How to restore shock absorbers “Izh-Jupiter 3”, “Dnepr”, “Ural”

Homemade shock absorbers for IZH Planet

To eliminate defects in the rear shock absorbers of the motorcycle IZH 6.113-05, and to change the oil, you will need to repair the rear shock absorbers of the IZH in the following several stages:
Place the motorcycle firmly on the center stand, then you need to remove the shock absorbers (if you remove two shock absorbers at once, do not forget to place a support under the pendulum so that it does not tilt and fall).

How to disassemble an IZh shock absorber? We take special brackets and compress the spring (a car puller will not work - its ears are too thick). It can be done differently. To do this, you need to take a gas key and insert it between the coils of the spring. You need to lean on the gas key with the weight of your body, the spring will compress, and in the meantime your partner must remove the two supporting half-rings.

Next, the spring is removed, then the plastic cup. Behind them, the spring preload adjuster is removed.

You need to clamp the lower tip tightly in a vice, then take a 27mm wrench and unscrew the seal housing nut. We pull the rod towards ourselves with force to pull it out completely. You need to be careful - there is still oil in the shock absorber.

When inspecting the rod, pay attention to the working edge of the seal. To replace the rubber, unscrew the rod nut (before this, clamp it by the upper tip in a vice) and remove the piston with valves from the rod. Then the seal housing, oil seal with rubber buffer.

Wash all parts in kerosene or gasoline. Replace worn parts. When assembling the shock absorber, do not forget to fill in 0.075 l. liquid MGP-10, you can use AU oil, but it is better to fill in oil of foreign analogues. At this stage it is already clear how to disassemble the IZh shock absorber, all that remains is to assemble it.

It is better to assemble the shock absorber with clean hands on a clean table. Sand, debris and dirt can get inside. If you follow the advice, it means that you will be able to repair the rear shock absorbers of IZH without any problems. This will help prolong the long and reliable operation of the shock absorber in the future.

IZh shock absorber device:

1-silent block. 2-support half ring. 3-cup. 4-support washer. 5-buffer. 6-spring suspension. 7-oil seal housing. 8-liner. 9-oil seal. 10-tank seal. 11-spacer sleeve. 12-stem bushing. 13-rod with tip. 14-rebound spring. 15-valve limiter. 16-valve disc spring. 17, 20 valves. 18-piston. 19-throttle disc. 21-valve plate. 22, 25 bushings. 23-spring. 24-rod nut. 26-regulator. 27-suspension body. 28-cylinder shock absorber. 29-pin. 30-valve. 31-lower valve body.

Source

Troubleshooting and repair: what to do with springs, boot, etc.

We check all components for wear, mechanical damage, and nicks. We especially carefully inspect the polished surfaces of the inner wall of the cylinder and rod. It makes sense to replace rubber O-rings, seals, and gaskets in any case. Even if they do not show signs of wear, soft rubber loses its properties under the influence of oils. If you disassemble the shock absorber, spend a small amount on consumables.

Tip: When replacing parts, you can change the characteristics of the rack by installing aftermarket parts.

If you thoroughly wash all shock absorber components, consider half the work done. Fine particles of road dirt or wear products from metal parts interfere with the operation of the stem valves. Coked deposits should be removed using strong solvents.

Then check the remaining elements of the strut: spring, damping pad, shock absorber boot.

Not all parts can be repaired; some will have to be replaced with new ones.

Cracks and holes in rubber parts cannot be repaired, only replaced.

Below are more specific cases of repair of rack parts and options for its execution.

Tuning IZH Planet 5 with your own hands

Back in 1987, the Izhevsk plant produced the legend of Soviet motorcycle technology - the IZH Planet 5 motorcycle. To this day, this model is in good demand; since then, hundreds of thousands of Izhovs have been sold.

The characteristics of the motorcycle are so good that from the moment of purchase the vehicle could be used both on rural roads and in the city, as evidenced by the powerful engine and modern design. Even with modern technology, Izh can compete and even win in some parameters. With an engine of only 1 cylinder, the motorcycle is capable of producing a considerable 22 horsepower. Fuel consumption at an average speed of 90 km/h is 5 liters. As for the factory maximum, the characteristics of Izh Planet 5 allow it to reach a speed of up to 120 km per hour. Thanks to its reliable design and high-quality Soviet assembly, the transport is unpretentious and easy to maintain after difficult operation.

Tuning Izh Planet 5. Preparation.

If you bought an expensive Japanese motorcycle, tuning it will become difficult, and you won’t be able to carry out the upgrade yourself. Do-it-yourself tuning of Izh Planet 5 is quite simple, you will only need to have a small set of equipment and from an old Soviet transport you will get a modern and powerful motorcycle. Any tuning consists of two types - external and internal (change in technical characteristics). Let's look first at the first option, namely modernizing the appearance.

External tuning of Izh Planet 5

Often, to improve the appearance, styling of individual elements is used, and let's start with the muffler. Previously, a muffler kit was made, including chrome pipes and various attachments. Having found such a kit, you will not only get a beautiful appearance, but also improve the performance of the exhaust system, and the engine will run even more stable and smoother. Therefore, we recommend starting tuning with the exhaust pipe.

Next, they most often replace the rear shock absorbers by installing a higher size. Raising the motorcycle will significantly reduce the pressure on the engine and gas tank, so replacing the shock absorbers is also necessary. But it is worth considering that for proper operation you will have to balance the wheels. Let's look at other changes in the appearance of IZH Planet 5.

As you can see, tuning Izh Planet 5, photos of which are sufficient, show that there are enough opportunities for modernization, and you can limit yourself not only to the above methods. Almost everything can be changed, it depends on your imagination and desire. Some craftsmen even created a sports body for the motorcycle, thanks to which you can’t even tell that it’s an Izh.

Do-it-yourself rack repair: is it necessary?

Replacing this unit is not a budgetary endeavor, so many car owners prefer to restore it themselves. It is not the entire assembly that breaks down, but its individual components, so during repairs you can only replace a few parts, and performance will be restored.

Attention! Not all shock absorbers can be restored. There are collapsible and monolithic structures (non-removable). It is not advisable to repair the latter, since it is impossible to restore the sawn body to its original condition.

Technical tuning Izh Planet 5

Any vehicle can be changed and its technical data can be improved. The engine and other elements of Izh Planet 5 are especially amenable to changes, because thanks to the high-quality and simple assembly of the engine, changing its components will be quite simple. Let's start with engine tuning, which will increase the performance of your vehicle.

To increase engine power, the first step is to repress the crankshaft. The result will be an increase in engine performance by 15%. You can read about this on the forums, or ask experienced people. The second option for engine styling is to install bearings from another motorcycle, namely the Java 350. It is strongly recommended to carry out such tuning only when you plan to operate the Izh on large and high-speed rides, because this change threatens to deteriorate the exhaust system.

Also, a standard increase in the power of any vehicle is the boring of the cylinder, so the Izh Planet 5 motorcycle, after increasing the volume to 75 mm, will receive a significant increase in speed, in most cases the maximum figure is 160 km per hour.

Shock absorbers IZH and the like - design and repair.

IZh shock absorbers are almost no different in design from the rear shock absorbers of other domestic motorcycles, with the exception of some small details, and therefore this article will also be useful to owners of motorcycles of other domestic models. And this article will describe in detail the design, maintenance and repair of Izhevsk rear shock absorbers, and I hope this article will be useful to beginners who own not only an IZH motorcycle, but also any other domestic bike.

The main advantage of shock absorbers (see photo 1) of Izhevsk or other domestic motorcycles is that these shock absorbers have a collapsible design, which means they are repairable and, with proper care, almost eternal. And new types of shock absorbers (for example, gas) which many have begun to install on IZhi, Java, and other domestic motorcycle equipment, although they are more advanced and comfortable shock absorbers, they are not collapsible (most models), and therefore are not repairable.

As was said just above, many of the more modern gas shock absorbers do not have a collapsible design, which means repairs will not be so easy, and sometimes even impossible, for beginners. In addition, most gas shock absorbers are produced in China and the quality (and resource) of many products leaves much to be desired.

And therefore, I think the good old models of Soviet-made motorcycle shock absorbers will remain relevant for a long time and will serve faithfully for many years, of course, with timely maintenance and repairs. But before moving on to repairing Izh shock absorbers and other similar domestic products, it will be useful to familiarize yourself with their structure, since knowledge of the device will make maintenance and repair much easier even for a beginner.

Well, anyone who knows how a domestic collapsible motorcycle spring-hydraulic shock absorber works can simply skip a few steps by scrolling the mouse wheel and go directly below to disassembly and repair.

Spring-hydraulic shock absorbers of Izhey, Ural, Dnepr and other domestic motorcycles have the same operating principle and almost the same design, see the photo above and the figure below. These shock absorbers also have a simple cam-type control device, which uses a movable cam and a fixed cam. For convenience, a lever with a ball at the end (indicated by a yellow arrow in the photo above) is attached to the movable cam of Izhevsk shock absorbers of the latest models (IZH Planet 5, Jupiter 5).

When the lever with the ball is turned, the movable cam moves relative to the stationary cam and thus increases or decreases the rigidity of the rear suspension of the motorcycle (depending on the condition of the roads and the load of the motorcycle). On older types of Izh shock absorbers (and on shock absorbers of other models of domestic motorcycles), there is no lever with a ball, and a special crescent-shaped wrench is used to move the movable cam and adjust the compression of the springs.

By the way, on the latest models of domestic motorcycles (for example, heavy motorcycles Ural, Dnepr), the shock absorbers of the latest models have a slightly improved design to increase ride comfort, and this design (shown in detail below in Figure 2) is similar to the design of the shock absorbers of VAZ and Moskvich cars.

Of course, the design of domestic shock absorbers is far from perfect and is inferior to most shock absorbers of foreign motorcycles, but I repeat once again that the main advantage of domestic shock absorbers is their easy maintainability and low cost of spare parts.

The basis of the design is a cylinder with a piston, to which a rod is attached, and on which the weight of the motorcycle presses. The weight of the motorcycle is resisted by springs and a hydraulic shock absorber system, which is filled with oil. Of course, the main purpose of the hydraulic system is to dampen vibrations of the rear suspension, but still the hydraulics help the springs a little to withstand the weight of the bike, cargo and driver and passenger.

A more detailed design of domestic shock absorbers of modern Izh, Ural or Dnepr motorcycles is shown in Figure 2 and they are similar in design, with the exception of some small details, and also differ only in the amount of stroke of the rod and the volume of fluid poured into the hydraulics (by the way, the shock absorbers of some domestic cars).

Shock absorbers of domestic motorcycles and some cars: A - compression stroke, B - rebound stroke. 1 - lower mounting eye, 3 - recoil valve nut, 4 - piston ring, 5 - restrictor plate, 6 - bypass valve spring, 7 - bypass valve plate, 8 - compression valve cage, 9 - compression valve spring, 10 - valve plate compression, 11 — compression valve disks, 12 — compression valve body, 13 — rod, 14 — cylinder, 15 — piston, 16 — rebound valve disks, 17 — rebound valve spring.

As was said just above, the main part is a cylindrical tank 2 (see Fig. 2) which is filled with shock absorber oil and to which the bottom and ring 1 for the rubber silent block are welded from below. A working cylinder 14 is inserted inside the main reservoir, and a plug 12 is pressed into its lower part, which serves as a housing for the compression valves. Well, inside the working cylinder 14, when the suspension is operating, a piston 15 moves, which is fixed in the lower part of the rod 13, and the upper part of the rod is connected to the motorcycle frame through a silent block.

The piston has 2 valves: the recoil valve is mounted at the bottom of the piston and the bypass valve is mounted on top of the piston. The bypass valve has a plate 7, which is pressed from above by a spring 6 and a restrictive plate 5, which is pressed against the piston 15.

The recoil valve consists of disks 16, which are pressed against the internal holes in the piston using a spring 17, the second end of which rests on the surface of the nut 3. And the compression valve has a plate 10 in which there are holes, as well as disks 11, spring 9, cage 8 and a housing 12 inserted into the bottom of the hydraulic cylinder 14.

Typical faults and problems + technologies for eliminating them

Depending on the type of shock absorber and the complexity of its structure, they talk about either repair or complete replacement of the mechanism

Shock absorber rod play: where it comes from and how to eliminate it

If you hear a quiet but distinct knocking sound when the shock absorbers operate, the likely cause is rod play. The cause is a loosening of the fastening nut. Often a malfunction occurs due to unprofessional repairs.

It's easy to fix, just tighten the nut. Additionally, you need to check the play at the rod attachment point. If you have been driving for a long time with such a malfunction, wear appears. In this case, the rod requires replacement.

How to shorten a rod and why it is necessary for a car

If you install shortened springs to lower the suspension, they will be unloaded when uncompressed. The reason is a mismatch in the length of the shock absorber strut. To eliminate the difference in size, the stem should be cut off or otherwise shortened.

It is necessary to grind it, extending the threaded rod to the required length. During turning, the metal must not be overheated, otherwise it will lose strength. Then use a strong die to cut the thread. We do this in several passes, since the steel of the rod is very hard. We try on the shock absorber and cut off the excess part of the threaded rod.

In the above example, the shortening occurs by 10 cm

You can turn the rod on a lathe. To do this, you need to remove it from the rack. The rod cannot be rotated inside the shock absorber. The next option is to secure the entire stand in the spindle using special tools. The rod must be fixed relative to the shock absorber body. The minimum spindle speed is selected.

How to lengthen it

When lifting the suspension, it becomes necessary to lengthen the shock absorber struts, otherwise the rebound travel will be too small. Welding work is not permitted. This reduces the strength of the metal when heated. The best option is to install extension pins. Internal and external threads must match the parameters of the rack.

Restoring the rod thread

There are at least four ways:

1. If the diameter of the rod is sufficient, the threaded part is cut off, a hole is drilled along the axis and a pin with a similar thread is screwed in.
2. A stud with a broken thread is ground down to the thickness of the old thread and a new one is cut. A nut with a smaller thread diameter is used.
3. Metal is welded onto the area of ​​the broken thread, the rod is ground and the thread is restored.

   The rod fastening nut is tightened with a torque of 30–50Nm; if you use a gun rather than a hand tightening, the thread is easy to break

4. A longer nut is used if the geometry of the shock absorber rod and bowl allows it.

How to fix it

When installing the shock absorber, it is necessary to keep the rod from turning. By tightening the fastening nut, you will rotate the rod. This may damage it and make it impossible to create the tightening torque.

Special turnkey flats are provided for fixing to the rod. By holding the stand, you can easily tighten the fastening nut without turning the rod.

Is it possible to restore the stand cup, how is it replaced?

The shock absorber support cup takes the weight of the front of the vehicle. Due to corrosion, it may lose strength. This worsens the car's handling and can lead to the strut simply breaking through the bowl and crawling out into the engine compartment.

A rotten or damaged support cup is a real threat to driver safety

There are two types of bowls: removable and stationary. The replacement bowl is replaced like a regular consumable; the stationary bowl is welded in place of the damaged one.

How to change silent blocks of racks

The metal eye of the shock absorber strut is attached to the body using a rubber (polyurethane) silent block. This part is destroyed during operation, but the rack remains fully functional.

Stock silent blocks on VAZ family cars are extremely unreliable and quickly deteriorate

To replace the silent block you will need a special puller-press. You can use a regular jack. The old rubber is squeezed out using a mandrel, and the new one is pressed into its place.

How does a strut support bearing malfunction manifest itself and what to do?

When the support bearing is destroyed or worn, controllability deteriorates. This can be determined this way: the wheels turn with some delay; when you turn the steering wheel while driving, you can hear something knocking in the area of ​​the support bowls.

The support bearing must be strong, as it experiences enormous loads when driving, especially off-road.

If you grab the rod with your hand and rock the car from side to side, a clear play is observed. When turning the steering wheel while the car is stationary, a crunching sound is heard in the area of ​​the support cups. Replacing the strut support bearing is the topic of a separate article.

How to install a new cartridge

The cartridge on many shock absorbers is a consumable item. The car owner himself can change it.

1. First you need to unscrew the stand cover.
2. After unscrewing, the oil drains out.
3. The old cartridge is removed from the housing.
4. The new cartridge is filled with oil and pumped.
5. Then fresh oil is poured into the housing, the rod is recessed and the cartridge is inserted into the housing. At the same time, the rod extends.

   In some types of shock absorbers, the operating procedure may differ

6. Next, you should assemble the mechanism and be sure to pump the shock absorber again.

Replacement of the rear suspension shock absorber protective cover

The protective cover prevents dust and dirt from entering the shock absorber rod. If there is damage, it must be replaced. To do this, the rack is dismantled, and the spring must be tightened using clamps or other ties and removed. When replacing the casing, it is necessary to put on new mounting clamps.

Covers protect the shock absorber from premature wear

Repair of shock-absorbing strut cups

Glasses are part of the body; their repair is classified as body work.

1. The damaged part of the metal is cut out using a grinder, the metal is thoroughly cleaned of paint and traces of corrosion.
2. A patch is prepared from sheet steel. You can take an undamaged part from the donor body at a car disassembly.
3. The repair element is welded with a continuous seam.
4. Anti-corrosion protection and painting are carried out.

To protect the rack cups, you can purchase similar amplifiers

How to replace front and rear shock absorber bump stops

The bumpers are designed to dampen shocks in the extreme positions of the rod and limit the travel of the strut. During operation, these elements are destroyed and must be replaced. If you continue to drive with a damaged bump stop, excessive roll appears, and the struts may fail due to impacts of the rod on the strut body.

A small detail whose importance cannot be underestimated

Replacement is carried out on the removed rack. The shock absorber is completely removed from the wheel arch and the spring is removed. When replacing the bumper, it makes sense to check the condition of the remaining external elements: silent blocks, boot.

There is a simplified replacement method, without completely removing the rack. Only the upper fastening is unscrewed and the bolt of the lower silent block is loosened. The strut is lowered together with the suspension arm, and a coupler is installed on the spring.

Video about the details of the repair work

Types of tuning for the IZH Planet 5 motorcycle.

The most popular domestic motorcycles were IZh bikes produced by the Izhevsk Machine-Building Plant; among them, the road version IZH Planet stood out - 5 tuning, which allowed the owner to get an individual motorcycle modified to suit his needs and desires, practically his own model.

The IZH Planet - 5 model replaced the IZH Planet 4 motorcycle on the assembly line in 1987 and was produced until 2008. The design of the fifth model allowed the technically competent owner to carry out tuning work with his own hands. For motorcycles, there are the following main types of tuning:

Change in appearance.

Despite the fact that the design of the fifth Planet model was probably the most interesting among all domestic motorcycles, tuning the IZH Planet - 5 motorcycle most often began with the appearance. The main reason for this was that work to change the external image can be classified as the simplest, not requiring deep technical knowledge and skills.

For this purpose, the following main work was carried out:

Complete or partial tuning operations to change the appearance immediately made the motorcycle recognizable and different from its serial counterpart.

How does a shock absorber work and how does it work?

Despite the difference in the design of shock absorber struts, the operating principle is similar. Inside a pipe (cylinder) filled with liquid or gas (or both), a rod with a piston moves. The kinetic energy of the suspension stroke is converted into thermal energy. For this purpose, the piston is equipped with forward and reverse valves. They slow down the movement of liquid (gas), thereby damping suspension vibrations.

Typical design of a shock absorber strut

The liquid (gas) inside the shock absorber heats up and the heat dissipates from the surface of the body. Overheating occurs when moving over uneven surfaces for a long time. The environment inside the shock absorber loses its properties, and the quality of work deteriorates. In this case, the shock absorber components begin to degrade, and the strut quickly fails.

Improvement of technical parameters

Tuning to increase power.

The design of the motorcycle engine allows for tuning to increase its power. One option is to re-press the engine crankshaft and change the support bearings. Usually, secondary shaft bearings from a Java motorcycle were installed as new bearings. This restoration made it possible to achieve an increase in engine power of the IZH Planet - 5 by 10-15%.

The next option for adding power was to increase the cylinder volume. For this purpose, its upper part was cut off and the sleeve was bored to 76 mm. Then the appropriate piston was installed, usually a piston from a Planet Sport motorcycle was used.

Increasing the speed of the motorcycle.

After this operation, the speed of the motorcycle increased, according to some sources, to 160 km per hour. Therefore, work to increase engine capacity was carried out by owners who planned to operate their vehicle mainly on highways.

The most difficult technical tuning option for adding power to the IZH Planet - 5 is the installation of supercharging. For this purpose, an exhaust valve is installed, the device of which corresponds to the analogues on the sports versions.

Then an exhaust resonator is installed, which has sharply directed parameters. Its task is to create a wave backpressure of the fuel mixture. Next, a spool valve is installed to obtain asymmetrical phases of engine operation, which avoids the direct release of the spent mixture.

Performing supercharging on the engine of the Fifth Planet is a rather complex process and therefore is not widely used.

Improved grip.

As engine power increases, it is necessary to carry out work to improve the clutch. Under standard conditions, the standard clutch works reliably.

But as the load increases, the risk of “burning” it and subsequent repairs increases sharply. The main steps for tuning the clutch come down to replacing standard discs with larger metal ones. Typically, such discs are made of two millimeter iron.

The use of thicker metal discs reduces slippage, warping, breakage and provides greater heat transfer.

Why do you need shock absorbers in a car, how they work

Front and rear shock absorbers are damping elements in a car's suspension. Paired with an elastic suspension part, which is a spring or torsion bar, the shock absorber performs several main functions:

• Damping vibrations of wheels and body;
• Maintaining wheel traction with asphalt;
• Ensuring a smooth ride.

To understand how a shock absorber works, you need to understand how it interacts with other suspension components. So, shock absorbers are necessary to reduce the amplitude of body vibrations, which appears as a result of the operation of elastic elements.

The elastic element is a spring, which is attached to the shock absorber. This design is called a rack.

The operating principle is based on hydraulic or gas resistance. Oil is most often used as the working fluid.