JAWA 2-stroke power tuning 350 cc / 559R (part 1)
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- Опубліковано 19 тра 2021
- Welcome to a little insight of how to get about 35 #twostroke HP from a 1960s JAWA 250, resulting in a top speed performance of almost 150 kmph.
Feel free to have a look into Part 2 video showing further details on the way into the skies: • JAWA 2-stroke power tu...
And how does it feel to ride this bullet? Just hop on for a minute: • JAWA 350 / 559R 2-stro...
The entire “making-of” in writing can be found here: forum.jawafreunde.de/forum/in... - Авто та транспорт
Siegfried von Stern. This work is a real masterpiece. You are an ingenious Tuner, Designer and Machinist. Thank you for the nice video.
Thanks for the very friendly words.
Excellent , masterful transformation into spirited bike , the engine sound at first start brought back my memories of hanging around with a local scramble gang , & yes , although I was only a kid then , I could hear the same spirit in this engine that the older guys had in their home - tuned scramble bikes ( Jawa C.Z. ) . I like the fact that you saved weight everywhere possible without losing strength , installed top grade roller bearings , many times stronger than ball ones , bored the cylinder out , possibly to the max , then ported & gas flow tuned it , just marvellous , the final polish , a big venturi carburettor , coupled up with an equally capable exhaust , it all just gets the gases in , exploded , & out again to maximum gas flow efficiency & speed . Well done , very nice job . Best Regards from England .
Thank you, Mr. Cleaver. Yes, good summary - that was the project. Only polishing I didn‘t do inside the engine. At least not on purpose. That doesn‘t really help the performance. Smoothing corner etc. is sufficient.
Great work, man!
I am now in the middle of Jawa 350/354 restoration, your video is very inspiring.
Good luck Peterman!
If you do this, you surely gonna fly ✈️✈️👍👍
Excellent job! I like how you balanced the flywheel with the tungsten plugs. 👍
Thanks Mate! 😎💪🏻👊🏼🤟🏼
Danke für die Dokumentation und die vielen Details!
Very nice work, man.
You have all my appreciation!
Thank you Mate.
Respekt für die Arbeit. Sehr schön so etwas zu sehen :)
Danke sehr freundlich. Ich freu mich auch immer wieder mal das Filmchen anzuschauen. Die Hunderten von Arbeitsstunden sieht man dem Bike nämlich nicht mehr an.
@@Quiet.Light.Engineering wird das ganze denn eigentlich noch regelmäßig bewegt?
This is extra-ordinary bro, I had this in mind from long time, there is somebody who can give time, money, patience !! Hats off bro 🤟👍👍
Glad you liked it!
You have the best old Jawa I have ever seen. Good job :)
Thanks. Its also great fun to ride. I’m glad the frame appears able to cope with the power. There is certainly more stable bikes on the streets but mostly less cool :)
@@Quiet.Light.Engineering I think, the Jawa frame is not that bad. I have MZ 251 and I had to reinforce the main frame. Originally its made from paper :-D
You've made an already beautiful machine, extraordinarily fantastic. That piston ported physics is a dying science. You're a gifted engineer and machinist.
With legislations round the world against 2 strokes, I'm a little heartbroken. I wish we could turn back the clock to the 70's and 80's.
Thanks Samuel, those are very personal words. Yes, those times are gone, but there is enough material around for a little fun.
You took me to the 70s
@@Anandkumar-hz8mn❤😊👊🏼
Really impressed with your work.
I hope it's still flying.
From the U.K.
Thanks Mr. Cooper! 👊🏼👍🏻🤟🏼
Am from Czech and I absolutely love your videos.
Welcome Petr. 🇨🇿🇨🇿🇨🇿🚀🚀🚀
Stunning craftsmanship
Sehr schön gefilmt und gebaut👍
Sozusagen.
WoW first time I have heard of a Jawa in 40 years. I used to ride a Jawa 450 enduro as a teen. Would love to get my hands on one as well a Bultaco. Great video Thanks for sharing.
They revived the Jawa brand in India last year.
@@SurajSinghTomarArya looks like a jawa ,but moto morini engine
The level of knowledge is beyond impressive!
Thank you.
What have you done there is something that most of mechanical engineers only dream to. I am a mechanical design engineer and i know that those things were study object in developement of all Japan motorcycles manufacturers in early 80' s when was the big boom of horsepower. Congratulations! I hope only there will be more videos uploaded by you! Cheers!
Thank you, Sir. More to come. Regards.
i love the style of introducing upgrades
Thanks for the friendly feedback.
Awesome work!
That’s amazing, very nice work man! I wish I could do the same for my TOMOS
You can probably find someone doing this for you on your TOMOS… there is experts everywhere.
Ik zou eens Floris heuping een berichtje doen. Je kan hem vinden op Instagram als je z'n naam intypt. Hij kan je Tomos laten vliegen
How beautiful, man ! The best presented, studiend engineered and crafted work I have ever seen ! It emanates passion and thought. AMAZING AMAZING AMAZING !
Thanks mate, for the very friendly words.
A very Neat job done with Perfection
Wow big respect man good job ..very nice video
Thanks Josef. And its great fun to ride that bike now!
I would absolutely love to have a sleeper like that.. I have always loved the idea of taking something that shouldn't into something that does...
Go for it. It‘s never too late Eric.
Для нормального просмотра, чтобы рассмотреть детали, поставил скорость просмотра youtube на 0,5. Проделанная работа потрясающе! 👍👏
добрый друг, большое спасибо за эти слова.
nice movie like the information and camera work really good lovely movie to watch
Thanks Mate.
Watching this felt like watching a movie. Superb ❤️
Thank you, it‘s was almost intended also, to get a movie out of this technical documentation of a change in engine character.
Amazing content 😍 love it, keep doin whatcha doin
Thanks.
Beautiful work mate nice bike too 😀👍
Thanks Mate.
awesome, nice work !
Круто! 🔥🔥🔥аккуратная работа. very high quality work, thanks!
Спасибо 👊🏼💪💪
great work...could you make a video of how you installed new carb in the old cylinder..would love to know..I too have a 71 Jawa
Thx you for sharing your work .
You are welcome, Sir.
I learned riding at 559 with automatict clutch i remember was funny that time of my early life . We try did also milling job on the head in order to encrease power but was not succsefully like in your case :)..very nice job ...fingers crossed from Slovakia ;-) Regards Stanislav
Thanks Stanislav. Nice story. Greetings to Slovakia 🇸🇰🇸🇰🇸🇰
que hermoso trabajo, felicitaciones
Nice work.
Cara você sabe o que está fazendo. Lindo trabalho!
very good work-
kind regards from east germany.
Danke! Grüße nach Ostdeutschland!
Almost nothing to notice on the outside (except for that well hidden carb). Really nice piece of work!
Thanks Phil. The carb cover belongs to the bike an must stay. Unfortunately the new carb is way too big, which is why the cover looks like it looks now…
@@Quiet.Light.Engineering Which Carb is it brother?
Супер👍
Работы много проделано.
Amazing 🤩👌💪 Greetings from Poland ✋👊
Thanks for watching. 🇵🇱 👍🏻👍🏻🤟🏼
What an amazing piece of art...wish you would do my KTM 525 (570)SX supermoto, its all ready stupid fast. It would be so rad, man access to a lathe is such a game changer also.
👊🏼🤟🏼🤟🏼
Cooler job ever...👍
beautiful
Thank you for the feedback.
Super work bro.... 👏👏👏 ❤❤❤❤make the same for old Royal Enfield motor cycles also...
Beautiful. Inspiring.
Thanks. All the best for your own project.
Klasse Arbeit!
Danke für das Lob!😊
No comments... i am impressed 😎
Well done, this is how I converted my Polish WSK motorcycle
🤟🏼✊🏻🇵🇱👍🏻
Brilliant work! This 559 flies!!
Which piston did you use? Can you share the specifications?
Hello. The 78 mm piston was specially made by Grand Master Wahl / Fellbach, Germany. Some more details can be found here: forum.jawafreunde.de/forum/index.php?thread/22776-projekt-jawa-573-ultrasport/
❤ big job bro. Like it. 👍
Thanks Jaroslav 🤛🏼👊🏼👍🏻
I've tuned a 1979 CZ 350 up to 107 MPH, back in 1987. I still have the bike, but with over 79,000 miles on the engine, plus the lower energy content of modern ethanol contaminated petrol, it is a shadow of itself regarding performance.
Other tuned Jawa & CZ bikes I've had fun with are:
1977 CZ 175-477.5 tuned up from 71 MPH to 89 MPH in 1987.
1977 Jawa 350-5-05 tuned up to 96 MPH in 1986.
1978 CZ café racer powered by a 1986 unrestricted 638.0 engine up to 115 MPH in 1991.
1980 CZ 350-472.4 Custom Mk.3 to 101 MPH in 1989. In 2001 I changed the engine to a derestricted 640 & 12 Volt electrics.
1991 Jawa 50-225 Babetta café racer powered by a Jawa 50-223 Mustang engine (58 MPH).
1988 Jawa 500-826 (Jawa 500R Mk.II) tuned up to 110 MPH.
💪💪💪🤟🏼👍🏾
Did you also achieve 50 Nm?
@@Quiet.Light.Engineering Probably close to 50 Nm. I had a problem with constantly breaking the CZ chain adjusters, usually within a few kilometres of fitting a new one. I eventually solved this by drilling one out and attaching it with a high tensile bolt. The engine then proceeded to slightly bend the adjuster bolt mounting on the swinging arm, but never broke it. I have the only CZ with a 30 degree chain adjuster mounting lug on the swinging arm.
Clutch plates lasted 6 to 8 weeks with daily use. I eventually used 1988 Suzuki GSX 750 R springs (they fit) and the clutch would last for as long as 14 to 16 weeks in daily use.
Chains were another issue. I tried an Izumi heavy duty 428 chain, but it was destroyed quicker than the Reynolds & CZ chains I was already using.
I did the work on the engine during a rebuild at 54,000 miles, using an already fast 1975 CZ 350-623 engine from an Italian market Aprillia headlight version. It had an oil pump slot on the crank, but never had an oil pump casing because CZ never put the CZ 250-471.2 into production. I had the cylinders bored out the cylinders to 58.5mm., replacing the stock Asso Werke forged pistons with 2nd oversize Asso Werke forged pistons.
The exhaust ports were raised 3mm. and the transfer ports by 2mm. with the "hump" in the transfer port bend ground out to direct the fuel mixture higher into the cylinder. All the cylinder port tunnels & the carb manifold tunnel were polished.
On the good advice from a friend's boss, who drag raced cars, the bearings were replaced with more expensive low friction rated SKF versions (I learnt that bearings have a friction rating).
The rear brake was changed to a TLS unit and both brakes fitted with Ferrodo AM-4 competition shoes.
The pipes are and still are Abbey Performance items marketed for the CZ 250 & CZ 350 in the late 1970's & early 1980's. They use an interesting non-straight through silencer design.
The sprocket ratio was changed to 19:52 because the bike had a nasty trait of lifting the front wheel, slightly, when powering out of a corner in 2nd gear on the previous 17:52 ratio. This didn't quite cure the issue but made it less shocking & more controllable.
Installing longer CZ Trail forks and Koni Dial-a-Ride 320mm. rear shocks nailed the unwanted power wheelie issue
The bike is currently sat on my drive with the engine out, at 79,800 miles, in pieces after the sprocket bearing wore out, causing the top gear selector fork to melt (no 4th gear). I last rode the bike in August 2020.
Gear change speeds are:
1st to 38 MPH.
2nd to 67 MPH.
3rd to 78 MPH.
4th to 107 MPH.
Andy, with all the extreme values you achieved: what sort of chain did you use for the primary transmission from crank to clutch? Knowing that is a wear point on JAWA I’m curious how you overcome that…
@@Quiet.Light.Engineering can you send me the Exhaust Port Timing along with the Transfer Port Timing
Nice filmed, and good skills
Отличная работа👍
Cпасибо большое товарищ! 🤟🏼👋🏻😉
Amazing 💪💪💪👍👍
Hola amigo, me encantó ese trabajo. Yo y mi papá tenemos un jawa 250 del 1963 y quedamos fascinados cuando vimos lo que hiciste. Nosotros vivimos en Cuba y aquí es muy complicado hacer ese trabajo porque no tenemos ni los materiales ni tampoco las posibilidades para hacerlo pues todo nos saldría muy caro, pero por simple curiosidad y si crees que te sea posible y no es mucha molestia. ¿Podrías mandarme todas las medidas exactamente para si algún día tengo la posibilidad de hacerlo? Te lo agradecería, fue un placer poder escribirle esto, muchas gracias por su increíble vídeo. Saludos cordiales desde Cuba.😁👍
Beautiful
Thanks mate.
Man, why did I not have this recommended before. Refreshing to say the least, and sure thing, keep that front wheel flying lol
👋🏻👋🏻👍🏻👊🏼💪🏼
Šikovny 👌🏻
absolutely amazing work out there
can u give me details of the bearings used
i want to upgrade my 634 , crank, gears etc
Thanks. I used normal high quality C3 bearings and a FAG NJ305 X-Life bearing for R/H crank side. A NJ bearing made in India by the way.
Hi, I had a 559, and good bike it was I never thought of it as a candidate for tuning! Did you cast the barrel yourself, with all the material to cut the ports? and was it nikasil?
Hi Mr. Day. The alu. barrel is from the military model 579 and I added a classic iron sleeve. There is not really enough material for “the right” port, which requires trick and compromise.
Great job 👏❤
Thank you Mate.👋🏻✊🏻👊🏼
I am impressed by the wonderful motorcycle ♪
Thanks. Yes, it a nice vintage model. And still not too expensive to get one.
Excellent work,closer to art than mechanical. She is absolute beauty.
Just wondering if it’s not too much fun for those old brakes and suspension.
Thank you Roman for the friendly feedback. Yes, brakes and frame stability are an issue, but this is not really used like a race bike.
Lovely!
You are a master mechanic
Thanks for watching!
Nice , I wish to be able to do the same one day .. Dank U!
Welcome Sir. The result shown in this video wasn’t my first work. Failure happens on the way. Just don’t give up.
And she fliessss.. fantastic work man😘
🥰👊🏼👍🏻
awesome job!!!! :)
Thank you! Cheers!
Nice work! I do similar with vintage 125 motocross engines.
🤟🏼👌🏻👊🏼💪🏼💪🏼🚀🚀🚀
Sir my respect !!
excelentttt work
Thank you, Elizabeth.
Sei il migliore!!! Che lavoro!!! Che suono e che performance!!! Sono ultra innamorato del mio 634 e vorrei contattarti. Forse non sono il primo che te lo chiede...Posso scriverti? Grazie comunque per i video!
Mille grazie. Twin engines I do not support currently. Sorry.
Very very nice job. What was the reed valve from? Windows in piston are still opened at BDC?
Thanks for your feedback. Valve is originally for RD350. Yes, in this case the piston window needs to be open in BDC to deliver charge to the boost ports.
@@Quiet.Light.Engineering Thank you for the answer and again very nice build.
Amazing job, i am currently in the process of doing somewhat the same amount of "custom tuning" to a Puch Monza, where i will be incorporating a reed valve intake into the engine block.
Why did you machine the side of the piston flat? I would have thought it would be stronger if you had left the material there?
Great work and great channel, love following your videos.
Thanks for watching. The piston machining was purely for weight reduction. There was too much meat before.
@@Quiet.Light.Engineering How did you conclude that the bearings could hold the power? I see in the video that you are measureing the needles in the bearing, what did you ude that measurement for?
I‘ve bought and used single piece rollers. One must ensure that diameter difference is less then 0,002 mm to make them taking the load all the same. Hence, the measurement at controlled temperature was for quality reasons.
Hi Siegfried - I have many memorable moments on my Jawa 250 from back in India. Your work is a masterpiece - are you selling these cylinders and heads ??
Thanks. Unfortunately there is nothing for sale.
Like a patriot I must say, that's absolutely amazing work. Very, very nice.
Thanks for your feedback.
Nice Job!
Thanks Mate!
Bravo, frend!! Excellent job!! But, driving normally, not broken again!! 😊
Thank you! Cheers! 😮
damn nicwe work !!!! ive broken soooo many gearboxes in my life normally 2nd gear but nevr anything close to that ;O
Thanks. The more modern version of this old JAWA gearbox which failed after the first tests was simply not made for such a high single torque. Many some bad luck for a piece of bad quality on top…
Wow! Great work. The ultimate 'sleeper'. Wonder if any CZ gears would work, they're totally bullet-proof. (I used to work as a CZ mechanic.)
Hello. Thanks for you comment. The gears from a „Libenak“ model I use now seem to work fine so far..
I'm a 20 year old from Australia have 17 years of motorcycle knowledgeable an experience only now coming to realise that from the 1970s an back is where all the power is dream bike other than gt750 Zuki would be the 59 t100
Very groovy😎🤙
Big respect
Thanks for watching and comment.
EXCELLENT 🤩👍
A quite I recall from the 1970s "There's not much can catch a well sorted Jawa".
That’s right Martin, that’s right. 😉
Nice jobbb
Nice work!
Congratulations!
I have a question.
At 1:12 what is the name of the too that you secure the venduri in lathe machine?
Thanks. The tool was home made and there is no name for it. The method is called ‘metal spinning’. Usually sheet metal is used to form any round shape one can think of.
@@Quiet.Light.Engineering yes i know yhe method.
We both speak about the plastic tool with the screw in the center so it can expand as you screw it in.right?
That’s correct. A cone in the middle pushed in by the screw fixes the pipe.
Very good Also the MZ ES like mine ! In Spain
👊🏼🤟🏼👌🏻
Echt geil gemacht. Prima gefällt mir.
Habe selbe eine 175 und 2 x 350er Jawa
Bei der 350er wiegt die Kurbelwelle 12 kg....
Die müsste auch abgedreht werden.....und Membraneinlass würde sich auch gut verstecken lassen..Block ausfräsen am Zentraleinlass.
Die Verdrängerringe machen sich da nicht so schön...
Warum hast du die kw Lager....tonnenrollenlager genommen...mehr Kräfte aufnehmen?
Hallo Herr Dr. Turbo L.,
das Rollenlager kann:
1.) etwas mehr Kraft vertragen
2.) unterschiedliche thermische Dehnung von Stahlkurbelwelle und Alugehäuse bei Festeinspannung abtriebsseitig ausgleichen, da Innenring verschiebbar
3.) Hauptgrund: ermöglich es den Motor konstruktionsbedingt (und nach Nacharbeit an den Passbuchsen) mit zwei Fingern zu zerlegen, ohne Drückerei, Wärme oder gar Hammer.
Grüße
S.v.S.
Да объем работ впечатляет!!!!!! 👍👍👍
👍🏼👊🏼💪
@@Quiet.Light.Engineering срезал маховик, тяга на низах пропала и мощность сместил на высокие обороты....
Стал мотоцикл для гонок по прямой)))
@@user-il4be9bq8l будто это плохо
holy moly was für ein biest xD, sehr gute arbeit !! dagegen sind meine "tuning" maßnahmen ein witz xD
Danke. Ja, die alte Dame macht ganz schön Druck. Mit ordentlichen Resodosen jetzt allerdings sogar noch mal mehr…
My rule of thumb for big bore projects is to ensure the liner is at least 2mm in thickness. Can we ask what the liner wall is on this build.
Sure: 2,5 mm left.
I start! Think alsow, meby! The crank shaft to big- heavy.
'What size carb is the aftermarket on you put on?
I just got my hands on a Jawa 350 634, and I was thinking of maybe adding a little power to it, like a bigger carb and one with an actual choke haha.
The carb is 38 mm. But that‘s too big if you don‘t switch to reed valve intake system.
@@Quiet.Light.Engineering thanks for the quick answer :).
No i do not have reed valves. Sadly I lack the equipment and knowledge to make such modifications as you.
I only know how to install a bigger carb, change cylinder or crank.
But I'm maybe thinking of a slight tune, so a slight bigger carb than the standard.
Do you know if there is any aftermarket "performance" cylinders/cranks for sale? I can not seem to find, only standard parts.
...hallo,es ist wahrsin!!
...tolle arbeit,aber ergebnis...spitze!!!
Selber hab ich auch eine restaurierte 350/360...wünsch ich mir auch solche leistung haben🥺....aber...
Frage,nehmen Sie aufträge ein?Wurde ich sofort Ihnen mein motor zuschicken.
LG aus Chiemsee!!!
Danke für den Zuspruch!
I bet KTM engineers are watching this video...Keep up the good job!
🤭🤭🤭
Very very nice.
Thanks George.
Hello, very nice bike you got, Please tell me the name of the carburetor?
Hi. A Keihin PWM38.
How did you balanced crank shaft? Can you explain in details how you know where to put thungsten and how much
Hi, thanks for your question. Is a little complicated to explain here word by word. The basic formula for the balancing factor can be found on the web. On the other hand it does not need to be to „precise“. Wether you go for 55 or 68% balancing should not make a lot of a difference. I recommend factors beyond 60%.
@@Quiet.Light.Engineering okey but i have heard that you cannot balance crankshaft for entier rpm range lets say if its supposed to run at 12k it will need to be balaced difrently than if its supposed to run at like 5k, is that true if so how can i deal with that, im trying to get max out of minsk 125 by selflearnig, i have readed two stroke performance tunig by g.bell but there was zero info about crankshaft balance, also some pro tips from tunner like you would be great
You are right, specific balancing work best at specific rpm ranges. Usually this is reason for factors in the range of 50 to 70%. Some tuners recommend even above 70%. But the ideal “point” also depends on how the engine sits in the frame i.e. direction and damping or not? You can only try if your balancing factor results in a response you can live with for the given rpm range. I.e. if the engine feedback does not hurt to much. I think no-one can calculate the ideal percentage for you.