In this article we will consider in detail the issues that relate to the correct adjustment of the clutch of the IZH Jupiter 5 motorcycle. The name of this motorcycle unit itself speaks about the main functions it performs, or rather, the crankshaft engages directly with the engine gearbox. Optimally, the clutch should be as smooth as possible without jumps. This is necessary for the movement of the motor vehicle and subsequent switching while driving. The clutch is located on the left side of the crankcase under the installed engine cover. In order to get to the clutch as quickly as possible, you will need to first drain the oil and unscrew the cover. In this case, you will need to unscrew all the necessary mounting bolts and then carefully remove all the levers.
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Electrical equipment of the IZH Jupiter motorcycle
The electrical equipment of the IZH Jupiter motorcycle differs only in the installation of the G-36M2 generator.
Electrical diagram of the IZH Jupiter motorcycle:
1 — rear light; 2 — neutral lamp switch; 3 - central switch; 4 — neutral indicator lamp; 5 — speedometer lighting lamps; 6 - main lamp; 7 — parking light lamp; 8 — light switch; 9 — sound signal; 10 — brake light switch; 11 - candle; 12 — control lamp; 13 - fuse; 14 - battery; 15 — relay-regulator; 16 - generator; 17 - capacitor; 18 - breaker; 19 - ignition coil.
"Sores"
“Planet” was good in its time, except for the ill-conceived launch mechanism. For those who have “Planet”, I think there is no need to explain what “return” means. Personally, once it gave so much that it tore the kickstarter shaft in half, bent the gearshift shaft and tore the ratchet on the clutch basket. Those whose slippers fly into the sky are lucky compared to my version...
Checking the clutch drum
The first step is to check the foot start ratchet mechanism. This is where the main load falls. Turn the clutch basket over with the ratchet facing you, remove the retaining ring and disassemble the ratchet.
We inspect the teeth of the ratchet: they should be sharp without chips or other damage. If the teeth are wrinkled or broken, the winding foot will slip 100%. Many suffer from this problem due to thick oil or a weak spring - in fact, the reason for the foot slipping lies in the ratchet.
If the teeth on the basket are not worn out, it is advisable to rivet the ratchet: buy a new one in the store or remove it from another basket and rivet it. I riveted several baskets and they went without any problems until the “victory”...
An example of ideal ratchet teeth.
Often and thickly, the rivets on the ratchet weaken and if you don’t notice this in time, they are cut off. To prevent this trouble from happening to you, move the ratchet with your fingers. If it wobbles, drill out the old rivets and rivet them again. Pulling old rivets usually does nothing.
If you are making a clutch “for yourself” and for a long time, be sure to check the condition of the teeth for the motor chain.
If the teeth have already begun to turn back, then such a basket should be immediately thrown into the trash. It will no longer be of any use: the operating noise will increase, it will 100% eat up the motor chain, and there’s never an hour when one “fine” day it will lick your teeth and you will then be forced to push your jalopy for a long time and tediously...
Checking the clutch basket inner drum
The inner drum is eternal by definition. The only problem that arises with it is that it breaks and sometimes cuts off the splines and the fit of the bolts under the pressure springs becomes loose.
Place the drum on the shaft and swing it:
- If the drum dangles too much on the shaft, inspect the splines and if they are broken, replace the drum with a new one.
Loosen the bolts under the compression spring one by one:
- If the bolts wobble, knock them out of the drum, anchor the seats and hammer them back into the drum.
Checking clutch discs
The main clutch problems occur due to the fault of the discs. If the discs are crooked or worn out, then no amount of even a super couture adjustment will correct the poor performance of the clutch.
Wear is determined visually and only on plastic discs: we inspect the disc and if we find a crack or a broken hook on it, with which it enters the outer drum, or we see that the round protrusions on the working surface have long been worn out, we throw such a disc in the trash.
The curvature of the disks is determined as follows: place all the disks on the glass one by one and try to swing them
- If the disk wobbles, it means it is 100% crooked and should be in the trash.
- If the disk lies flat, leave it.
Adjusting the alignment of the motor transmission teeth
We put an adjusting washer on the input shaft of the gearbox, then we put the spacer sleeve of the outer clutch drum there. We put a spring washer on the crankshaft journal. We install the outer drum and the drive sprocket of the motor transmission on the engine, tighten the bolt on the sprocket. We apply a ruler to the sprockets and look at the alignment of the teeth under the motor transmission.
- If the teeth do not converge, we adjust their convergence by placing or removing adjusting washers under the clutch basket
In my case, the teeth of the basket and drive sprocket are aligned.
After adjusting the alignment of the teeth, remove the drum and sprocket from the engine and leave the adjusting washers and spacer sleeve.
We put the thrust washer of the kickstarter return spring on the gearshift shaft.
We put the kickstarter shaft on the shaft of the gear shift mechanism and insert the return spring hook into a special groove.
To avoid injury to your hand, tension the kickstarter spring only with the crank!
We put the claw on the shaft, tighten the bolt and, depending on personal preference, tension the spring. Personally, I tensioned the spring two turns. It turned out a little tight, but the paw didn’t dangle like snot and always returned to its place.
We install a basket with a sprocket and a motor chain on the shafts. We place a tin rod or stick under the chain and tighten the bolt on the sprocket with the maximum possible force.
Purpose of the clutch IZ Planet and IZ Jupiter
Clutch - the name speaks volumes about the job it does. In our case, the crankshaft engages the gearbox of the IZH Planet and IZH Jupiter engines. The connection should occur smoothly without jerking, this is necessary to start moving and smoothly change gears. In case of heavy loads, it protects engine parts from damage.
The clutch is located in the left half of the crankcase, under the left engine cover.
To get to the clutch, you need to drain the oil and remove the cover with the gasket, first remove the levers and unscrew the mounting bolts.
The basket is constantly in working condition, the discs are tightly compressed by springs.
The motor transmission consists of two sprockets. The small drive is located on the crankshaft. A large star driven on a drum. The connection is made by a motor chain.
The engine gear ratio is 2.17 for all single-cylinder IZh models. For IZ Jupiter, the gear ratio is 2.57.
When assembling the motor transmission, the planar arrangement of the stars is controlled. No more than 0.4 millimeters are allowed.
Switching off occurs using a special device. The shutdown mechanism is installed in the right engine cover. This mechanism is used to make adjustments.
Life hack: how to adjust the clutch on an Izh-Jupiter 5 motorcycle yourself?
The adjustment procedure depends on the design features of Izhevsk motorcycles. The fifth generation is equipped with a shutdown mechanism, which is combined with a gear shift device. Adjusting the clutch control should begin by centering the machine's cam relative to the roller with the lever, which are mounted on the body of the right crankcase cover.
First of all, the distortions of the pressure plate (No. 1 in the photo) are removed, for which the lever on the steering wheel is secured with wire or rope in the squeezed position. Next, turn on 1st speed and rotate the rear wheel, while observing the axial runout between the pressure plates and the end of the drum. The nuts (No. 2 in the photo) that are closer to the point of maximum deflection need to be tightened, and the tightening force should be determined experimentally. Repeat the operation until the runout becomes minimal.
The following operation is performed when the gear shift unit has been disassembled for repair, or after replacing the right crankcase cover. Motorcycle owners interested in how to properly adjust the clutch on an Izh-Jupiter 5 should definitely familiarize themselves with the work technology:
- Disconnect the cable end from the clutch control lever on the steering wheel.
- Between the end of the weakened fastening of the machine cam and its cotter pin, install such a number of washers so that the gap between them and the cotter pin is no more than 0.4 mm.
- Tighten the cam bolt with enough force to prevent the cam from turning.
- Place the right crankcase cover in its original place and secure it with screws.
- Remove the hatch on the left crankcase cover, loosen the locknut and tighten the adjusting screw until it touches the thrust rod, then tighten it another 2-3 turns.
- Move the gear selector pedal up and down by 20-25 mm, then carefully remove the right crankcase cover.
- Without changing the position of the cam on the shaft, tighten the bolt securing it with a force of 2-2.5 kgm .
- Replace the right crankcase cover and remove the adjustment screw.
- Screw the adjusting bolt until it touches the thrust rod, then unscrew it half a turn and secure it with a locknut.
You can check the correct setting by pressing the foot switch pedal. In this case, moving the front end of the pedal 5-6 mm from the neutral point should not lead to movement of the pressure disk; as you continue pressing, the disk should move without distortions. The final adjustment is made with a special screw on the steering wheel bracket; the free play of the end of the lever should be within 3-5 mm .
Experienced motorcyclists who know how to properly adjust the clutch on an Izh-Jupiter 5 motorcycle note the following points:
- A properly adjusted clutch begins the shifting process at the moment when the lever is released by half or a third of its full travel.
- If the upper rule is not followed, then slippage should be expected under severe loads.
- If there is no free play of the lever, then the force of the clutch springs is spent on stretching the cable rather than compressing the discs. In difficult conditions, when maximum traction is needed, the clutch may not work.
Clutch adjustment IZH Planet
To adjust the clutch control mechanism of motorcycles IZH Planet 5, IZH Planet 4, IZH-56, IZH-49, use adjusting screw 1 and locknut 2. By loosening the locknut by turning the screw clockwise, reduce the free play of the control lever. When turning the screw counterclockwise, the free play increases. After completing the adjustment, tighten the locknut. The normal free play value is determined by the free movement of the end of the clutch lever by 5..10 mm.
The normal amount of free play is determined by the free movement of the end of the clutch lever by 5..10 mm.
Features of clutch settings
It is possible to check the correctness of the clutch settings by pressing the pedal in any direction. Moving the first end of the lever 3-5 mm from the neutral position should not affect the pressure plate, that is, it should not move. After completing this procedure, it is possible to adjust the manual squeeze using a specialized screw to make the adjustment. After this, the IZ Jupiter 5 clutch is assembled, during which it is necessary to strictly adhere to the sequence of all necessary actions.
Adjusting the clutch springs
Adjusting the springs is not difficult, the main thing is to get it right. We start by placing the motorcycle on the center stand. Then remove the lid, draining the oil in advance. We squeeze the lever on the steering wheel to the limit and make sure to fix it. Next we turn on the speed, preferably the first one. We take the wheel and begin to rotate. We try to determine by touch how much effort we are applying. We look at the coupling as it rotates and determine which springs are loosely tightened. We mark them with chalk, then tighten them. We begin to rotate the wheel again and if you feel that the wheel has become easier to spin, then everything has been done correctly. The process must be repeated to achieve a better result. After this, we check the result obtained while moving. If, as the load increases, the clutch begins to slip. All springs must be tightened using nuts. In this case, all nuts must be turned the same number of turns.
Clutch setting
Adjusting the springs usually does not take much time and is not considered a complicated procedure. To carry out these actions, the motorcycle is placed on the stand, the oil is drained, and then the installed cover can be removed. After this, the special lever will need to be squeezed to the maximum and securely fixed. Then it is recommended to turn on the first or second speed, take the wheel and start rotating. Based on the load, we determine which springs are more tense and which are looser.
Then, when we have figured out which springs need to be tightened, we rotate the wheel to check the result. It is necessary to pay special attention to such a fairly important point that when the load increases, the clutch will not slip. After all of the above steps are completed, the IZH Jupiter 5 clutch basket is assembled. Adjusting the IZH Jupiter 5 clutch is important for stable and safe riding on this popular motor vehicle. Therefore, when you feel that it is necessary to carry out these actions, then you should not delay it.
Clutch faults
Possible malfunctions that may appear during operation of IZ motorcycles.
The clutch of IZH Jupiter IZH Planet is slipping reasons
The malfunction is noticeable during sudden acceleration. We increase the speed, but the motorcycle does not accelerate. The same thing happens when driving on a steep hill as the load increases. The motorcycle cannot overcome the obstacle and stops, although the crankshaft speed does not drop. The discs get very hot and wear out quickly. It is impossible to operate the equipment in this condition; the cause must be found and eliminated.
This malfunction indicates that the disks are poorly pressed against each other.
There may be several reasons:
- The adjustment was not carried out correctly
- The springs have lost their former elasticity
- The discs have worn out and become thinner.
- Wear of drive parts
A serious problem could be a jammed control cable. The reason is damage to the shell and the resulting rust underneath. Gentle cleaning and lubrication, better replacement.
Check and wash the adjustment mechanism itself located in the right engine cover. Small particles of road sand that get into the mechanism with water can slow down the operation. After squeezing the lever, the parts do not return to their original position.
When is it necessary to repair and adjust the gear clutch on an Izh motorcycle?
Regardless of the amount of experience the motorcyclist has, the feelings regarding gearbox malfunctions are almost the same:
- At first it seems that the clutch is slipping slightly. After two or three days, confidence appears - yes, it is slipping, because as soon as you add speed, the acceleration rate lags behind the engine speed level. The breakdown is especially obvious when moving uphill.
- The clutch “leads” or the clutch is incompletely disengaged when the control lever is depressed. In such a situation, the disks of the assembly remain pressed against each other and do not stop transmitting torque to the gearbox. You can finally verify such a breakdown after lifting the rear wheel - it continues to rotate in this situation.
If you want to know how to adjust the clutch on a motorcycle Izh-Jupiter 5 , then information about the reasons causing the listed factors would be useful:
- Use thicker oil in winter.
- Weakening of pressure springs.
- Worn clutch discs.
- Wear of clutch control mechanism elements.
In most cases, if signs of slipping or incomplete disengagement of the clutch are detected, a simple adjustment of the mechanism is required. To do this, it is enough to have a “13” key and a slotted screwdriver.
