Do-it-yourself injector for a Ural motorcycle - drawings

How to install an injector on a Ural motorcycle

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Injector to the Urals

So, the topic: FUEL INJECTION ON IRBIT MOTORCYCLES.
The idea of ​​​​developing fuel injection for boxer engines came, in general, unexpectedly, almost simultaneously with the acquisition of Solo, although the acquisition itself was also quite unexpected, not only for me but also for those around me. There was experience in development and manufacturing, there was a wealth of experience in repairing fuel systems of foreign cars. The companions said to hell with you, giving in under my pressure. Well, here we go.

They began to build the system according to the classic automotive principle. Receiver, on top there is a throttle valve, above it there is an air filter, from the receiver there are intake pipes and injectors near the cylinders. As a result, the receiver, damper and air filter did not want to fit between the box and the frame. Everything turned out small, miserable, nested one inside the other. The electric fuel pump and fuel filter were nowhere to be found. No, there's a lot of space on the frame, but that's when. But once you think about it and attach the pump to the frame, you realize that there is no way to fix it, and there is no way to ensure a fuel supply and removal, and then it sticks out like an eyesore and gets in the way. Nevertheless, everything was arranged, crammed in, manufactured and tested.

The production of the new system began with a revision of the concept of placement of units. In the end it turned out very well. A large receiver, between the box and the frame, on the side there is a throttle pipe with an air filter under a polished body, a la V-twin. On the other side is an electric fuel pump and a fuel filter. And to maintain symmetry, they are closed with a decorative cover similar to the air filter housing. On top there is a pressure reducing valve and an idle air control. There is also an air temperature sensor. It turned out that almost the entire system was implemented as a single unit. Take it out of the box and install it on the motor.

Now about the system itself.

To diagnose the system, the harness has a special connector to which you can connect either a motor tester or a computer. If necessary, you can make adjustments right there.

Source

Carburetor design

The carburetor for the Ural motorcycle is a horizontal device designed to prepare the air-fuel mixture. The float chamber is located in the center of the assembly. The mechanism is equipped with a flat throttle valve with vertical stroke, two dosage systems - the main one, the idle one. They shape the volume and quality of the mixture.

The starting device is located separately, consisting of three main blocks, Fig. 2:

• building 8;
• chamber with float 38;
• cover 4.

Rice. 2. Schematic representation of the carburetor for 63. 1 - Fitting with lock nut; 2 - Throttle spring; 3 - Throttle lift limiter; 4 - Housing cover; 5 - Lock nut; 6 - Dosing needle bar; 7 - Throttle; 8 - Housing; 9-Air channel of the sprayer; 10 - Float lever axis; 11 - Spray body; 12 - Sprayer; 13 - Float chamber cover; 14 - Main fuel jet; 15 — Idle fuel jet; 16 - Lock washer; 17 — Channel for supplying the fuel mixture from the starting device; 18 - Float; 19 — Stop for adjusting the fuel level; 20 - Fuel valve; 21 - Drainage hole; 22 - Emulsion hole: 23 - Transition hole; 24 — The air channel of the jet is idle, running; 25 Dosing needle; 26 - Air channel of the float chamber; 27 — Fuel receiving fitting; 28 — Idle speed adjustment screw; 29 — Mixture quality adjustment screw; 30 - Air channel; 31 - Starting lever; 32 - Rod; 33 - Spring; 34 - Starter plunger; 35 — Float drowner; 36 - Plunger needle; 37 — Fuel jet of the starting device; 38 - Float chamber.

The float chamber communicates with the atmosphere through the vertical outer channel of the housing 26. The top cover of the chamber has a drainage hole 21. The carburetor of the Ural motorcycle is equipped with a lever float mechanism consisting of two floats 18. Both products have the shape of rectangles, connected together by a common lever made of the innovative material caprolactam as one piece.

Axle 10, pressed into the lever, presses the structure with floats against the two columns of the housing. The brass fuel valve 20 visually resembles a needle. There is an elastic washer on top of the cone. It is practically eternal, almost not subject to wear. Thanks to it, the Ural carburetor always has a stable level of gasoline in the float chamber. The valve has a groove at the bottom that connects it to the float. Therefore, it never gets stuck in the guide channel.

moto magazine: “Caucasian injection”

All modern motorcycle manufacturers are transferring their equipment from carburetor power systems to injection ones. “Why is my Ural worse?” - Vladimir Polyakov from Sochi thought and created an injection system on his Voyage. Yes, such that any plant will be jealous: fuel consumption by the engine has been reduced to three liters per 100 km!

The microprocessor and fuel pump are located in the underseat tank.

Instead of the usual carburetors - Italian plumbing.

But in order for the control system to issue commands accurately, it needs reliable information from the sensors. This is a crankshaft position sensor, a variable resistor that monitors the position of the throttle valve (borrowed from some ancient Opel), and a mass flow meter for the air sucked into the engine power system.

The microprocessor “communicates” with the driver through the display.

The ignition system consists of a two-spark coil from the Oka and a VAZ switch. But the switch does not have the function of changing the ignition timing depending on the speed and load on the engine, therefore it is entrusted with the function of a power switch that controls the “bobbin”. The signal comes to the input of the switch from the microprocessor, and it, according to the selected program, determines the moment at which the spark should “strike”.

The coil took the place of the generator. For what? And then, so that you can install an energy source in front of the engine and get rid of oil leaks from under the oil seal and the ever-howling drive gears. Now the on-board power station is rotated by a toothed belt from an electric planer. The pulley is installed on the camshaft shank, which was empty due to the lack of a standard ignition system.

The flow meter is installed between the air filter and the throttle valve.

The generator now has a “dry” drive.

The fuel system is the pinnacle of genius of the entire development. At first glance, you might think that it was made in Italy - this idea is suggested by the inscriptions “Made in Italy” on the intake pipes. In fact, everything is much more prosaic; it’s just that when creating the injection system, parts from Italian plumbing were at hand. These shiny pipes became a second home for VAZ injectors (their performance turned out to be suitable for the cubic capacity of the cylinders). I had to tinker while choosing the angle of installation of the injectors, because the fuel in the spray pattern should fall into the air stream and not settle on the walls of the intake tract. The air is “managed” by one throttle valve, in front of which there is a mass air flow sensor. The fuel pump, located under the saddle, and the vacuum fuel pressure regulator, which took the place of the gas tap, were also borrowed from the “ten”.

The crankshaft position sensor is located in the crankcase inspection window.

Additional engine modifications

In addition to the above methods of tuning a Ural motorcycle, there are several more secrets. It is possible to install a crankshaft from the K 750 on the Ural engine, which will increase the cylinder stroke to 78mm.

Thus, it is possible to significantly increase the working volume of the Ural engine. It's quite difficult to find, but it's worth it. Another problem with the motorcycle is the tight response to the throttle and slow acceleration. The reason for this is that the flywheel is too heavy, the weight of which is designed for riding with a stroller and for transporting heavy objects.

According to the drawing, it is possible to reduce its weight by a couple of kilograms. Due to the weight reduction, the inertia of the crankshaft will decrease, and the acceleration dynamics will significantly increase. To fully realize the power on the road, the gears of the gearbox must be replaced with 9 or 10 pairs. In conclusion, we would like to note that tuning the Ural motorcycle engine is justified only for racing purposes; for everyday use, such an engine will have a short resource and significant fuel consumption.

I want to install an injector on a Ural motorcycle

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A story about how one day I messed around with the engine and decided that I’d had enough of carburetors!

This was due to the fact that I am generally a lover of all kinds of know-how. My thought did not pass over my horse either. It all started out banal. Once I had to completely disassemble the engine. But, since this thought has been haunting me for a long time, the assembly dragged on for some time. To begin with, I had to cut down the gearbox a little, cut off part of the air filter and a small corner of the frame under the tank so that a normal 60 Ah battery would fit. Next, it was necessary to fasten the starter accordingly. By the way, it also had to be altered a little, since I took a gearbox from a dozen. I had to abandon the standard speedometer (and in general I’m thinking of installing a regular LCD display), the battery blocked the path for the cable. What follows is mostly technically routine work.

Spare parts A. from dozens 1 Controller (brains) 2 Air flow sensor (MAF) 3 Wiring for the controller 4 Crankshaft sensor (CSC) 5 Knock sensor 6 Throttle valve with IAC and TPS 7 Ramps from injectors are desirable

B. from Volga 8 fuel pump 9 injectors. and something else

Tools 1 A good set of wrenches 2 Accordingly, a hammer (where would we be without it?? 3 Drill 4 Grinder 5 Welding 6 Preferably a milling operator with his own machine

I won’t say that the horses have doubled, but... . The dynamics changed noticeably for the better, the speed began to pick up faster. on carbs, I didn’t even dream of super-tuning the mixture, since I’ve already gone through all this a long time ago and got everything possible and impossible out of them. horses may not have doubled, but they have been added. and yet, I have not yet tried to install a turbine, since it is this that now may well replenish the herd.

I tried installing something similar when I still had carbs, but it was naturally useless, since the forced air simply pushed gasoline back into the carburetor, more air began to enter the engine, the mixture became leaner, the speed increased simultaneously with a sharp drop in power, then naturally stalled.

Source

Ignition

Following an increase in power and replacement of pistons, it is advisable to replace the spark plugs. Spark plugs A20 DV and A17 DV from Zhiguli are suitable for Ural. Some craftsmen install an additional candle. This increases engine power at high speeds, reduces consumption and can become a replacement for boost. But work will have to be done to develop an independent spark generation system. At the same time, the air filter is changed, which reduces friction losses during intake.

If the engine is old, then it is advisable to replace the carburetor and install an injector. This can be done with your own hands or with some help. Tuning the Ural motorcycle can be done using injection spare parts from the VAZ "Ten"

Injector Ural.

If the price tag is acceptable and it works as it should, then why not.

how to contact them?

There's an email address there

How neat? No one wrote to him? Why don’t you know?

You'll probably start pouring yourself.

I wouldn't mind, but the quality is completely different there. And I'm rather weak in electronics.

So the fact of the matter is that there is nothing to pour there. Everything is standard. Program! That's the most important thing. Automotive stores are full of ready-made components.

I didn't like the location of the lambda probe.

what the hell is MTZ on a six-volt crankcase? the bed is intact, not cut down. judging by the peeling paint and thick ass, it looks like a Polish one from a Fiat)))

Oh you! I'm hungry for details

Cool! How simplified everything is! No flow meter, no DPKV. Only the ignition timing from the camshaft, TPS (one!) and lambda. Oh, and two temperatures. The air is calculated by revolutions and throttle opening, a completely normal assumption. Moreover, with lambda correction. By the way, it was also possible to refuse it. But then the debugging process would be more complicated and would require an external gas analyzer. And here self-learning may be prescribed, but not a fact. The dampers need to be synchronized in any case, so one sensor is enough. But the details are, of course, interesting!

They haven't said the price yet.

I sit and look, and suddenly the price is delicious.

Everything depends on the quality of both. All other things being equal, the injector is more reliable. IMHO.

Well, this is the case if the firmware allows you to work with the majority of failed sensors, just like on a car.

Yes, that's the right word! Spare brains for this injector will be expensive. This is not January, which you can actually buy for 3 rubles. It is not yet clear to me what type of fuel pump it is. Probably some common one.

And here you can only do without thermometers and lambda. The DPRV is not duplicated in any way, just like the DPDZ. In the usual scheme, they are replaced by DPKV and DMRV, respectively. This results in a reservation of x2. And then the output of any sensor will lead to failure of the entire system. So simplification comes at the expense of reliability. In addition, such a DPRV is much less reliable than a conventional inductive DPRV and comb, which I have never encountered that failed. I only heard it as a curiosity.