WORKSHOP MANUAL
Contents
1. and adjust the required mixture richness by means of the air screw Adjust the idling speed by means of the fast idling screw and the twist grip play by means of the bowden control Adjust the throttle stop screw so as to ensure as regular operation of the engine as possible with smooth tran sition points between idling and higher speed RPM 2 di 4 5 18 Fig 18 JawaMoped com 7 20 Fig 19 Removing Alternator Rotor Using Special Fig 2 Service Tool No 16 65672 4 3 Fig 20 Releasing Alternator Cover Spring and its removing Slackening Alternator Holding Bolt Fitting Guffero Seal 17 X 28 X 7 Using Special Service Tool Fig 23 No 928 1200 1 2 Fig 22 Removing Alternator Stator Removing L H Engine Crankcase Cover Fig 24 JawaMoped com eI Fig 25 Removing Primary Transmission Gear Take care of the needle roller bearing 26 needle rollers are fitted the respective dimensions being 72 On fitting grading according to the Table below is to be observed Classing 2 1 Class Dimension 1 2 000 0 002 2 1 998 0 002 3 1 996 0 002 4 6 1 994 0 002 5 1 992 0 002 Fig 26 Pulling Off of Gear Wheel Fitting Gufero Seal in Position in Crankcase Pressed Out Crankshaft c w RH Crankcase Cover Fig 28 Fig 27 Using Special Service Tool No 928 1200 1 2 Pressing Out Crankshaft From Crankcase Using Special Ser2. 201 is3 25 IT oss Fig 5 II ENGINE It should be noted that elementary maintenance jobs specified in the Driver s Manual are omitted l Removing engine from frame a Remove engine cowlings see Fig 6 b Disconnect the spark plug cable petrol feed pipe and throttle control bowden c Disconnect the electric wiring from the Tranzimo unit d Disconnect the chain from the primary sprocket see Fig 7 e Disconnect the exhaust pipe from the cylinder f Free the engine and pull it clear of the frame see Fig 8 lig 7 Fig 6 JawaMoped com x Fig 9 Slackening of clutch securing bolts and flywheel removal The starting clutch plates require no special attention A point of prime im portance is to keep the clutch compartment dry and clean Pulling off sleeve by means of special service tool No 16 19755 3S Fig 11 DIA N Nh PS Fig 10 Pulling off clutch carrier using Babetta special service tool No 975 1100 1 2 Prior to removing the clutch drum be sure to take out Seeger circlip Fig 13 Pulling seal ring out of clutch drum Fig 12 Starting clutch removal Do not lose wire clips Fig 14 JawaMoped com 15 Cylinder Barre Removal Fig 16 Fig 15 Cylinder Head Removal Removing gudgeon piston pin using special service tool Fig 17 No 50 1200 1 1 Maximum permissible gap of a worn piston ring is 0 5
3. damaged In addition check the air gap between the rotor and pole shoes 0 3 mm i e 0 012 If no defect of this sort is found or if rectification of the respective defect has not helped measure the feed voltage as follows Disconnect the red wire from the TRANZIMO unit charge the 4 uF 600 V capacitor via the KY705 diode and check the capacitor voltage by means of the Avomet II DUIO measuring unit At 600 RPM of the engine i e starting speed of the engine a voltage of approximately 40 V must be ascer tained If the voltage is below this specification or no voltage can be measured the feed induction coil must be replaced by a new one If the voltage of the feed induction coil is correct check the voltage of the pulse forming coil in the same manner white wire within a range of 3 V the respec A Published by After Sale Service Department tive voltage must attain approximately 0 3 V If no voltage can be measured the entire stator frame with riveted on starting coil must be replaced by new one 9 Pova sk Bystrica SSR 5 The semi conductor part of the TRANZIMO unit can be repaired only if the fault is D 1 due to the transistor itself this can be ascertained by replacing rhe transistor with a new one 35 JawaMoped com
4. follows 1 Remove the carburettor from the engine dismantle it and clean thoroughly the individual components Discard any worn parts and replace them with new ones Check the flange for level face and if pitted true it on a piece of emery cloth placed on a flat surface Having reground the carburettor body clean it again thoroughly Check the setting components for compliance with specifications For checking use ihe JSK 3 test station with the respective attachments and scales as follows a For checking the main jet use the hose attached to the extension marked A D Attach the general purpose holder to scale D b When checking the idling jet proceed in a similar manner attaching the holder to scale A c Check the carburettor throttle for wear with regard to the throttle chamber The play must not be excessive otherwise the throttle is liksly to vibrate noisy operation pinking der 6 Having reassembled the carburettor check the needle valve for leakage Attach the hose of the valve tester to the fuel feed line and turn the carburettor so as to close the needle valve The tester must be set to a reading of 0 4 kg cm 5 69 psi The maximum permissible pressure drop is one graduation i e 0 05 kg cm 0 71 psi per 5 seconds 7 Adjust the throttle needle and throttle stop screw as per specifications and finish the assembly procedure 8 Install the carburettor in position on the engine Start the engine warm it up
5. to 0 6 mm A 0 D SJ 0 002 to 0 024 D POSSA b t 16 Cylinder Grading Table Diameter X H6 A B 0 Standard 39 00 1 0 016 39 00 0 006 39 006 0 005 39 011 0 005 Rebore I 39 25 0 016 39 25 0 006 39 256 L0 005 39 261 0 005 Rebore 1 39 50 0 016 39 504 0 006 39 5064 0 005 39 511 0 005 Rebore III 39 75 0 016 39 75 0 006 39 7564 0 005 39 761 0 005 Rebore IV 40 00 0 016 40 00 0 006 40 006 0 005 40 011 0 005 Piston Grading Table Piston Grading A B C Rebore I 39 115 0 006 39 106 0 006 39 111 0 005 39 116 0 005 Rebore II 39 366 0 016 39 356 0 006 39 361 0 005 39 365 0 005 Rebore III 39 616 0 016 39 606 0 006 39 611 0 005 39 616 0 005 Rebore IV 39 866 0 016 39 856 0 006 39 861 0 005 39 866 0 005 JawaMoped com fr Se en a 17 3 CARBURETTOR The Babetta moped is provided with a JIKOV 2909 DC carburettor with the following technical specifications Main jet 63 Idling jet 35 Throttle needle Ind notch from above Fast idling screw ly turn The basic maintenance of the carburettor comprises dismantling flushing with clean petrol and blowing dry with compressed air Be sure to clean the jet solely with petrol or acetone and air Never use pieces of wire or any other hard items in order to avoid any hazard of damage to the calibrited holes In case of a more thorough overhau of the carburettor proceed as
6. WORKSHOP MANUAL of Moped BABETTA Q e The Babetta moped is a vehicle of simple design with minimum maintenance requirements The workshop manual is mainly in tended for workshops carrying out major overhauls We assume that your workshop is well equipped with standard tools and naturally also with the respective special tools for the Babetta moped With an adequate stock of genuine spare parts you will be able to effect all repairs within the shortest possible time and with maximum precision Through our Service Information Depariment you will be informed of any new models and modifications regarding the moped After Sales Service Pova sk stroj rne Manufacturer Pova sk Stroj rne Nat Corp Pova sk Bystrica Exporter MOTOKOV PRAHA CZECHOSLOVAKIA 1972 This copy provided free of charge by awa oped com for your own personal use Not to be sold or used for any commercial purpose Enjoy Printing Tip These pages are A5 size landscape If you want to print a copy in printer set up set to print full size multiple page vertically 2 to an A4 sheet J awaMoped com GENERAL INDEX Page I General Data 1 Babetta Special Tools 4 2 Lubrication Chart 6 3 List of Bearings and Seal Rings 8 4 List of Gears e Jo 10 5 Transmission layout 12 II Engine l Engine Removing from Frame 13 2 Engine Dismantling 14 3 Carburettor b d A4 4 owe am
7. d com III FRAME Pedal Transmission Removal Fig 35 Fig 34 Removing Drive Gear Shaft When replacing the bearings it is advisable to warm up the crankcase to approximately 80 C Front Telescope Plug Removal Fig 36 28 Front Telescope Nut Slackening Fig 38 Fig 37 Front Telescope Spring Retainer Release Front Telescope Slider Plunger Removal Fig 39 JawaMoped com Front Fork Exploded View Fig 40 For safe braking a minimum diameter of 81 5 mm 3 2 of the rear brake lining is required it If the lining is worn below this specification must be replaced with a new one Front and Rear Wheel JawaMoped com 32 IV ELECTRICAL EQUIPMENT 1 Alternator Electric current is supplied from a 6 pole alternator of standardized unit design with ferrite basis The ignition system proper is contactless Instead of contact breaker arm a trip coil is fitted in the arm of the alternator stator Individual alternator circuits First circuit Ignition feed pole and primary path indicator coil of contact breaker Second circuit Headlamp and tail light feed pole Bulbs One PS 25 1 6 V 21 W Ba 15s One C 11 6 V 5 W SV 8 5 Babetta Alternator Fig 42 JawaMoped com black xp UN cac green red white yellow 1 Alternator 2 Tranzimo unit 3 Sparking plug with cable shoe 4 Tail lamp 7 Headlamp 2 Babetta Moped Electric Wiring Diagra
8. el Fig 2 JawaMoped com 3 List of Bearings and Seal Rings Ref No ol egin Part No 43204 43005 43006 28 2207 43001 40001 50112 50102 50101 50115 50009 50305 ame O CO Juul O J O WN 00 Description Engine bearings Bearing 6203 C3 Bearing 6001 C3 Bearing 6004 C3 Primary transmission needle rollers Wheel hub bearings Bearing 6001 Steering mounting Ball 5 Seal rings Guffero Guffero seal Guffero seal Guffero seal Guffero seal Seal ring Seal ring CSN 02 9281 2 Dimensions mm 17 X 40 X 12 12 X 28X 8 20 X 42 X 12 2 X 12 12X28X 8 KXXXX N r NN Un UT DONI O N D O Wh O PH 00 x XXXX u zl I Q bo O bo bo kl A O 43005 2 6001 c3 50112 17x28 x 7 28 2207 2x12 50102 28 7 j 50112 S 17x28x 7 50101 G 20x30x7 6 O 6004 03 _ Fig 3 JawaMoped com 4 Review of gears Ser No Description Gear Gear Gear Gear Sprocket Sprocket Pedal transmissions Sprocket Idling sprocket Number of teeth 20 34 12 36 12 39 32 18 TTT REIN W 7 KIN 27 A Fig 2a Filling and discharging oil screw 1 Filling hole screw 2 Discharge oil screw 3 Control hole Fig 4 JawaMoped com 12 5 Transmission Layout 11
9. gy ensure the tolerance limits specified above Be sure to check the crankshaft for correct running alignment prior o fitting it to the engine In case of a new crankshaft misalignment may be due to an accident care less transport dropping it on the ground or possibly reconditioning of the shaft To ensure correct axial play of the crankshaft in the crankcase adhere to the specifica tion of 38 0 2 mm 1 496 0 008 regarding the distance between the bearing shoulders after press fitting Ensure a correct distance between the flywheels at the point of crankpin specified to a minimum of 12 1 mm 0 476 Fig 30 Crankshaft Alignment Procedure Check axial alignment of the crankpins as per Fig 30 If the two crankshaft halves are misalined out of parallel take the shaft from between the centres place it on a suitable pad copper aluminium and using a hammer of soft material or possibly a hand operated crank press proceed to align until the most correct axial alignment of the crankpins is obtained The two crankshaft halves are not misaligned if the readings of the two dial indica tors are equal while the shaft turns After this check if the respective out of true of the functional parts exceeds 0 06 mm 0 0024 aling the centre line of the crank shaft by bending the two shaft halves as necessary The procedure can be seen in Fig 33 Ref Nos 2 3 According to the respective misalignment of the crankshaft cent
10. m Fig 43 34 3 Tranzimo Unit MS 50 Moped Ignition Circuit Checking Procedure 1 Check the spark length on a standardized three electrode spark gap on starting a flashover of 6 mm 0 236 must occur Turn the engine with tbe spark plug screwed in If the spark length is satisfactory check the spark plug or possibly the cable shoe If these components are sound the fault is to be traced outside the igni Interchanging of the wires soldered to the transistor may result in deterioration of the transistor More over care must be taken tion system 2 If the spark length is unsatisfactory or if misfiring takes place check the following po not to overheat unduly the transistor a Sound condition of the TRANZIMO rear cap if the cap is detective replace l it with a new one and clean the area round the transistor terminals on soldering b Correct connection of the individual conductors to the semi conductor part of the TRANZIMO unit as per the Wiring Diagram C Perfect connection in the connectors 3 If the fault persists check the semi conductor TRANZIMO part for sound condition by connecting a tested TRANZIMO unit to the connecting wires If the spark is now satisfactory the defect is due to the semi conductor part If the fault still conti nues the alternator is faulty 4 In the alternator compartment check whether the wires are properly soldered to the coil ends or if they are not mechanically
11. ng puller remover Clutch sealing sleeve removal 2 975 1100 1 2 Crankshaft remover drift Clutch carrier removal crankshaft removal 3 928 1200 1 2 Fitting cartridge Guffero seal fitting 4 50 1200 1 1 Gudgeon piston pin remover drift Piston fitting removal 5 975 1400 1 1 Advance feeler gauge Ignition timing 6 928 6000 1 1 Alternator rotor puller Alternator rotor removal Fig 1 JawaMoped com 2 Babetta Moped Lubrication Chart drei E E Ref No Lubrication point Lubricant Note BEE ord ecc 1 Engine two stroke engine oil SAE 30 upper engine lubrication Oil M 2 T petrol ratio 1 30 2 Gearbox gear oil SAE 30 80 PP80 filling capacity 0 13 litre 3 Steering bearing grease AV2 on dismantling wash and lubricate 4 Twist grip throttle control lubrication grease A00 after washing apply to sliding parts 5 Brake and decompressor SAE 30 oil M6A levers 6 Bowden controls light oil fill into bowden casings 7 Wheel hub b arings bearing grease AV2 top up bearings 8 Brake cam lever pin brake lubrication grease A00 after cleaning provide with a light cams brake shoe fulcrum grease coating pin 9 Chains graphite grease oil A00 clean and lubricate as necessary 10 Stand pin SAE 30 oil M6A 11 Pedal bearings SAE 30 oil M6A 12 gt Front fork telescopes SAE 30 oil M6A 13 Idling run wheel SAE 30 oil M6A e
12. p wx we x UA 4 Crankshaft K s 24 III Frame 1 Wheels Brakes 1 EN Low wu M IV Electrical Equipment 1 Alternator K 8 e amp uh 532 2 Wiring Diagram x 95 3 Tranzimo Unit 1 35 TECHNICAL DATA Engine type Swept volume Bore x stroke Compression ratio Power output Clutch Gearbox Overall transmission ratio Pedals to rear wheel ratio Starting Front suspension Front suspension stroke Brakes CRE Brake dimensions Tyres Tyre inflation pressure front rear Curb weight Carrying capaciiy Road speed steady peak Fuel tank capacity Maximum climbing ability Noise level Ignition Spark plug Headlamp Tail light Bell two stroke air cooled single cylinder 49 c c 39 X 41 mm 1 55 X 1 61 l to 6 5 1 5 HP at 4500 RPM automatic centrifugal dry One speed unit 1 15 75 1 0 568 by pedals telescopic fork without damper 60 mm 2 36 shoe type drum brakes operated by handlebar mounted levers 85 X 20 mm 3 35 X 0 79 23 027 1 75 atp 2 25 atp 42 kg 92 6 lbs 90 kg 220 lbs 35 km p h 32 m p h 40 km p h 25 m p h 3 litres 2 64 Imp pt reserve 0 5 litre 0 88 pt 10 73 dB contact less semi conductor PAL 14 5R 21 W 6 V 5 W 6 V smooth JawaMoped com I GENERAL DATA 1 Babetta Special Tools BE i Part No Description d Purpose No l 16 19755 38 U14 Tippi
13. re line as per the dial indicator readings bend the flywheels so as to converge in case of readings or so as to diverge in case of readings If necessary proceed to align at several levels not only as shown in the picture For final alignment observe the specification 0 06 mm 0 0024 regarding the per missible out of true of the functional points If this method fails to ensure the per missible tolerance limits in the peripheral out of true of the shoulder carrying the drive gear of the primary transmission the respective half the crankshaft is faulty and must be replaced with a new one or reconditioned by grinding Since this opera tion is considered rather exacting it is advisable to entrust it to skilled craftsmen only JawaMoped com Table of Con Rod Big End Grading BEE 10 9 8 7 6 Roller A B ba D E Pin N 9 8 7 6 5 Roller A B C EN D E Pin W 8 7 6 5 4 Rolle A o B C D E Pin WS J de J 4 2 Rene Sets be tee m 6 7 5 6 45 34 2 3 Roller A B D E Pin 26 Detail of Engine Drive Release Mechanism Fig 32 Fig 31 Removing Control Gear On fitting be sure to lock the pin in position Removing drive Gear Fig 33 The change over switch piu be assembled so the pin grooves are between the change over switch balls JawaMope
14. vice Tool No 975 1100 1 2 Pressing Out Crankshaft Fig 29 JawaMoped com 4 Crankshaft Dismantling and Reassembly 1 To dismantle the crankshaft use a press developing a pressure of approximately 5000 kg 11 023 lbs Prior to dismantling mark the respective position of the crankshaft flywheels by means of check marks using a square Press out the crankpin first from one crankshaft web and then from the other one Renew the connecting rod crankpin and cage complete with rollers according to the Grading Table Thoroughly clean the crankshaft components paying particular attention To the journals which must be perfectly dry 5 Press the crankpin home into the flywheel so that its face is just flush with the flywheel outer face 6 Install the cage complete with rollers lubricate with mineral jelly 7 Press fit the flywheel according to the check marks previously provided 8 After press fitting the crankshaft must be centred Ha Wh Crankshaft Alignment Check the crankshaft for alignment and permissible out of round tolerances in a spe cial jig between centres using two dial indicators Clamp the crankshaft between the centres so as to ensure free rotation The maximum permissible peripheral out of true of the functional points is 0 06 mm 0 0024 The shoulders for the bearings are to be considered as functional points Both the desing of the machine and the respective production technolo
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