Increasing the voltage: Java wiring with IL parts
For various reasons, you may be the owner of a legendary Java - it’s your father’s, older brother’s motorcycle, or you just bought a legendary vehicle for the occasion.
But here’s the problem - the motorcycle is often far from ideal condition, for example, you may be upset by such a nuisance as the wiring of the Java, which has delaminated from old age, was probably stored in an unheated barn or garage, and a new set cannot be found in your city. There are few well-maintained examples of Java left. What’s most offensive is that the work of replacing most parts and assemblies is quite simple , but the lack of spare parts immobilizes your vehicle indefinitely. Moreover, the price of parts tends to rise every year, which forces us to show skillful hands and ingenuity. But the result lives up to all expectations.
Diagram of operation of a gearbox with a divider
Most KamAZ trucks in use today are equipped with five-speed manual transmissions. The gear shift pattern in such gearboxes is quite familiar: the driver depresses the clutch and moves the lever to the required position. It is important to understand that KamAZ vehicles are heavy-duty trucks, that is, adjusting the position of the lever must be done strictly in stages.
gearbox and divider switching diagram
The typical transmission modes for a truck with a diesel engine are low (“H”) and high (“B”) operating modes. The development of these two options was carried out specifically in order to minimize the load on the engine of the machine, both with a maximum load and when empty. Many KamAZ vehicle models allow you to switch these modes without using the gearshift lever.
The driver just needs to raise or lower a special divider switch and literally squeeze the clutch for a second.
The mode is adjusted automatically: a lowered switch activates a light driving mode, and a raised switch activates a stronger driving mode.
Dealing with switching gearbox modes on KamAZ trucks is relatively simple. To change gears 1-5, use the corresponding lever located to the right of the driver's seat. For example, acceleration of a truck involves the use of the following gear shift pattern: 1B-2B-3B-4Н-4B-5Н-5B . On a clogged highway or in difficult road conditions, use 1H-2H-ЗH-4H-4В-5H-5В .
It should be borne in mind that the KamAZ gearbox device allows you to change speeds only if the clutch is disengaged. To switch from the upper mode to the lower one and vice versa, you need to move the switch to the appropriate position and only then press the clutch all the way and as sharply as possible. Literally in a second you need to release the pedal for the desired main gear to engage.
During the operation of the vehicle, it is very important to monitor how much oil is in the KamAZ gearbox, and, as necessary, add lubricant in a timely manner, preventing possible problems and malfunctions.
Model appearance
Outwardly, although it was relatively simple, it still attracted attention . The large headlight, with round turn signals protruding from the sides, and the dashboard wells located on top were combined very harmoniously.
And even though the wheels on the motorcycle were spoked, they sparkled very well in the sun.
The tank of the motorcycle was voluminous, but had a neat shape; in the rear there were quite large pads for the driver’s knees . But the most important thing on the tank was the inscription “Jawa”.
The 638 had a double, flat seat divided in the middle by a strap for the passenger to hold onto. glove compartments under the seat and tank on both sides .
This motorcycle received the nickname “Bench” due to the fact that under the seat there were decorative pads that stretched along the entire seat and ended with a brake light. Because of this, the seat was combined with the rear brake light.
How to adjust the shift mechanism
The procedure for adjusting the Lada Kalina gearbox lever is carried out on an inspection hole, overpass or lift, best with an assistant monitoring the process in the cabin. Tools you will need:
- wrench 13 (convenient with a ratchet);
- slotted screwdriver.
Diagram of the Lada Kalina gearbox lever
Having blocked the wheels with rollbacks, the gear selection lever is fixed in the “rear” position. Next, work continues under the bottom of the car:
- use a 13mm wrench to unscrew the nut of the coupling clamp;
- make sure that it moves freely relative to the gearbox drive rod.
Review Java 350 638
This model is considered a continuation of the Java 350 634 motorcycle, the characteristics of which can be viewed at the link. The new model featured a more powerful engine and discreet design. In those years it was considered stylish and sporty, so in the 80s the Java 638 was the dream of thousands of people. The new product also differed from its younger brother in the absence of chrome in some parts. This could be explained by the fact that production was cheaper during release. Unfortunately, the 80s were a difficult period for the USSR, so they were unable to expand production and make the model as popular as the Java Old Woman, produced long before the 638 Java.
Current reviews of the Java 638 characterize the motorcycle as a true friend, which has a pleasant appearance, thoughtful details and, unfortunately, their absence on the market. The biggest disadvantage is the current shortage of parts for this model. There are more than enough motorcycle owners, but even finding Java 638 spare parts in an online store is sometimes difficult. Owners also consider spare parts too expensive.
Hyundai Elantra HD Gear Shift Adjustment
Hi all! I encountered this question when I changed the clutch... The fact is that all gears were engaged normally, only the engagement of the “second” gear was not in its “right” place, but somehow closer to the “fourth” gear. At first I made a mistake about installing the clutch, maybe I did something wrong, but then I remembered - we have a cable transmission and there is a certain gearbox adjustment!
To adjust the gear shift, you need to remove the “central tunnel” in the car and get to the direct gear shift mechanism! Therefore, first you need to remove the center console with the armrest (although not everyone has it).
Maximum current selection
The manufacturer’s official instructions, in addition to the technical regulations, also prescribed recommendations regarding the selection of maximum current from the generator:
- A power of 15A is permissible for selection, provided that the temperature of the stator winding does not exceed 155C;
- With the Java-638 trailed stroller and with all constantly switched on consumers, a long-term connection of one more consumer is allowed, the power of which does not exceed 42W (3A);
For reference: this recommendation applies to a climate zone where the maximum ambient temperature does not exceed 30-40C, and the engine operates at low speeds, preventing the generator from developing full power.
At higher temperatures, such as when operating a motorcycle in southern latitudes, there is a risk of thermal damage to the stator winding. There is also a high probability that the wiring to Java 638 may suffer insulation damage.
How to change gears on KamAZ
Most KamAZ vehicles are equipped with a manual 5-speed gearbox. Gear shifting is carried out by pressing the clutch pedal and selecting the desired gear with the gear lever, but this must be done in stages.
- — Change gears with the clutch disengaged.
- — Press the clutch pedal all the way.
- — Engage and shift gears at minimum idle speed.
- — Start driving only from first gear (to avoid premature failure of the clutch).
The KamAZ 15th series gearbox and ZF gearboxes are equipped with a divider with two modes: increased “B” and decreased “H”. To switch the mode, you need to move the gear divider control switch to the desired position, and then press and after a short delay (1 second) release the clutch pedal - the gear will engage automatically. To simultaneously change gears and engage a higher or lower gear, you must set the divider control switch to the “B” or “H” position, then depress the clutch pedal and shift the lever.
Gear shift diagram
Shift diagram for a 144 transmission
Shift diagram for a 154 transmission
Gear shift diagram in the ZF 9S1310 model gearbox Gear shift in the ZF 9S1310 model gearbox): 1-2-3-4-low gears (lowest range of the multiplier); 5-6-7-8-high gears (highest range of range). When slowing down, change gears only sequentially: 8-7-6-5-4-3-2-1. Always keep the gear engaged when driving. Low gear “C” is intended for starting in difficult road conditions and for maneuvering. On ZF gearboxes, it is prohibited to switch from the highest range to the lowest at a speed of more than 30 km/h and to move with the gear shift lever in neutral.
To get moving, you need to switch gears in several stages; for example, let’s look at the KamAZ start and acceleration scheme on a flat, hard-surfaced road:
- 1st gear, high mode (B);
- 2nd gear, high mode (B);
- 3rd gear, high mode (B);
- Transition to the 2nd low (H) stage and switch to 4th gear;
- Transition to the primary stage (B), the gear remains in 4th;
- Shift to a lower gear (H), engage 5th gear;
- Return to the higher gear (B), stay in 5th gear.
Brief description of the circuit: 1B - 2B - 3B - 4H - 4B - 5H - 5B .
The main feature of starting to move on a KamAZ is a smooth start and acceleration using lower gears.
In case of heavy workload or difficult driving conditions, it is advisable to switch the first four gears in a low mode (H), then switch to the 4th high gear, then the 5th low gear (H) and then to the 5th high gear (B).
Motorsports [edit | edit code]
Java motorcycles have successfully performed in sports, in particular in motocross and six-day Enduro competitions. Particularly significant successes were achieved in speedway and ice speedway. In the 1960s and 70s, Java motorcycles with four-stroke engines were among the best speedway motorcycles in the world. They were attended by multiple speedway world champions Barry Briggs, Ivan Mauger, Ole Olsen and many other athletes. Soviet and Russian racers Gabdrakhman Kadyrov, Sergei Tarabanko, Anatoly Bondarenko, Nikolai Krasnikov and others have repeatedly become world champions on ice speedway motorcycles using “Java” motorcycles. The Russian national ice speedway team continues to use Java motorcycles.
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