Detailed wiring diagram for IZ Jupiter 5 - problems and their solutions

The IZH Jupiter 5 motorcycle has been produced from 1985 to the present period at Izhevsk Motorcycles OJSC. The basis for this popularity of the model is the design, good technical characteristics and successful wiring diagram of the IZH Jupiter 5, which, unlike the previous generation, allows the use of a large number of different electrical equipment.

The fifth Jupiter model belongs to the middle class of road motorcycles, can travel on roads with different surfaces and, what is very important, is equipped with a cargo or passenger trailer with a carrying capacity of up to 100 kg, slightly inferior in loading to the Ural motorcycle with a sidecar. Other positive properties of IZ Jupiter 5 include:

1. Powerful engine.
2. Maintainability (do-it-yourself repairs are possible even in rural conditions).
3. Economical to operate.
4. Affordable price.
5. High-quality electrical circuit with a powerful generator.

Among the technical parameters of the motorcycle, the main ones should be highlighted:

• power – 25.0 l. With.;
• engine volume – 348 cubic meters. cm;
• type of lubrication – joint;
• highest speed – 125 (95 with trailer) km/h;
• fuel – gasoline A76;
• cooling – air;
• frame design – welded tubular;
• electrical equipment voltage – 12 volts (battery sources, generator).

Ignition on IZ Jupiter 5 is carried out in a contact version through a switch connected to the battery.

General diagram of electrical equipment

Regardless of whether you repair or improve your motorcycle, all work will be based on the diagram presented below. This is a universal wiring diagram for IZ Jupiter 5 12 volts, which is suitable for early modifications, late models, including luxury singles and Jupiters with a sidecar.

Wiring IZ Jupiter 5 connection diagram:

Izh Jupiter 5 ignition switch connection diagram

We mark the Hall sensor mount in such a way that the distance to the rear wall of the sensor through the magnet slot from the center of the armature is around mm.

What advantages open up to users who decide to install electronic ignition on the Izh Jupiter are described below. Get a nightmare! Thanks to the modulator plate, smooth ignition operation is ensured.

What kind of precise engine operation can we talk about here? An ignition adjustment is necessary if the engine is running poorly, the muffler or carburetor is firing. As soon as the voltage is on the pin. A caliper will be needed as a depth gauge. The most common of them are listed below: Ignition gaps change their original position while driving a few days after adjustment; A spark occurs every once in a while, since the contacts regularly burn out; Capacitors are constantly damaged; Low spark power; If you add two or three volts to the battery, it is quite difficult to start it. If the engine is 1-cylinder, then the cutout angle in the modulator should be approximately degrees, but if the engine is 2-cylinder, then the cutout angles should be 60 degrees.

Its thickness is 0.45 mm. We connect the second wire from the switch to terminal “1” of the ignition switch; the second wire from the same terminal goes to the signal. Tighten the screws well.

Replacing the head light Riding Jupiter 5 at night is the lot of the most daring and experienced bikers. Thus, the coils are supplied with 12 volt voltage from the battery (diagram 1). The ignition timing must match on any cylinder used. If your spark appears earlier or later, then perform the following steps. We determine the moment of spark by the spark itself.

Connect it to the second and third contacts of the DC. After turning on this key position, power is supplied from the battery to the primary circuit according to a simplified scheme. Now you can use BSZ. Then loosen the screw and turn the eccentric. As a result, a charge of less than 12 V appears on the spark plug, which poorly ignites the combustible mixture in the cylinders.

A discharge is applied to the spark plug, which causes the mixture to ignite, causing the crankshaft to start moving. Using the generator bolt, turn the crankshaft clockwise. It is necessary to ensure that the breaker contacts open to the maximum distance. The characteristic knocking sounds of iron components in the crankcase and accompanying detonations also disappeared. WIRING TO IZH (PLANET 5)

Wiring Problems

Practice shows that if the motorcycle was stored in a dry garage and was not subjected to dubious alterations, then the Jupiter 5 wiring diagram lasts a very long time. From time to time you need to change some consumables, such as lamps and ignition coils, but otherwise it functions quite stably. However, this is not always the case and problems do occur, for example:

• wire breaks;
• electrical circuit short-circuit;
• failure of their individual branches of the circuit;
• weak light from incandescent lamps;
• incorrect operation of indicators;
• misfire;
• reduction in engine power;
• complete failure of the system.

The problems described above can arise both due to natural wear and tear of wiring elements, and after incompetent intervention in the circuit. There is no universal solution to the problem in this case, and in order to find out what caused the breakdown, you should be patient and have some basic knowledge of the technical part of the motorcycle. First of all, you should get a multimeter or assemble a primitive network indicator using a 12-volt light bulb to “ring” the wiring for breaks. Having found a circuit node that is not working correctly or a wiring break, it will need to be eliminated, the network’s functionality re-checked, and so on, until operation is completely restored.

Specifications[ | ]

• Overall length 2,115 mm.
• Overall width 780 mm.
• Overall height 1,025 mm.
• Ground clearance 135 mm.
• Dry weight of the motorcycle is 160 kg.
• Maximum speed 110 km/h.
• Fuel tank capacity 18 l.
• Cruising range on the highway is 400-450 km.
• Fuel consumption on the highway is no more than 4 liters per 100 km.
• Fuel: Gasoline with autol 10-18 in a ratio of 25: 1
• Fordability 300 mm.
• Engine Stroke 58 mm
• Cylinder diameter 61.75 mm
• Number of cylinders 2
• Engine displacement 347 cm3
• Compression ratio 6.8
• Maximum power 18 hp. With.
• Air cooling
• Lubrication system combined with fuel
• Carburetor type K-28ZH

Multi-disc clutch, in an oil bath with an automatic release mechanism. The gearbox is four-speed, two-way. Motor transmission is a rollerless double-row chain, gear ratio - 2.57. Transmission from the gearbox to the rear wheel is a roller chain, gear ratio - 2.33. The frame is tubular and welded. The front fork is a telescopic spring type with hydraulic shock absorbers. Rear suspension pendulum spring with hydraulic shock absorbers Type of brakes drum Type of wheels easily removable, with tangential straight spokes. Tire size 3.25-19″

How to improve the standard electrical system?

As we have already said, standard wiring does not cause any particular complaints due to its solidity, ability to withstand oxides and rust at the joints, without losing functionality. That is why complete replacement of wiring is a questionable procedure, but upgrading individual parts makes sense. By individual parts, we mean such functional elements as head lights, indicators, turn and stop lamps, ignition system, generator. Let's talk about each of the elements separately.

System assembly and installation

The contacts in the breaker, the capacitor, the ignition bobbins and the armor wires, which are part of the previous ignition device, are probably eliminated. The switch should be installed in the glove compartment on the right, and the ignition coil directly under the tank. There are no gaps for fastening on the reel, which means it can be attached using a thick layer of adhesive tape. The standard bolt is also eliminated along with other parts.

In place of the bolt, install a pin of the specified size and put on a washer. Then, the rotor is tightened with a nut located at its end. The hall sensor is attached to the stator by any means. The basic rule when installing it is to set the optimal cross-sectional distance of the modulator and the ratio of the radius and line of symmetry.

When the hall sensor can be secured, we apply the modulator. It should fit into the hole made in the sensor. In most situations, there is a discrepancy between the sizes, so it is necessary to place washers on the stud. If you manage to maintain the required gap, it is recommended to install an engraver and tighten the modulator with a third-party nut.

Installation of BSZ

Contactless ignition system - this element has become so popular that it rightfully occupies the place of the most popular improvement to the standard ignition circuit. From the factory, the IZ Jupiter 5 wiring model is equipped with a contact ignition system. It is unable to hold the ignition angle advance settings for a long time, has failures in operation and low accuracy. The disadvantages of this system can be listed for a very long time, so owners switch to electronic ignition, thereby increasing power, reducing consumption and getting a flat torque and power curve.

Major problem with motorcycle wiring

On IZ Jupiter 5, the wiring had a large number of contact terminals. Therefore, the main cause of malfunctions in the electrical circuit was a violation of the integrity of the connections. This led to such moments as: there is no charging for the battery, the generator does not provide the necessary 12-volt voltage to the system, the switch is not able to generate the necessary charge for the ignition coil, loss of functionality of all lighting devices, and a number of others.

The cause of loss of connection in the terminals was contamination and oxidation of the contacts. This was especially true for motorcycles produced at the beginning of mass production. The main way to solve this problem was to exclude these terminals from the IZ Jupiter 5 wiring.

To do this, we used soldering the wires directly to each other (by analogy with the Tula motorcycle), as well as sealing the terminals on the supply wires to the following main elements:

• battery;
• generator;
• coil and spark plug;
• switch;
• lighting devices.

This increased the reliability of the connections and, as a result, ensured the operability of the specified parts, and also made it possible to turn on charging for the battery in order to subsequently confidently start the engine of the IZH Jupiter 5 motorcycle.

Source

Motorcycle Upgrades

New electrical devices have appeared on the motorcycle:

1. New generation alternating current generator with a power of 100 W;
2. A new electronic unit consisting of a rectifier and voltage regulator BPV14-10;
3. Electronic switch;
4. Ignition coil IZH-PS;
5. Modern instruments and warning lamps.

In addition, the power of lighting devices has increased, in comparison, for example, with the wiring diagram of IZH Planet 2:

1. Headlights;
2. Side lights;
3. Direction indicators;
4. Stop lights.

For reference: the combination of engine reliability and improved visibility has increased vehicle safety on public roads.

Most common problems

Most often, the motorcycle in question loses or shifts poorly in second gear.
This may be due to careless turning on of speeds. For example, when picking up high speeds in first gear without neutral, when engaging the second speed gear, an impact occurs, which contributes to intensive wear of the unit. Therefore, it is not recommended to “spin” the first speed too much. If, nevertheless, problems with the second position continue, there are several options for resolving them. In some cases, the simplest method will help, without completely disassembling and then reassembling the Izh-Planet 5 box. It is necessary to place the motorcycle on the right side, and then remove the kick starter and gear shift foot along with the shaft. Next, the crankcase cover and clutch basket along with the discs are dismantled.

When the gears of the box wear out, the meshing of the teeth deteriorates. In turn, this leads to slipping, jerking and failure of the second gear. Another reason could be wear on the input shaft bearings. Since it moves slightly to the left due to vibration, it is necessary to move it into place with light blows using a mallet. The installation of washers of suitable diameter will allow you to fix the element in the desired position. Then the bearing stopper and other dismantled parts are reassembled in the reverse order.

Dashboard

The new instrument panel fits well into the appearance of the new motorcycle model, combining:

1. Speedometer;
2. Automotive type ignition switch;
3. Control and warning lamps.

New instrument cluster IZH Jupiter 4

The display of warning lamps separately from the instrument scales had a positive effect on the information content. Now the driver can easily see their readings, additionally provided with inscriptions.

It is also easy to replace burnt out lamps:

1. Using a Phillips screwdriver;
2. Remove 3 screws (in the diagram above under No. 3);
3. Remove the cover;
4. Remove the failed lamp;
5. Install working;
6. Reassemble the shield in reverse order.

Do-it-yourself engine tuning for IZH Planet 5

Having figured out what the tuning of the IZH Planet 5 motorcycle will look like, the rider may find the power insufficient. So it is, because the factory ones are 20 - 25 hp. The original engine is enough for tight streets, but on the highway the engine stops the speedometer at 120, beyond which it is quite difficult to get out. That is why, the next step is to tune your engine. The first step is to conduct a complete audit of the main elements that affect power: ignition, air filter, carburetor, exhaust. 50% of success lies in the correct setup and maintenance of these “capricious” motor components. If everything is in order, but there is still not enough power, then there are two further options:

• The first is modification of existing units;
• The second is a comprehensive tuning of the IZH Planet 5 engine with replacement of parts.

The first option is suitable for those who are trying to maintain the factory condition of their bike. Then, to drive a little faster, you can clean the exhaust, which inevitably becomes clogged with oil residue. The next step may be to install higher flow jets on the carburetor. At the same time, we inspect the filter element; it should fully cope with its task; monitor the oil level. The last item will be replacing the spark plugs and fine-tuning the ignition. With the right approach, you can get the most out of your engine. The maximum speed will not increase, but the engine response will definitely improve. Some models have a “traction” drive sprocket with a large number of teeth; if you replace it with a “high-speed” one, you can add at least 10 km/h to the maximum speed. Riders who are primarily concerned about the sense of speed should prepare to study a lot of specialized literature, because in order to noticeably improve the engine's power, its main components will have to be replaced. It’s worth starting with an audit of the cylinder-piston group. It is best to immediately replace the crankshaft with bearings, connecting rod and piston with rings with analogues from Japanese models. New spare parts will be stronger and lighter than the old IL Planet 5 tuning will significantly improve the engine, allow it to spin up more easily and preserve its service life. Next we replace the intake system, this is a new, more efficient carburetor. Behind it is installed a low-resistance filter and another important intake element - a reed valve. The exhaust should also be replaced. Only part of the knee will remain from the old spare parts, and a special resonator will be welded behind it (diagrams with dimensions can be found on the Internet).

Due to the characteristics of 2T engines, the exhaust cannot be direct-flow; it must provide a reverse impulse, which will prevent the air-fuel mixture from splashing out of the combustion chamber. After the resonator, a muffler is installed, which in general may be absent if you prefer a loud roar of the engine. Last but not least is the ignition system. It is better to immediately replace it with an electronic one, because the contact one almost always gets lost and has to be adjusted very often. The electronic system eliminates the need for regular inspection of the mechanism and allows you to maintain the power and torque curve at any speed.

Converting the electrical circuit to work without a battery

Unlike cars that have a closed engine and electrical wiring, parts of the IZH Planet 3 motorcycle are more susceptible to external factors than others:

1. Rain and snow;
2. Direct sunlight;
3. Mechanical damage from bushes.

The factory instructions provide:

1. The need to constantly check the electrolyte level in banks, because when the motorcycle tilts, it inevitably leaks out;
2. The need to constantly check the electrolyte density. This forces motorcycle owners to have a hydrometer, distilled water and hydrochloric acid on hand to restore the required density with their own hands.