.
Check condition of the brakes and control mechanisms.
Check tyre pressure.
Check headlight, brake light, side lights and horn.
Check condition and mounting of special equipment, tools and spare parts in the 'ZIP'.
Check by touch temperature of hubs, brake drums, gearbox and final drive casing.

 
Every day service, after riding (time 1-2 hours)

Top up fuel and oil.
Remove any mud and wash the motorcycle. Do not wash before the engine cools down. Cover the air filter to prevent any water ingress. Avoid any electrical equipment and wiring.
Check mountings of the front fork.
Test shock absorbers, springs and front fork.
Check tightness and condition of the wheels and spokes, condition of the tyres and adjust tyre pressure.
Check for any free play in wheel axles.
Check mountings of the mudguards, spare parts and number plate.
Check tightness of engine mountings, engine heads, cylinders, exhaust pipes and silencers.
Check for any fuel or oil leaks.
Check tightness of mountings of the gearbox final drive gear and propeller shaft.
Adjust the clutch lever (5-8 mm of free play).
Check condition of control cables.
Check condition and mountings of the battery, dynamo, horn, headlight, sidelights, brake light, wires, ignition coil and sparking plugs.
Check condition and mountings of the motorcycle frame and rear suspension.
Check the mountings of both saddles and footrests.
Check all the sidecar mountings, frame and suspension.
Perform short test drive to check engine and brakes.
Clean the air filter and replace the oil (in the summer – every 500 km, in dusty conditions – every 150-200 km, in the winter – every 1000 km)
Grease the swivel of the gear change foot lever.
Clean the tools and put them back in place.

 
Service no. 1 every 400-500 km (time 3-4 hours)

This service include all the actions of the every day service plus:
Dismantle both carburettors and fuel valve sediment bulb and clean them in clean petrol. Small holes and passages should be blown through with compressed air.
Start the engine and adjust the carburettors on idle and mid revs. Equalize the adjustment of both carburettors.
Check and adjust if necessary valves gap.
Check and adjust gear change mechanism.
Check and adjust the brakes.
Adjust wheel spokes (without removing the wheels).
Clean the battery and terminals and grease. Check the electrolyte level and top up with distilled water if necessary. Check for leaks.
Once a month recharge the battery.
Every three months discharge and charge the battery (reconditioning).
Every 1000 km change the engine oil.
Check and top-up gearbox oil.
Grease wheel hubs and steering bearings.

 
Service no. 2 every 2000-2500 km (time 5-6 hours)

This service include all the actions of the service no. 1 plus:
Remove wheels, dismantle hubs and bearings and remove all the old grease. Wash and blow with compressed air. Check and adjust the bearings and pack with new    grease. Exchange the wheels clockwise, including spare.
Dismantle the brakes, clean the shoes and drums, replace shoe linings if necessary, grease all the moving parts. Pay attention to prevent any grease going to contact with    friction surfaces!
Check and adjust alignment of the motorcycle and the sidecar.
Check saddle mountings for tightness.
Check sidecar body mountings.
Check conditions and completeness of special equipment, spare parts, tools and auxiliaries.
Check and top-up oil in the final drive gear,
Change oil in front fork shock absorbers.
Grease the twistgrip (in the winter also dismantle and clean).
Grease the brake and clutch levers axis.
Grease the axis of brake pedal and the linkage.
Oil contact breaker axis.
Grease propeller shaft joint.
Grease rear mudguard and 'ZIP' box hinges and luggage compartment lock.
Oil speedometer cable.

Additionally every 4000 km:

Check and clean dynamo commutator, brushes and their springs.
Clean sparking plugs electrodes and adjust the gap.
Check contact breaker contacts, clean if necessary and adjust the gap.
Replace grease in the dynamo rear bearing.
Check and clean horn terminals.
Check condition of high tension leads.
Dismantle, clean and grease sidecar attachments swivel clamps.
Change oil in the gearbox.
Change oil in the final drive gear.

Additionally every 8000 km:

Dismantle steering damper, clean and re-grease bearings.
Remove rear and sidecar shock absorbers, dismantle, clean, replace rubber seals if necessary and fill-up with new oil.
Remove engine heads and cylinders, grind the valves, clean carbon deposit of the heads, pistons and piston rings. In case of excessive oil consumption replace the    piston rings.


 
 
TOOLS, SPARE PARTS AND EQUIPMENT
   'ZIP' kit has to be carried at all times. It consists of driver tools, a set of spare parts and auxiliaries.
   Driver tools set consist 28 parts (fig. 88). Additionally there are two ignition keys, luggage compartment lock and tool box key.
   Spare parts set consists of:
   1. Sparking plugs – 2
   2. Right carburettor fuel pipes – 2
   3. Spokes – 10
   4. Head gaskets – 2
   5. Spacer sleeves – 3
   6. Shock absorber seal rings – 3
   7. Shock absorber seals – 3
   8. Complete clutch cable – 1
   9. Left carburettor fuel pipe – 1
 10. Compression piston rings – 4
 11. Spoke nuts – 5
 12. Stop light switch – 1
   Spare parts, driver tools and auxiliaries are kept in two canvas bags. In a small canvas bag located in the compartment on top of the fuel tank should be kept: spanners, adjustable spanner, screwdrivers, handles, pliers, ignition key and filler gauge. In a large bag located in the metal removable box should be kept spare parts, all other tools, basic driver's repair kit, dynamo repair kit, tyre pressure gauge, hammer, funnel, small file for cleaning contacts, grease gun and tyre mounting levers.
   Auxiliaries and tyre pump are carried in special brackets in the luggage compartment. Tyre pump rubber pipe should also be located in the large canvas bag.

Rys. 88. Tool kit

  1. Driver's basic repair kit
  2. Hammer
  3. Tyre pump
  4. Dynamo basic repair kit
  5. Tyre pressure gauge
  6. Filler gauge
  7. Funnel
  8. Pliers
  9. Adjustable spanner
10. Small screwdriver
11. Tubular spanner 14 mm
12. Tubular spanner 8 mm
13. Needle file
14. Combination spanner 36 x 41 mm
15. Hook spanner
16. Tubular spanner 10 x 14 mm
17. Tubular spanner 11 x 12 mm;
18. Tubular spanner 19 x 22 mm;
19. Tubular spanner handle
20. Open-ended spanner 9 x 11 mm;
21. Screwdriver
22. Grease gun
23. Tyre mounting levers
24. Open-ended spanner 8 x 10 mm;
25. Open-ended spanner 12 x 14 mm;
26. Open-ended spanner 14 x 17 mm;
27. Open-ended spanner 19 x 22 mm;
28. Special spanner

 

HOME
GAZ 69
POLISH ARMY BIKES
THE POLISH SOLDIER
SHOWS AND EVENTS
LINKS AND CONTACT

 

Copyright © 2012 Voytek Wojciechowski.
Site design and maintenance by Voytek Wojciechowski.