Intake, compression of a two-stroke motorcycle engine IZH
We start moving to TDC and block the purge channel on the left with the upper part of the piston. This creates a vacuum in the crankcase.
While the exhaust window of the cylinder is still open, exhaust and purging continue; after closing, compression of the combustible mixture begins.
The upward movement does not stop, and the edge of the skirt opens the crankcase inlet port. Through which the fuel mixture is sucked from the carburetor. Intake occurs.
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Warm greetings to everyone! We continue to restore IZH-Jupiter 4, which we recently purchased. The history of the acquisition can be read here: Part 1 We are slowly going to great lengths and starting an irreversible process))) Anyone who is interested, you are welcome under cat.
After waiting in line at government services, I managed to make an appointment for the next day to re-register the motorcycle. In the evening we decided to check the motorcycle, since it had not been touched for almost a month before. It didn't start right away, there was no charging. It was decided to take a spare battery to get there and back. After starting, it began to ring very violently, as if the fist of friendship was about to come out. What’s even more disgusting is that after 2 attempts to start the kickstarter flew off along with the gearshift foot... The splines there had been licked long ago, they just tightened it to the fullest extent and stomped it as far as was enough. Oh, yes, the sector itself has not yet returned to its original position. Morning. I anxiously go into the garage and think: if only I got there, if only I got there... I got there without any problems, the registration was done quickly. And when it was time to go home, as luck would have it, he didn’t want to start. I had to dance with a tambourine in front of everyone: I stomped it twice, picked it up from the ground, twirled it, and so on. Started up! That's it, go home. On the way I had to overtake a car, and when I passed it, I decided to put it in 3rd gear, BUT! The shift foot and kick starter have successfully disappeared! Oh, I had to stop and go look for them on the side of the road... I found them, installed them, and drove off. I got home and realized that such a shame had never happened before. Well, it was scary to drive in such a ruin (there’s no other way to call it). And we also had a path to a warm garage with a load in the stroller awaiting us. With which? But... This is how we carry motorcycles)
I was too lazy to hook up a trailer to the car and load it all there. It would be better if he took it away on a trailer... After a kilometer of travel with such a load, the kick got lost again. And the devil pulled me and my friend to carry the donor in a stroller. Passers-by looked at us as if we had escaped from madness. And at the end of the road, about 100 meters from the garage, the donor fell on the steering wheel and it got jammed on the left side, keeping this barge from entering the bushes, we somehow taxied out and got to the garage. I have never had such a quest before. This is too much)
All! Finally, this hellish day is over and both motorcycles are delivered to the garage! I got so tired of them within a day that I didn’t come to the garage for 2 days, my eyes wouldn’t have seen them!
After a short break, I decided to start this difficult task. It was necessary to completely disassemble the units and evaluate what was there and how. I started with a donor that had low mileage.
He understood it easily. After a thorough wash, all the dirt was knocked off, which made disassembly very easy. I decided to keep all the fasteners.
Half an hour later the motorcycle was dismantled. I haven’t damaged anything yet, I just put everything in a corner and decided to do it after disassembling the second copy. I put all the little things in drawers and then sorted through and weeded out the trash.
Well, one is disassembled. Second - get ready!
And here he is! I don’t even know what to call him, a victim of circumstances or a lucky guy? In any case, I have not yet completely recovered from that hellish day)
This is how the wing was secured... Everything there was so rusty that half fell apart and half couldn’t be unscrewed. Well, in general, we dropped him off during the evening so that he could just get there, and he got there, even though he was banging like a pan with stones, but he survived.
But this has been heating me up for a long time! Then we found a spacer in the stroller, which the owner used to hammer the kick onto the shaft all the way, apparently he also suffered for a long time, but was in no hurry to repair it.
An hour later, the second motorcycle was also dismantled. Everything was worse here, everything was rusty and dead. I'm even thinking about replacing the frame with a newer one.
The color of the mood is orange)) And again a bunch of spare parts.
Does anyone need a box of potatoes? Okay, I'll leave it to myself.
Well, the day has passed, everything has been sorted out. Then everything will need to be sorted out and prepared for painting.
I decided to keep the original fasteners and have them galvanized so that they look like new. As a result, I collected all the good fasteners and small parts in the garage, that is, I scooped up almost everything that could be given for galvanizing. BUT, all this needs to be prepared - as I was told, there should be no oil, grease, or dirt. And most of the parts and fasteners were covered in oil, dirt and grease. I had to clean almost every bolt, nut, and part with a metal brush, and yes, THIS whole mountain had to be cleaned by hand.
Then he added more spare parts and gave it all away for transformation.
It's time to disassemble the engine and see what's left alive.
Everything is more or less here.
The piston was badly worn, the gap between the piston and the liner was very large. It was for this and several other reasons that it rang.
Drained the oil. Well, like butter... At first it seemed to me that I had milked a cow. This is the kind of emulsion we got.
Well, someone has already climbed. Strange homemade washer. It’s already a common occurrence to see a broken sector of the ratchet.
Having removed the covers of the guns, I was dumbfounded. Some smart guy installed all the main bearings as sealed type ones. 3 bearings simply jammed, I couldn’t even turn them by hand. How did this engine even work?! It felt like the seats on the axles were already loose and were simply spinning in the bearing race. Hmmm... Well the engine was “repaired”. Moreover, due to the heating of the crankcase, half of the bearings simply fell out, as you guessed, all seats were gone. There is only one way out - to change the crankcase, since assembling these is already a perversion, and restoring the seats is too expensive. Forgive the engine, but you want to go to non-ferrous metal. As a result, half the engine went into ferrous metal - the chain, the basket, the crankshafts, half the gearbox, the winding shaft, the crankcase... Just like that.
But what to do!? That's right, I have a crankcase with a mileage of 6000 km, where all the seats are perfect, and no one has climbed into the engine except me. I will do it. True, out of grief that he was drowned, I didn’t remove the cover of the gun, I’ll have to do it now. There are creepy footage from the scene.
That's why the engine was stuck. To remove the covers and press out the bearings, I had to heat the crankcase with a burner for a very long time, everything was rusty.
I have a question about cleaning the engine. I was already tired of washing all this, and there was a lot of dirt and oil, which were somehow removed with a screwdriver. I gave it all to a specialist. washing and gave the installation to spare no chemicals. The guys at the car wash were understanding, also izhatniks, so they understood everything almost without words and did everything perfectly! The next day I didn't recognize the engine. Everything was clean, everything sparkled. Not a speck of dust under every rib! They also washed the inside, I was satisfied. Now I will give all the engines there, it’s time to save energy and time)) This is such a beauty. And next to it is another replenishment... In principle, I should not be allowed to go where they sell engines or spare parts for IZHs, I couldn’t resist and bought an almost new engine from Yu6. It's been about a week, I've already managed to take all the parts for painting. And then I was informed that the galvanization of parts and fasteners was completed, and I could pick it up. But not everything was so simple; the locality in which the parts were located was not very accessible in terms of road. It was possible to get there by car along a good road, making a detour of 50 kilometers or a little more. But the road was shorter, only 15 kilometers were in such a terrible condition that it was decided to overcome them on Jupiter, and at the same time take one last ride before winter. You know, I love autumn landscapes, the air is so special. I like this atmosphere.
This is the fucking road! Such pits as after a bombing. Moreover, the cars that were unlucky enough to drive here were driving in 1st or 2nd gear, but on the IZh it was convenient to go around everything and maintain 60 km/h, which is nonsense for such a road. It’s like the 21st century, but the roads are like under Tsar Pea. But once there was asphalt here.
I returned home and brought a whole bag of updated parts. Yeah, it looks completely different!
Beauty! Well, now the hands themselves are reaching out to collect. We are slowly getting out of the thorns, the fasteners and parts have been updated, the engine has been cleaned, the frame and trim will soon be painted, spare parts have been purchased - assembly is coming soon. That's not all, I found many more parts in the garage and decided to donate all the leftovers for such a transformation, since they will soon be used for other motorcycles. And this set is enough for almost 2.5 motorcycles. Now you don’t need to buy new bolts, everything is original)
For comparison. On the right is a new factory fastener, on the left is a restored one. Looks quite decent. I also forgot to mention that most often the store does not have bolts with the required length, thread pitch, or special bolts, such as for fastening the center stand. So, rather than running around looking for new bolts, which are most often raw materials, these will last as long as they lasted before.
You can start assembling, almost everything is prepared for this.
Pendulum. We change the bushings. I will leave the old axle between the bushings, since the new one is very thin and does not inspire confidence. Wash the old one, wipe it and put it back in its original place.
We install everything in its place and generously fill it with lubricant. Now it will last for a long time.
On the running boards, only the rubber bands and cotter pins themselves were updated, the rest is original. Beautiful.
Slowly the frame is acquiring attachments. The fasteners look original, of course.
The rear shock absorbers are in poor condition. It's not for long.
Now everything is washed and ready for assembly. The glasses were already galvanized before.
We collect. Everything worked out.
We install it in place. Also below are the original stoppers, or whatever you call them.
Let's move on. Maybe all these little things bore you, but I liked it when everything original and updated fell into place. This time, during restoration, attention is paid to every detail.
Assembling an anti-theft lock. The bolts, interestingly enough, came from the ignition switch from a VAZ-2108. Successful unification)
We assemble the damper.
The steering column is ready. Not a single ball fell out)) The grease is also clogged, so it will last a long time.
It's time for the instrument panel. All connectors have been cleaned, small things are ready - just collect them.
So the tool boxes are in their place.
Rear casing line. Here, too, what can be done has been transformed.
The casing is assembled. Before assembly, the covers were ground in to ensure a perfect fit. The grease was clogged into the drive sprocket bearing. The covers were placed on a thin layer of sealant to prevent dirt from getting into the casing. It has already been verified from experience that after such assembly the inside is always clean.
Slowly everything is falling into place. It has a view!
It came down to the turn signals. Also like new.
Getting the remotes ready for painting. At least one of them is new, but it was poorly painted. So let's redo it.
One of the last dirty jobs. Disassemble all 4 pens. The best feathers were on a motorcycle with 6000 miles, so we choose the best inner liner and collect it. The native feathers have already completely died... Although what is dead cannot die)))
I'm fixing a couple of bugs. I put the shock absorbers on the wrong side, and the adjusting bolt for the brake pedal position. Now everything is as it should be.
The front end is almost ready too.
Now the remotes are ready for assembly. We also lubricate the runners a little and assemble them.
Before the inspiration went away, I updated the oil dipstick. Do this do this.
Now it's the engine's turn. Although it has been washed, the remaining dirt still has to be completely removed.
I remove the pins and start cleaning everything. Moreover, there was rust and even traces of water in the hairpin thread.
Now you can assemble the engine. There is already light eroticism here - completely naked carters without any trifles. I've been waiting for this moment for a long time, since the engine is my favorite activity, especially when everything is so clean and tidy. Hands reach out to collect themselves. Having removed the casting flaws, almost polished the KShM chambers, everything was ready, but on this note I will end the second part, since a lot fit into it))) And stop tormenting you with a long story, it’s better to leave the sweet stuff for later.
To summarize, a lot of work has been done! There is as much more to come, if not less. It’s worth it, because now everything has been sorted out and assembled slowly, using original components. Although this is not a factory assembly, I think it is no worse. All that remains is to gain strength and finish the motorcycle, fortunately there is less and less left. I hope that in Part 3 there will be a summary of all the restoration work. Thank you for your attention, see you soon! Do not be ill))
