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 mpq) |
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. 4th speed
gear
8. Main shaft
9. Slide
bearing
10. 3rd and 4th gear dog
clutch
11. Thrust washer
12. Slide bearing
13. 3rd speed
gear
14. 2nd gear
sprocket
15. Hub
16. 1st and 2nd gear dog
clutch
17. 1st 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. 4th speed gear;
14. Dog clutch;
15. 3rd and 4th gear fork;
16. Dog clutch;
17. 3rd speed gear;
18. 2nd speed
gear;
19. 1st and 2nd gear fork;
20. 1st 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 |

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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 |

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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 |

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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 |
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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 |

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Service
schedule
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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. |
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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 |

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