Zundapp K800

Data Sheet Zündapp K800

functioning

four-stroke

Number of cylinders (pieces)

4

Bore (mm)

62

Stroke (mm)

66.6

Displacement (cc)

804

Compression ratio

1:5.8

power of the motor in HP at revolutions / min.

22/4300

speed

Vmaxcalculation

piston clearance (mm)

left: 0.1, right: 0.09

valve assembly

standing

valve clearance when engine is cold (mm)

outlet: 0.25; intake: 0.25

Alternator

Bosch REA 50/6

ignition timing

automatically

Carburetors

Amal5/406 P or Amal M74 / 431 P

translation for rear-wheel drive

solo: 7:39, SW: 6:38

gear ratio 1st gear

1:3

2nd geargear ratio

1:1.8

gear ratio 3rd gear

1:1,13

Gear ratio 4th gear

1:0,88

Wheelbase (mm)

1405

Maximum length (mm)

2165

Maximum width (mm)

815

Maximum height (mm)

900

Seat Height (mm)

720

Ground clearance (mm)

120

Turning circle (m)

4.6

Tire Size

3.50 – 19

tire pressure front / rear (bar)

1.5 / 1.75

maximum allowable load (kg)

200

Fuel tank capacity (liters)

15

Fuel consumption (L/100km)

5.5 Solo

Oil Consumption (L/100km)

0.15

Weight with full fuel tank (kg)

212

Type of lubrication

pressure circulation lubrication

K 800 chassis and engine numbers

von

bis

PS

Hubraum/cm³

Baujahr

140001

140185

20

791

1933

140186

140847

20

791

1934

140848

142606

22

791

1935

192001

192570

22

791

1936

192571

194719

22

791

1937

194720

196965

22

791

1938

Schlagzahlengröße Nameplate: 3 mm

stroke Size of frame and engine: 5 mm

All information subject tomodel:.

stock parts for Zündapp motorcycles

motorcycle  K 500, KS 500, CP 500, K 800 and K 800 W

 

Description

Number

Type of bearing

bore

dia

width

point of use

6204 Z

1

Radiaxlager with sealing washer

20

47

14

front wheel, left

6205 Z

1

Radiaxlager with sealing washer

25

52

15

front wheel, right

I-92422 a

2

longitudinal bearing disc

26.5

43.06

5

control head, above

6mm ball

18

ball for I-92422 a

6

Control head, above

I-98903

1

angular contact ball bearing disc

26.5

47.06

5.5

I-98904

1

angular contact ball bearing disc

26.5

47.06

5.5

control head, down

7 mm ball

16

ball for I-98903 and I-98904

7

I-82456

52

needle

3

18.8

rod bearings only for K 500

I-82455

26

needle (per cylinder)

3

18.8

rod bearing

I-97253

1

cylindrical roller bearing

30

62

20 / 15.6

crankshaft, front, only for KS 500 and PPS 500

6207 Z

1

Radiaxlager with sealing washer

35

72

17

crankshaft rear

needle 2.5 x 15.8

136

needle

2.5

15.8

rocker arms, only for KS 500 and PPS 500

6205/22

1

Radiaxlager

22

52

15

alternator forward, only for K 500

NL 25 (DIN 5412)

1

cylindrical roller bearing

25

52

15

alternator, front, only for KS 500 and PPS 500

R 9

1

Radiaxlager

9

26

8

alternator, front, only for K 800 and K 800 W

6205 (DIN 625)

1

Radiaxlager

25

52

15

transmission main shaft, front

6303 (DIN 625)

3

Radiaxlager

17

47

14

Gear

3303x or I -93 128

1

Double-row angular contact ball bearings

17

47

22.2

pinion shaft, front

NM 17

1

cylindrical roller bearing

17

47

14

pinion shaft, center

6204 Z

1

Radiaxlager with sealing washer

20

47

14

rear, left

6206 Z

1

Radiaxlager with sealing washer

30

62

16

rear wheel, inside

6205 Z

1

Radiaxlager with sealing washer

25

52

15

rear, right

All information without guarantee!

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content:

A) Zundapp two-stroke

  1. motorcycles,as the two-stroke engineworksengines??

  2. What are the advantages of three-phase motor against the nose piston engine

  3. When the ignition occurs at the two-stroke engine

  4. Which arrangement, the two-stroke

  5. Whatcooling have two-stroke engines?

  6. What material are the pistons what

  7. are the piston pin stored?

  8. What is the lubrication of two-stroke engines?

  9. When the two-stroke engine is four-stroke,

  10. whythe two-stroke engine Strikes Back

  11. Howcan I protect when two-stroke engine piston and cylinder before abnormal wear?

  12. Keep on muffler something be changed?

  13. carburetor

  14. air filter

B) Zündapp four-stroke

  1. motorcycles,as the four-stroke engine works?

  2. Which arrangement, the four-stroke engines?

  3. What is the firing order of the two-cylinder engine

  4. Howis the firing order of the four-cylinder engine?

  5. What is the lubrication of four-stroke engines

  6. Whatdo I need to know about the valve clearance?

  7. How to edit valve and valve seats,

  8. whythe four-stroke engine Strikes Back, and especially when-shows?

  9. carburetor

  10. air filter

  11. camshaft

C) General

  1. How to maintain the battery

  2. Whatmust know of the preignition

  3. Whatyou must know from the ignition key?

  4. Like the alternators are driven?

  5. How many watts consumed the high beam and the glare?

  6. When illuminated while driving the warning light on?

  7. When burning the backups,

  8. whycan despite the correctly chosen spark plug ignition problems occur?

  9. When the motor is too hot whatthe

  10. are  fuel consumption figures have been set from the factory?

  11. Which couplings we use?

  12. What gear do we use?

  13. point exits the exhaust smoke,

  14. whyjump the engine hard to

  15. ?How relieved you start

  16. How to remove the compression ring

A) Zundapp two-stroke motorcycles

1) Howworks the two-stroke

simple cross flushing-Type Aengine?..

gas inlet and gas outletby cast into the cylinder channels

precompression12:35 atmospheres below the piston. Compression and combustion process above the piston.

Controlled by opening and closing of channelsby the piston.

controlledOver flow through piston with deflecting.

Type B – Three power flushingchannels…..

gas inlet and gas outlet by cast into the cylinder channels

precompression 0.35 atm below the piston

compression and combustion process above the piston

control by opening and closing of the channels by the piston

Over flow through transfer duct and two opposing auxiliary  offset by 90 degrees to the overflow channel.

main current draws colliding flows upward and pushes the burned gases to the exhaust channels. piston flat, cylinder head curved spherically

A) Zundapp two-stroke motorcycles

.?2) What are the advantages of three-phase motor against the nose piston enginehas

cheaper;;pistonsimple, flat, easier and less expensive

Combustion chamber

compression can be set higher,level

lowflushing losses, therefore higher efficiency, with

lower

heating;.better combustion and therefore less residue

A) Zundapp two-stroke motorcycles

3) When the ignition occurs when two-stroke engine4.5?

with every rotation of the Kurbeiwelle once and while at the machine to 200 cc cylinder capacity  mm before top dead center (see technical table). Ignition timing is adjustable in two-stroke engines with the exception of K 350 and KK 350 by hand.

A) Zundapp two-stroke motorcycles

4) Which arrangement, the two-stroke engines?

The cylinder is vertical in the frame.

The motor rotates at the Zündapp motorcycles chain drive in the direction of travel.

“shaft drive transverse to the direction of travel”.

 

A) Zundapp two-stroke motorcycles

5) What cooling have two-stroke

engines?-aircooling. Cylinders (gray cast iron) and cylinder head (light metal) are provided with large cooling fins.

A) Zundapp two-stroke motorcycles

6) What material are the pistons?

Special aluminum alloy. The piston windows are oval ground. To prevent damage to the three piston rings by snagging in the exhaust and transfer ports, the piston ringsare secured by dowel pins from twisting.

A) Zundapp two-stroke motorcycles

7)How are the piston pin stored?

Floating, ie the piston pin fits into the bushing inlet of the connecting rod in the cold state. The aluminum piston has to be heated to about 80 degrees Celsius before installation in an oil bath or on a hot plate. At the operating temperature, the flask is heated and expands in his eyes from so much that the claim secured by retaining rings piston pin floats.

 

A) Zundapp two-stroke motorcycles

8) What is the lubrication of two-stroke engines?

Mixed lubrication. During this break, we recommend a fuel Oelgemisch 1:20, later 1:25are:.

The advantages of this lubrication

No oil pump, no oil tank, no Oelleitungen and good matching conditions on the engine load. One can use one and the same Oelsorte in summer and in winter.

We recommend Gargoyie mobile oil BB or Zwo-ta-mix, either because the tests performed and the results obtained form the basis for our constructions.

A) Zundapp two-stroke motorcycles

9) When the two-stroke engine is by:

four-stroke,the four-stroke racing is periodically exposing the firing order

Excessive fuel nozzle to rich mixture, condensation of the fuel mixture in the engine is cold, insufficient filling in for a warm engine, excessive Verbrennungsrücksände in the exhaust ducts or in the muffler .

 

A) Zundapp two-stroke motorcycles

10) Why the two-stroke engine Strikes Back?

These observation at shows, or even while driving is due to push-back of the combustion mixture through the carburetor. They say the carburetor is popping or are:..

sneezes,the error sources

Insufficient fuel oil mixture by clogged supply to small nozzle, incorrect air or the wrong spark plug, fault in the ignition system or large combustion residues

A) Zundapp two-stroke motorcycles

11) How can I protect when two-stroke engine piston and cylinder before abnormal wear?

There must never be too lean the fuel mixture. For longer full-speed drives often the air twist grip is too close to a very short time.

The air filter must be kept in order.

When stopping the engine choke lever close, bring before turning off the ignition the engine to higher rpm, full throttle and then immediately turn off the ignition. This causes the motor housing and the cylinder fills with strong overly rich fuel-oil-air mixture which cylinder liner and engine parts covering with a strong oil film. Due to the cooling of the engine caused condensates inside. If the oil film is not strong enough as they attack the cylinder barrel and the bearing points. The result is rust.

During motor standstill the throttle grip is too close.

 

A) Zundapp two-stroke motorcycles

12) Must at muffler something be changed?

No, otherwise violation of the police regulations. Also decreases particularly in two-stroke engines, the necessary back pressure. Their performance drops and the carburetor setting is no longer correct.

 

A) Zundapp two-stroke motorcycles

13) carburetor.

In mixed lubrication, it is necessary to clean the carburetor often. The fuel admixed oil is reflected in prolonged shutdown of the machine in the holes and channels and may require a narrowing of the cross-sections cause. The washing of the carburetor with gasoline alone is sufficient.

At the factory setting of the carburetor nothing can be changed. The only exception to this is the readjustment of idling, what happens to the idle air screw and the throttle stop screw.

A) Zundapp two-stroke motorcycles

14) air filter.

Proper care of the air filter protects the cylinder, piston and engine parts from abnormal wear.

During the dry and dusty season and after driving on bad roads the filter needs daily, but at least cleaned after 300 to 500 milesfollows:..

This cleaning is performed as  The metal wool wetting filter is

  • unscrewed and rinsed vigorously in a container with gasoline

  • to dry down on the warm cylinder and then with blown by compressed air or with the air pump1.

  • prior to installation in an oil-kerosene mixture 1:  submerged, drain.

B) Zündapp four-stroke motorcycles

1) How does the four-stroke engine?

Gas inlet and gas outlet via valves controlled by tappets (KS 500 by pushrods and rocker arms) of the cam while.

The 4 measures carried above the piston. Piston flat, only with KS 500 slightly arched.

Ignition takes place every second revolution of the crankshaft. (Stroke)

B) Zündapp four-stroke motorcycles

2) Which arrangement, the four-stroke engines?

The engine is rubber-mounted suspended in the frame. The cylinders are arranged opposite to and transverse to the direction of travel (flat engine).

Direction of rotation of the crankshaft, as seen in the driving direction, counterclockwise.

The advantage of this arrangement is the balanced operation and the excellent cooling.

The transversely arranged to the direction of boxer engine is the best solution for air cooling, which can be reached without additional fan since the cylinders are situated in the free flow of air.

B) Zündapp four-stroke motorcycles

3) What is the firing order of the twin-cylinder engine

this?takes place at two cylinders when the piston reaches top achieve dead center, ie, the one piston then starts, power stroke while the other is done with the exhaust stroke. This eliminates the distributor.

During two-cylinder engine comes on every revolution of the crankshaft ignition.

B) Zündapp four-stroke motorcycles

4) What is the firing order of the four-cylinder engine?

Track-1

cylinder front right

4 cylinder rear left

2 cylinders Left front

3 cylinders right behind

The four-cylinder engine comes on every half revolution of the crankshaft ignition.

 

B) Zündapp four-stroke motorcycles

5) What is the lubrication of four-stroke engines?

through positive drive gear oil pump. In the motor housing cast channels the oil lead to the bearings for the crankshaft and camshaft.

K500 and K800 When it is pressed from the front main bearing of the crankshaft drilled and distributed to the crank pin. The outer two crank webs at KS500 are behind over and provided with holes for the crank pin. In the back rotation, the oil is injected and passes through the centrifugal force to the crank pin-.

K500 and K800 have Oelpumpendruck 2  2.5 atm at n = 3000 rpm of the engine. The pressure can be obtained by an adjustable ball valve through which excess oil flows back into the oil pan during operation of the oil pump to be regulated-..

at the Oelpumpendruck KS500 is 1  1.5 atm at n = 3000 rpm of the motor

by the in the sump superior suction strainer is sucked in the oil and pressed to the lubrication points.

In shunt an Oil filter is on, which every 5000km must be changed.

In the motor housing of K800 at the oil change 2500 cc, filled with KS500 and K500 2000cc,

  • oil change after 500 km

  • oil change after 1000 km

  • oil change after 2000 km

 

then regularly every 2000 km.

The engine must be flushed with fresh engine oil, not with flushing oil or petroleum. Residues of these detergents would reduce the lubricity of the neueinzufüllenden motor oil.

 

B) Zündapp four-stroke motorcycles

6) What do I need to know about the valve clearance?

The intake valve and the exhaust valve is 0.15 mm 0.20 mm game KS500 0.20 mm bezw . 0.25

mm.Valves are adjusted on a cold engine, so that the material expansions occurring during the heating of the motor are compensated. This setting is for new or rebuilt engines to check the first time after a distance of 100 km and, where appropriate, to set the record straight.

Machines that are exposed to high stresses (off-road use), one valve clearance to 0.20 mm can be used without interference for the motor bezw . Set 0.25 mm.

B) Zündapp four-stroke motorcycles

7) How to edit the valve and valve seats?

  1. Lets after the engine power, yet the setting of the valves is in order and they do not pinch in the guides, then you need the valves for post-processingexpanded as

    1. Remove cylinder heads,

    2. With clamp for valve springs ZWN 239 people (Zündapp tool number 239) to compress the valve springsclean:..

    3. collars removed, so that the valves and springs can be removed

  2. check valve guides and follows.Have the valve stems in the guides to big game, the latter using the firing pin ZWN must be 307 replaced. The new channels are connected to the reamer DIN 206/7, vorzureiben 92 mm, and then be wiped with the reamer DIN 206/6, 012 mm.

  3. The valve seat is machined with special mills ZWN 194a and polished with the grinding spindle ZWN 132.

  4. The width of the valve seats which 1.0 mm should be up to 1.5 mm, with the routers 194a and 195a ZWN regulated.

  5. Valve guide for the exhaust valve is then reamed with a reamer DIN 206 / B, 035 mm from the valve side of the reamer ZWN 338 deep conical ready rubbed onto 10 mm. A machining of valve seats without proper guidance serves no purpose.

  6. Assembly is in reverse order.

  7. Valve cone itself are to grind the most appropriate on a special grinding machine in accordance with an angle of 45 degrees.

 

B) Zündapp four-stroke motorcycles

8) Why does the four-stroke engine back and especially

when-shows?,the engine is too cold or has too much ignition advance. The valves or the valve clearance are not in order.

 

B) Zündapp four-stroke motorcycles

9)

carburetor.,The Zündapp K800 motorcycle is equipped with a pump carburetor which allows good acceleration at low engine range. The operation of the pump is with the nozzle needle, which is attached to the gas valve. In the event of abrupt opening of the slide each time inject 1.5 cc of fuel into the mixing chamber of the carburetor.

K500 and KS500 are equipped with carburetors without a pump. At the factory setting of the carburetor nothing can be changed. The only exception to this is the readjustment of idling, what happens to the idle air screw and the throttle stop screw.

 

B) Zündapp four-stroke motorcycles

10) air filter.

Proper care of the air filter protects the cylinder, piston and engine parts from abnormal wear.

During the dry and dusty season and after driving on bad roads the filter needs daily, but at least cleaned after 300 to 500 milesfollows:..

This cleaning is performed as  The metal wool wetting filter is

  1. unscrewed and rinsed vigorously in a container with gasoline

  2. to dry down on the warm cylinder and then with by blowing compressed air or with the air pump1.

  3. prior to installation in an oil-kerosene mixture 1:  submerged, draingiven..

B) Zündapp four-stroke motorcycles

11) camshaft

to adjust the camshaft or for controlling the valve timing 0.4 mm valve clearance must be  be. The Ueberschneidungsmittel is then at K500 and K800 exactly at top dead center and KS500 3 degrees before top dead center.

 

C) General

3) What you have to know from the ignition key?

Stuck key deep enough into the notch until the warning light comes on. After the ride, pull out, otherwise the battery discharges through the coilkey.

Pocketed  Charging lamp is on, put the engine in gear, charge lamp goes out, battery invites totwist.

key  Burning light. Dimming for high beam from the handlebar.

C) General

4) As the alternator are driven?

For K800 by gear. For shock-free drive into the drive gear, a damping spring flat steel and from model year 1937 has placed a rubber washer.

For the other models, the armature of the alternator is overhung mounted on the crankshaft.

C) General

5) How many watts consumed the high beam and the glare?

In 50 W audio system

remote light 35 watt

low beam 35 watts.

During the 30 wattsystem

remotelight 20 watt

low beam 20

watts.,it is wrong in the 30 watt system to improve the high beam instead of the 20 watt double filament bulb incorporate a stronger bulb. The filament of the stronger bulb is then no longer exactly in the focal point of the mirror. Thus in the light cone creates a big dark spot. The light is apart scattered and significantly shortened the range.

C) General

6) When illuminated while driving the warning light on?

Alternator is not charging, regulator is defective, ground terminal of the switch is bad, the coals of the alternator are not good at (sticking in the guides ), the fuse is defective or not well clamped (loose contact).

C) General

7) When burning the fuses?

(Only the Bosch headlights have fuses).

The voltage regulator is defective,

switching errors are,

lines are short.

Unvorschriftmäßige fuses should not . use

fuses with higher amperage or Staniol damage the controller, the cables and the alternatorcarburetor.?

8) Why can despite the correctly chosen spark plug ignition problems occur

Incorrect setting of the

Main jet too large or too small, as idle jet, idle adjustment is set incorrectly, air filter dirtycarburetor.

error on the

snagging the swab, seat of the float needle is knocked out, float defective fuel level too high or too lowengine.

error on the

worn cylinders and pistons, piston rings firmly burned, wrong valve setting, the venting out of order, seals the suction line not work properly. Oil level is too high for four-stroke engines,

fuel oil mixture to fill in two-stroke engines

or Oelsorte unsuitablecause:..

Oelpumpendruck too high,

too much ignition retard,

capacitor or coil defective, burned breaker contacts

spark plugs, which are too low in Glühwert

Ignitions, abnormal stress on the bearings get hot the cylinder, poor performance, strike back in the carburetor, great fuel economy, braking the motor.

For this reason, for example, if a spark plug fouled, do not just install one with a lower Glühwert, but always the root cause of Oelüberschusses . determine

spark plugs, which are too high in Glühwert, oiling very easily. . Poor starting, poor performance, great fuel economy and launching system according downhill are the sequelae

from the face of the spark plug, you can read the following:

insulator rusty brown:

surface smooth, bright and right without special license plate, candle in order, carburetor adjustmentgray.

insulator pale

Surface smooth burned off center electrode, it andon the insulator

set too leanGlühperlen, carburetors,

gaskets on the motor housing, cylinder, etc. check Candle in Glühwert too low, switchblack-black-brown.

insulator

surface dull sooty, too much fuel, possibly unsuitable fuelblack.

insulator

surface convex, crusty, and oily deposits (Oelkohle), piston and cylinder badly worn piston rings adhere to the body, piston ring gap is too large,connecting rod bearing laterally too much slack,

:..considercompression, view new piston rings, let off excess cylinder, remove Pleuelspiel

engine oil with fuel interspersed, oil change, candle is too high in Glühwert, replace it.

C) General

9) When the engineis too hot?

Haupfdüsetoo small Kraftsfoffzufuhr insufficient nozzle installed, cylinder head gasket is damaged, misplaced combustion residues in the compression chamber, channels, unsuitable Oelsorte, too little pre-ignition, cooling fins dirty-.?

C) General

10) How are the fuel consumption figures have been set at the factory

with a good engine has been run at  20 degrees Celsius, average speed 60 km-hour And of continuous driving, on a good level road .

Fuel consumption increases:

  1. If long distances at high speed and full throttle to be coveredfuels….

  2. in the urban and the mountainous terrain

  3. At lasting starting in city traffic

  4. through permanent establishment and zadelka turning the handle for the throttle slide in K800 with pump carburetor

  5. When using  for which the carburetor is not regulated (use gasoline benzene mixtures, such as Aral, Esso, dynamin, etc.).

  6. When non-conforming spark plugs.

  7. At very low and very high temperatures.

  8. At ignition noise.

  9. filthy When the air filter.

  10. In installed mufflers.

  11. When not properly sealed or burned valves.

  12. When fully worn piston or burnt-piston rings.

C) General

11) Which couplings we use?

Derby All models have multi-pane metal discs couplings. Derby and Derby E-Luxury 200, built in 1934 have Korklamellenkupplungcork.

single disc,

K200

KK200

K350

KK350

K500

twin-disc clutch, Cork:

K500

K800

For all Derby models is important to note that the lower of the two connecting holes between the gearbox and clutch housing is to (eventually sealed with a cork and then pour into the transmission only 550 cc thin liquid Gargoyle Arctic Mobiloel).

 

C) General

12) Which gear we usemouth:.

Derby All models have Zündapp three-speed gear transmission

Zündapp four-speed chain transmission connected by

K200

KK200

K350

KK350

K500

KS500

K800

 

C) General

13) When exits the muffler smoke fromengine:

a) two-stroke

  1. The fuel mixture is too full, so it will be held incomplete combustiontransmission..

  2. Stuck piston rings, (stronger cylinder and piston wear)

  3. engine sucks from the  Oil from (only possible for the Derby models built before 1935, see paragraph 11)engine.

 

b) four-stroke

  1. oil level in the engine is too high or inappropriate Oilguides…

  2. Stuck piston rings, (stronger cylinder and piston wear)

  3. Worn plunger and

  4. Large side Pleuelspiel.

 

C) General

14) Why does the engine difficult to

  1. pilot jet is dirty, the idle screw is too far

  2. open.,the engine gets too poor fuel mixture.

  3. occurs false air through faulty seals.

  4. jumps?The breaker lever will hang the contacts in breakers are no longer properly.

  5. Capacitor is damaged, the insulation of the wires is not

  6. flawless.,the battery is too weak.

  7. gas and air valves are not adjusted properly.

  8. contact springs in the switch are lame or damaged.

  9. piston rings are firmly burned.

  10. The Valve clearance is insufficient, (badly sealed or burned valves).

  11. pilot light is not lit.

C) General

15) Howfacilitates starting?

not initiallyignition plug, to overflow carburetor, open the gas valve 1/3, pass several times, throttle valve 1/2 open, close, air slide, put ignition on late ignition, switch on the ignition, depress strong.

Information is from zuendappboxer.de.

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