63861799

generator/electronic ignition for JAWA 638-640, 632 and

System 638 61 799
CZ 472/6
=> €/$
(with stock 3 phase 12 V generator)
Magnet based generator with integrated fully electronic ignition.
Output 12V/210W DC. Solid state ignition with own power supply
from within the system. Replaces 3-phase magneton
generator, points (or older electronic ignition), condenser, ignition
coils. You may drive without a battery, if you want. There is no
need for changes on engine casing. Not fitting in engines with
Ducati magneto.

• all parts are new

• 3 phase magneton generator is no more available
• you may drive without battery
advantage over original system • very stable ignition with solid spark
• better starting, better fuel burning
• no worry anymore with setting points

• assembly instructions
• wiring diagram
documentation • parts in the pack (foto)
• information on driving without battery

• JAWA 638 with the system

• closer view at the new system in the engine
• the new ignition coil on the bike
photos
• the new regulator on the bike
• position of the new stator on the engine

VAPE spol. s r.o., Bílanská 1647, 767 01 Kroměříž, Czech republic

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 63861799

Assembly instructions for system 638 61 799 00 Version 08.02.2010

If you can install and time a stock ignition and possess basic mechanical skills, you
can install a VAPE system!
If you never have worked on your ignition, better have it done by someone who
knows.
VAPE can not monitor the compliance to those instructions, nor the conditions and methods of
installation, operation, usage and maintenance of the system. Improper installation may result
in damage to property and possibly even bodily injury. Therefore we assume no responsibility
for loss, damage or cost which result from, or are in any way related to, incorrect installation,
improper operation, or incorrect use and maintenance. We reserve the right to make changes
to the product, technical data or assembly and operating instructions without prior notice.

Please read these instructions fully and carefully before starting

work on your motorcycle
Please bear in mind that any modification of the material as well
as own repair attempts which have not been agreed with VAPE
may result in a loss of warranty. Do not cut off wires. This leads to
a loss of reverse polarity protection and often results in damage
to electronics. Also, please take note of the information provided
on the information page for this system. Check that what you
have bought really corresponds to the motorcycle you have.
Wrong ignition settings may damage your engine and even hurt
you during kickstart (violent kickbacks). Be careful during the first
test runs. If needed change settings to safer values (less advance).
During assembly check carefully that the rotor (flywheel) does not
touch the stator coils or anything else, which may happen due to
various circumstances and lead to severe damage.

Designated use
This system is designated to replace stock dynamo/alternator &
ignition systems in vintage and classic motorcycles whose engine
IMPORTANT: characteristics have not been modified aftermarket. This system
is not a tuning system and it will not bring significant increases in
engine output. It does however significantly enhance
roadworthiness and comfort by offering better lighting, better
function of side indicators and horn and, compared with the aging
stock systems, increased reliability. As our system does not
tamper with engine characteristics it does not increase emission
of gaseous pollutants and noise. In most cases emission of
pollutants should even be reduced due to better combustion. If
used as designated the system therefore will not normally infringe
the existing legal status of the motorcycle (this statement is valid
for Germany, for other countries, please check locally against your
road licensing regulations). This system is not suitable for use in
competition events. If used other than the designated way,
warranty will be voided and it might well be that you do not
obtain the desired results or, worst you loose legal

VAPE spol. s r.o., Bílanská 1647, 767 01 Kroměříž, Czech republic

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 63861799

roadworthiness.

The charging system is only suitable for use with rechargable

12V (6V systems 6V) lead-acid batteries with liquide electrolyte
or sealed lead-acid batteries, AGM, Gel. It is not suitable for use
with nickel-cadmium, nickel-metal-hydride, lithium-ion or any
other types of recharchable or non rechargable batteries.

This is a replacement system and not a copy of the stock

material. The parts in this system therefore look different
and might fit differently (notably ignition coil and regulator)
requiring some adaptation by you.
During assembly imperatively start with assy of engine based
parts to see that those really fit before you start fitting the
external parts. In many cases customers assemble those first and
thereby often modify them in breach of warranty which renders
them unfit for renewed sale. Replacing old ignition systems is not
a matter of taking something from a supermarket shelf as there
have been very many types, versions and possibly unknown
aftermarket modifications which harbour plenty of room for
error.

Our systems are NOT tested for use with third party electronic
devices (such as GPS, mobile phones, LED lighting etc)and may
cause damage to such parts. Possibly existing electronic
tachometers will not work with the new system. Read our
information for suitable solutions. Possibly existing safety
switches and electronic valve controls are not supported. It might
be that your motorcycle was originally equipped with an ignition
that did limit top speed for legal reasons. The new system does
not have such a facility, so check your legal situation beforehand.

If you have no expertise for the installation have it done by an

expert or at a specialist's workshop. Improper installation may
damage the new system and your motorcycle, possibly even lead
to bodily harm.

Before you order a system, please check whether a puller tool for
the new rotor is included in the kit. If not, better order it at the
same time. You might want to order light bulbs, fuse, horn,
flasher unit etc.
Never use anything other than the recommended puller tool to
pull the new rotor again. Damage to the rotor as a result of use of
other tools or methods is not covered by warranty.

The rotor is sensible to blows (including during transport). Before

assembly, please always check for damage (on rotor without
magnet plastification try to push the magnets aside with your

VAPE spol. s r.o., Bílanská 1647, 767 01 Kroměříž, Czech republic

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 63861799

fingers). After impact the glued in magnets might have broken

loose, sticking to the rotor solely by magnetic force, so that one
does not notice right away. During engine run the damage would
be considerable. Before placing the rotor onto the engine, please
make sure that its magnets have not collected any metal objects
such as small screws, nuts and washers. That equally would lead
to severe damage.

If you have access to the Internet, best view those instructions

online. You get larger and better pictures by clicking onto them
and possibly updated information. System list at
http://www.powerdynamo.biz

You should have received those parts!

Please observe that the sensor (pickup)

is only loosely mounted by us, as you
have to set its gap. Tighten the screws
carefully after setting.

To pull the old rotor, you will need a puller

tool M10x90 (part-no.: 70 80 899 90 -Not
provided!-).

Notes on wiring:
Experience shows that in the course of time nearly every motorcycle undergoes changes to its
wiring. As a result, wire colours and wires themselves on your bike might differ to those we
describe. In case of doubt, please consult the original wiring diagrams for MZ (e.g. on
www.ostmotorrad.de).

Disconnect your battery and take it out of the motorcycle for the time of work. For driving
without battery, please observe our information on driving without battery.

Disconnect all cables from your old generator, regulator, regulating relay and the
ignition coils and remove those parts. You may pull your old rotor from the crankshaft
by means of a puller screw M8x90.

VAPE spol. s r.o., Bílanská 1647, 767 01 Kroměříž, Czech republic

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Check whether the neutral gear wire had been running through the pieces of harness you
are going to remove. If so, if will get removed and you will have to install a new one.

Note: When you make use of the non-

battery option, you will need to install a
high capacity condenser (22.000�F) in
place of the battery to smoothen the
pulsing voltage. Otherwise your flasher unit
will go heywire.

Caution: It might be that your local

road traffic regulations demand the
existence of a parking light facility (and
hence battery).

Place the premounted stator unit onto

the engine. The pickup module will
show towards about 11 o'clock. It will
fit however only in one position, so
nothing can go wrong there.

Place the new rotor onto the crankpin.

Make sure that the arresting pin sits in the
rotor's groove and the rotor sits tighty on
the shaft. To pull the rotor again (when
needed) use a simple screw M12 as a
puller.

VAPE spol. s r.o., Bílanská 1647, 767 01 Kroměříž, Czech republic

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 63861799

Turn the rotor slowly by hand and check

clearance between the sensor and one of
the rotor noses. This has to be ca. 0,4mm.
You may adjust the gap by loosening the 2
holder screws of the sensor and shifting it a
little.
Do not forget to tighten the 2 holder
screws of the sensor carefully. If loose, the
sensor will get into contact with the rotor
and will be destroyed. It is a good idea to
check secure fitment from time to time.

Check that the base plate for the pickup sits in its middle position. This position is highlighted
by a marking. Normally that will do for timing. Should you need a different timing position,
loosen the holderscrew of the plate and shift it accordingly. A shift clockwise will bring less
advance, a shift anticlockwise more advance. Typically that should be 2.7mm before top dead
center (BTDC)

Mount the regulator/rectifier unit

somewhere on the bike, say where the old
rectifier had been.

Fasten the new ignition coil with its holder

at the frame under the tank. Try to put this
coil as far as possible to the front (and
away from the heat of the cylinders).

VAPE spol. s r.o., Bílanská 1647, 767 01 Kroměříž, Czech republic

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 63861799

Modify the existing wiring of your JAWA 638-640 as follows. This is important. If do you not
do this the new regulator will be damaged and the system might not start!

Disconnect the charge control light from

ground (the red pilot light in the cockpit)
and reconnect it to switched plus (pin 15 of
the ignition lock). Should you want to drive
without battery you need not do this
change. In that case you will leave the
green/red wire from the new regulator
(see below) unconnected as the charge
control will not light anyway due to the
missing battery.

Disconnect the engine stop switch at the

righthandside of the handlebar from plus
and reconnect it to ground.

The other wire from the switch,

formerly running to the ignition coils
will remain, it will be reused and
connected to the blue wire of the new
ignition coil.

You have to switch now reversly. "ON"

is now "OFF" - and vice versa!

Connect the parts as shown in the respective wiring diagram!

For our standard DC regulator (95 22 699 06), use the wiring diagram 72xk12:
For our DC regulator with built in smooting condenser (73 00 799 50), use additional the
wiring diagram reg_102:
To facilitate wire exit through the often small openings in the engine casing, the plastic plug of
* the generator's wiring that leads to the ignition coil have not been put onto the wire terminal.
You should place the plug there only once all has been properly installed on the engine side.

VAPE spol. s r.o., Bílanská 1647, 767 01 Kroměříž, Czech republic

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 63861799

Look for the ignition coil with its female plug

and the three wires (red, yellow and white).

Put the provided 4-position plug housing

onto this plug and insert the three wires (red,
yellow and white) from the generator. Make
sure that the terminals engage securely in
the housing and that you connect:

• red to red
• yellow to yellow
• white to white

Should you need (or want) to get the terminals out of the plug housing again, enter a paper
clip from front next to the terminals and push the little barb aside. Than pull the wire out.
* Connecting VAPE alternator to lighting circuit (via regulator):

The 2 black wires running from the stator coil

carry the voltage for lights, horn, flashers etc.
They have nothing to do with ignition.

This voltage (something between 10 and 50

volts AC) has however to be stabilized
(regulated) and for most uses rectified into
direct current (DC) as it primarily is
alternating current (AC).

For this we offer 2 different regulators:

Attention: Any confusion between plus and minus (with the DC versions) leads to
immediate destruction of the regulator. This will not constitute a warranty case as it is
negligence! One can recognize a burnt regulator mostly by its sharp smell.

* Regulator type 1: with standard DC regulator (95 22 699 06), use the wiring diagram 72xk12:
The new regulator/rectifier has a compact plug
with 6 positions, of which one is not used. A
female plug cover fitting to this plug is
* delivered. Into this female plug you have to
insert the following wires (which have terminals
that snap into the plug):

... connect to pins 1/4 of the new regulator

The two black cables leading from the (from there equally black wires lead inside
generator ... the unit). It does not matter which wire
connects to which of the both terminals (1/4)
as they carry alternating current.
The new brown cable with the round eye ... connects pin 3 of the regulator unit (from
terminal ... there equally a brown wire goes inside the

VAPE spol. s r.o., Bílanská 1647, 767 01 Kroměříž, Czech republic

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 63861799

unit) with the negative pole of the battery or

(in case you drive without battery) to ground
(chassis).
... connects to pin 5 of the new regulator
The new red cable with the round eye (from there equally a red wire goes inside
terminal ... the unit). Here your regulated positive
voltage comes out to connect to battery plus,
Take care: or (in case you drive without battery) to the
Wrong polarity will damage the electronics! voltage input terminal of the main switch
(ignition lock, German bikes: pin 51/30).
Make sure that you have a 16A-fuse between battery and vehicle circuitry.

... is for the charge control light. You

connect there the wire that formerly did run
from the control light to the original
The green/red wire at pin 6 of the new
regulator.
regulator ...
Sure that this control only functions with a
Remark:
battery present. Should you drive without
Until November 2007 this wire has been a
battery but still connect the wire, you will
single wire outside the compact plug.
see that the light glows even as the generator
generates voltage. So without battery, do not
connect it.
The charge light control function is based on a transistor switch and is an additional function.
Even if that should fail, the regulator might still be in ok working condition. Simple check: have
the engine running, turn lights on, disconnect the battery. If you have bright lights the unit is ok.

Regulator type 2: with DC regulator with built in smooting condenser (73 00 799 50), use
*
additional the wiring diagram reg_102:

• the 2 black (sw) wires are the AC input

from the alternator (as it is AC it does
not matter which black to which black)
• the red (rt) wire is the 12V DC output
plus
• the brown (br) wire is gound, internally
connected to housing

VAPE spol. s r.o., Bílanská 1647, 767 01 Kroměříž, Czech republic

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 63861799

Connected to ground - it will stop ignition!

Remains the blue (sometimes blue/white)
This type of wiring is used in motorcycles
wire at the ignition coil. This is the kill (cut-
which originally already had magneto
off) wire.
ignition and therefore switched off by
shortcircuiting against ground.
Note:
* Should you experience ignition failures,
Those vehicles have by design a main lock
disconnect as a first measure this blue wire.
(or some kill switch) that connects a pin to
In many cases that will permit you to get
ground when in OFF position (German
mobile again (particulars see: technical
bikes: pin 2). The blue(/white) wire of the
help)!
ignition coil will be connected here. In that
way the cut-off works like previously.
Screw the high tension (ignition) cable ...
... into the ignition coil and pull over the rubber
seal before mounting the coil (it will be easier).
* Please do not use any spark amplifying
cables, such as "Nology supercables" or "hot
Please do use the cable arriving with the
wire". This will disturb the system and
pack and not any old cable.
possibly damage it.
You will do yourself a favour to treat your bike to new spark plugs and spark plug sockets
(preferably some between 0-2kOhm). Plenty of problems are to be traced back to "apparently
good" (even completely "brand-new") sparks plugs, terminals and cables.
Do not use spark plugs with an intern suppression resistor. NGK (e.g.) offered such spark plugs
coded with an "R" (for resistor).

In our twin outlet coils both ends of the

secondary go to the spark plugs.

Typical resistance between both exits is

*
6.2kOhm. Both exists fire at the same time
(as many twin systems do). Sparks will be
polarised however at a 180 degrees
difference which might manifest when you
strobe it.

Ignition will only work correctly if both plug terminals are connected. You may not test one side
with the other open (not sitting on the mounted spark plug). This is because (effectively) each
exit uses ground from the other. That means also that both plugs are working in serial, adding
resistances, so better use low resistance spark plug (resistor) sockets and make sure they are
good. If in doubt, measure resistance on a hot socket (warm it up before measuring).

Is the flow from ground of one side via spark plug there, via coil, to the other spark plug
and its ground interrupted you get no spark - on neither side. If you really want to test only
one side, put the HT wire of the other to ground (earth it) than it will work. Sometimes a
coil deprived of its ground from the other side searches for a substitute - with some solid
fireworks around it to the chassis.

VAPE spol. s r.o., Bílanská 1647, 767 01 Kroměříž, Czech republic

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 63861799

Finally - and before installing the battery and before the first kickstart - please re-
check carefully all connections and fitments against the wiring diagram. Do check battery
and light bulbs for correct voltage (12V).
*
Should something not work, please consult our trouble-shooting guide on our homepage.
As a first step disconnect the blue wire from the coil and re-test.
IMPORTANT: During crank shaft repair the dynamo shaft is often machined and gets shorter.
The result is a rotor sitting lower, possibly touching now with its rivets the stator coil. The result
*
is a destroyed stator and ignition failure.
For more detail and how to check see (online) here.

Important safety and operating information

Safety first! Please observe the general health and safety regulations motor vehicle repair
(MVR) as well as the safety information and obligations indicated by the manufacturer of
your motorcycle.
# The timing marks on the material are for general guidance only during first installation.
Please check after assembly by suitable means (stroboscope) that settings are correct to
prevent damage to the engine or possibly even your health. You alone are responsible for
the installation and the correctness of settings.

Ignition systems generate high tension! With our material right up to 40,000 Volts! This may,
if handled carelessly, not only be painful, but outrightly dangerous. Please do keep a safe
distance to the electrode of your spark plug and open high tension cables. Should you need
# to test spark firing, hold the spark plug socket securely with some well insulating material
and push it firmly to solid ground of the engine block.
Never pull sparkplug caps when engine is running. Wash your vehicle only with engine at
standstill and ignition off.

Should you have received in the kit HT cables with a fixed rubber boot(which does not
# contain a resistor) you might have to use spark plugs with an inbuilt resistor (or replace the
cap with one containing a resistor) to comply with your local laws.

After installation, please check tightness of all screws, even those preinstalled. If parts get
# loose during run, there will be inevitably damage to the material. We pre-assemble screws
only loosely.

Give the newly installed system a chance to work, before you start to check and test values,
or what is worse apply changes to it.
Our parts have been checked before delivery to you. You will not be able to check much
anyway. At any rate do refrain from measuring the electronic components (such as ignition
coil, regulator and advance unit). You risk severe damage to the inner electronics there.
You will not get any tangible results from the operation anyway. Bear in mind that also
#
your carburetor, your spark plugs and spark plug sockets (even if completely new) might be
the reason for malfunction. The general experience with our systems is that the carburetor
will have to be re-adjusted to lower settings. Should the system not start after assembly,
first disconnect the blue (or blue/white) cut-off wire directly at the ignition coil (or in some
cases advance unit) to eliminate any malfunction in the cut-off circuitry. Check ground
connections carefully, make sure there is a good electrical connection between frame and

VAPE spol. s r.o., Bílanská 1647, 767 01 Kroměříž, Czech republic

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 63861799

engine block.
In case of troubles, please consult our Knowledge Base first before you send off the material
to us for checking

The spark of classic, points based ignition systems has with about 10,000 Volts
comparatively little energy and looks therefore yellow and fat (which however makes
it highly visible). The spark from our system is a high energy spark with up to 40,000
# Volts and therefore is needle thin focused in form, and blue in colour, which makes it
not so visible. Furthermore you get spark only at kick-start operated speeds and not
by pushing the kick-lever down slowly with your hand (as you might get with battery
based ignitions).
Systems using a twin outlet ignition coils have a few peculiarities. Please observe that during
tests on one side, the other has either to be connected to an fitted spark plug or securely
# earthed/grounded. Otherwise there will be no spark on either side. Also with such open
exits long and dangerous sparks may fly all over the coil.

Never do electric arc welding on the bike without completely disconnecting all parts
containing semiconductors (ignition coil, regulator, advance) stator and rotor need not be
# taken off. The same is true for soldering. Before touching electronics disconnect the
soldering iron from mains! Never use copper putty on spark plugs.

Electronics are very sensitive to wrong polarity. After work on the system, do check correct
polarity of the battery and the regulator. Wrong polarity creates short circuits and will
# destroy the regulator, the ignition coil and the advance unit. As a rule, wiring will always be
colour to colour. Instances, where colour jumps between wires are expressly mentioned in
our instructions.

When you handle the new rotor, take care not to damage its magnets. Refrain from direct
# blows to the circumference of the rotor. When transporting never put the rotor over the
stator. Observe our information relative to transport of the material.

Do not use spark plug sockets with a resistance of more than 5kOhm. Better use 1 or 2kOhm
ones. Bear in mind that spark plug sockets do age and thereby increase their internal
resistance. Should an engine start up only when cold, a defective spark plug socket and/or
# spark plug is very probably the cause. In case of problems check high tension cables too.
Never use carbon fibre HT-cables, never use so called "hot wires" which promise to increase
spark.

# It is a good idea to cover the rotor in a thin layer of oil to reduce the risk of corrosion.
Never use a claw puller or a hammer to disengage the rotor. Its magnets might become
# loose in the event. We offer a special puller for disengaging the new rotor again (see
assembly instruction)!

Should the motorcycle not be in use for some longer period, please disconnect the battery
# (so existing) to prevent current bleeding through the diodes of the regulator. Though, even a
disconnected battery will empty itself after a while.

VAPE spol. s r.o., Bílanská 1647, 767 01 Kroměříž, Czech republic

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 63861799

Please do observe these remarks, but at the same time, don't be afraid of the installation
process. Remember, that before you, thousands of other customers have successfully
# installed the system.
Enjoy driving your bike with its new electric heart!

VAPE spol. s r.o., Bílanská 1647, 767 01 Kroměříž, Czech republic

support@vape.cz