Jawa 559 Gear Box / Transmission Assembly

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I would also like to mention that the assembly ( I find) easier in second (yes!) neutral position between 3rd and 4th gear.
Same way it goes together for all Jawa 250 and 350 models from 1946 to about 1973. Gearbox of models made after 1970-73 is different only in number of teeth on gears and shape of shifting forks , otherwise the same process. Same goes for all street CZ motorcycles.
125 and 175 models are also very similar, just slightly scaled down. Hope this video is helpful, since English instruction manuals that describe this process in detail are somewhat hard to find, and most mechanics on this side of Atlantic will not touch those obscure bikes with a ten foot pole..
Any other questions regarding repairs on mentioned motorcycles are welcome. Engine has very simple iternals , especially the single cylinder models, and are easy to work on. Unlike most people think there's lots of new aftermarket parts available from Czech Rep and Europe for almost any model, and quite inexpensive - to North American standards.

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15 ноя 2012

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Комментарии : 26

@discoverydreams6182 Год назад

Thank you sir

@MrSvv78 11 лет назад

Absolutely bulletproof. Very robust and dependable machine capable of far trips - if you don't mind cruising at around 90 km/h. Only weak spot is the old 6v dynamo, but it can be replaced easily with modern 12v CDI available from powerdynamo in Germany aand few other european Jawa parts sites.. I went quite far on my bike, some trips over 3000km never having any problems

@TheRantz 11 лет назад

Nice video, very helpful when assembling Jawa gearbox, put mine together quite a long time, i wish i would discovered this video much earlier :)

@MrSvv78 11 лет назад

The engine on video - is one of my spare ones. Just used as an example. I only took it apart to inspect and change some bearings that were rusty from 30+ year storage in a shed.

@enfielddnepr 11 лет назад

thanks for you reply.. i also found a dutch article about giving the 559 more pwer.. i think it would be great to give it a littele more-so the engine stays in omne piece- for travelling against strong wind, maybe only raising the compression..

@GustavoGlv 7 лет назад

Nice explanation. thanks.

@WerHatDieKokosnuss 7 лет назад

Hey, got a question here: I can't put the main shaft into the bearing just as easily as you do. Without some decent blows with a hammer, the shaft won't slide into the bearing. And as it sits really tight in there, I can't feel how much play I have to get rid of by using the spacers disks, because the shaft ain't moving at all. Can I leave it just like that, without using spacers disks at all?

@enfielddnepr 7 лет назад

I have the same experience with the axle fitting in the bearing. With the last gearbox i did there was no problem. I think there are batches not so measure-tight made..The main axle is pulled to one side by the clutch, so no play. The secondary axle must not have too much play, or else you get trouble with 2nd and 4th gear. Shim the axle out to the left- not right- at abut .1mm

@slushymud 8 лет назад

Hi, i just saw video and you make it look really simple to assemble the jawa gear box. I'm from India and have a 1972 Jawa 353. I had my engine re-built but there is a significant power drop when i shift from 3rd to 4th. I was told it is because of the bore being weak. Not sure why that would happen only in the 4th gear because of the bore. Anyway.... i replaced it but the problem still persists. Would appreciate your comments. Thanks

@abhineeshnangla55 8 лет назад

MrSvv782 years agoJust e-mail me. 410yrn@gmail.com

@enfielddnepr 10 лет назад

Hi, i have some questions about dis- and re- assembly of the 559 engine, considering the crankshaft fittings, may i ask you something about it?(i cannot find a workshop-manual about this bike..)

@baseerbaseer900 6 лет назад

thnx alot

@MrSvv78 7 лет назад

sorry to all of you, i haven't checked this conversation in a long time. got a different e-mail now, s-voskresensky@hotmail.com All questions still welcome.

@enfielddnepr 8 лет назад

Hi, my 559 gearbox jumps out of 3rd gear, only when engine is warm, and when pulling away. When assembling the engine i must have missed something. Besides worn gear blocks on the side, it could be exsessive play in one of the axles? can you help me?

@juanmoreno-cu7ie 9 лет назад

Mr svv78 got a question for you...what is the size in milimeters of the thin rod that pushes the clutch inside? The one that goes interacting with the clutch lach at the right bottom of the bike? Thanks greetings from Colombia

@enfielddnepr 10 лет назад

i tried to fit the 12V 638 generator on the 559, but the rotor has different fitting and theres'no room for the stator, but there's someone who made it fit??

@enfielddnepr 10 лет назад

i just bought a 559 project bike, so thanks for the tutorial! maybe you can tell me which type barum/mitas fits best on the bike? i already have a 638 for some years and i love it!

@MrSvv78 11 лет назад

In Czech Rep. there's a man named Vojtech Hlasny - he went all over the world on his CZ250. About seats - guitar shaped one is better I find, but if you got original. Modern turkish repro is kinda stiff. I got mine from jawashop dot com. Both styled seats are intershangeable and can take only seconds to swap.

@enfielddnepr 10 лет назад

i will mail you, tanks!

@enfielddnepr 11 лет назад

Cool, do you think that ist is better then the 350 twins of the same period? pleased to hear that 80km/h or even 90? cruising is possible. And how's the buddy seat at long trips? the 353 seat looks more comfy, but i don't know if you can swap them..

@enfielddnepr 11 лет назад

What can you say about the durability from the crankshaft and overall engine of the 559??

@MrSvv78 11 лет назад

Well, in East Bloc 350 twin Jawa was kind of "superbike". yes, it's faster and bettter , but only in that way. It can hold 100km/h on the highway. But 250 singles even thogh slower, they are more user friendly and more dependable, fit to go to Dakar and back.

@MrSvv78 10 лет назад

arie sams, this is correct, ithe one from 638 will not fit. You need to go to powerdynamo (dot) biz and they will have correct 12v system, that even runs without battery.