Assembling the Izh-Planet 5 box: detailed instructions, diagram and recommendations

The assembly of the Izh-Planet 5 box is often carried out during its repair or replacement of parts. This unit is not highly reliable. This is due to the low quality of components, poor assembly, and poor requirements for the manufacturing accuracy of bearings, crankcases and other mechanisms. You can find your advantages too. Firstly, it is cheap to produce. Secondly, it can be repaired with your own hands. Let's look at what the part is and how to assemble the Izh-Planet 5 box, and also learn useful recommendations.

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.

Installation of the cylinder-piston group

It is not advisable to remove the gearbox cover until the sealant has dried; there is no need to rush in this matter.
It’s better not to rush things and install the cylinder while the sealant dries. Add some motor oil:

To improve lubrication, it is advisable to drill holes in the piston bosses. But you don’t have to drill - it depends on your desire.

Install the piston pin retaining ring into the boss. Before installation, it is advisable to bend the locking ring a little and be sure to check how it fits after installation:

We heat the piston with a hairdryer and, using a mandrel, drive the finger into the piston so that it comes out no more than 5-6mm.

We look for an arrow-shaped mark on the bottom of the piston.

We orient the piston with the arrow towards the exhaust port of the cylinder (“towards the exhaust”), put the piston on the connecting rod, hammer in the piston pin and install the second retaining ring.

We insert the rings into the cylinder and measure the gap between the locks with a feeler gauge:

To improve the wearability of the rings and reduce noise from engine operation, it is advisable to chamfer the edges of the rings. If hunting gets too much trouble: place the ring on a flat surface and use a file to slightly round the edges.

We put the rings on the piston, fill the piston with the rings with oil, install a gasket under the cylinder (preferably with sealant), tighten the rings with a clamp. We cut the clamp out of tin and from the same tin we bend the bracket with which we will fix it.

After the rings go into the cylinder, unfasten the clamp, lower the cylinder and screw it to the crankcase.

We turn the crankshaft several times and if the piston moves in the cylinder easily and without grinding, lower it down a little, pour a little engine oil into the cylinder, install a new gasket on the cylinder and screw the head on.

We install the additional crankshaft support bearing in its place, place the required number of adjusting washers on top and secure it with a retaining ring. The adjusting washers must ensure axial play of the crankshaft within 0.1 mm.

Before installation, sealed bearings must be opened! The usual 304 goes here.

On the other side of the crankshaft we install a flange with a main oil seal.

Pay attention to the oil channel through which oil flows to the right main bearing of the crankshaft. According to the good old collective farm tradition, this channel is sealed with sealant and the lubrication of the bearing stops

To avoid this trouble, place the flange dry without sealant and everything will be fine.

After the sealant has dried, you can begin adjusting and assembling the gearbox and replacing the clutch basket.

Numbers of bearings and oil seals for the Izh-Planet motorcycle engine 2, 3, 4 and fifth model.

Other faults

It happens that disassembling/assembling the Izh-Planet 5 box may be necessary if the fourth speed disappears. This is often due to broken bearings on the output shaft. Such a nuisance occurs due to the presence of axial play, displacement of the bearing assembly, or its failure. You can try to fix the problem in the same way as repairing the second gear. If this does not help, you will need to completely disassemble the unit.

When the speed switch jams from a high range to a low mode, the spring system of the switching mechanism has failed. It needs to be replaced. Strained operation of the unit after assembling the Izh-Planet 5 gearbox indicates incorrect installation of the adjusting washers. To avoid this, it is necessary to mark and record the previous placement of these elements during the process.

Detection of faulty parts

To learn how to determine the damage and degree of wear of gearbox gears, consider the classification by which you can make the right decision about repairs. The gear needs to be replaced if:

• there is at least one broken tooth, or the presence of cracks in any part of the tooth caused by plastic deformation of the gear material.
• when the working surface of the gear is chipped by 20 percent or more, when the depth of chipping is 5 percent or more of the tooth thickness.
• if there is corrosion on the working surface of the gears;
• if the contact patch is less than 80 percent of the width of the teeth, and less than 60 percent of the height.

Disassembling and assembling the Izh-Planet 5 box

First, you will need to completely dismantle the clutch, starting device and motor transmission, and also drain the oil. After these manipulations have been carried out, you can begin to remove the gearbox. In the area of ​​the right side of the motor, unscrew the eight mounting screws. The driver's footrests, foot brake lever, and crankcase cover on the right side are removed. The clutch cable is disconnected and the ball and pusher of the input shaft are removed. After this, the circuit is disconnected. Designations in the photo below: clutch discs (1,3), lower disc (2), inner drum (4), nuts (5, 6).

The crankcase cover is placed on the prepared rags or paper. You can pull it out by grabbing the star with your hands and pulling it towards you. If the element does not budge, look at the worm shaft support washer, which may have become warped. Place tweezers or a knife into the hole between the crankcase and the cover, and then straighten the part. When dismantling the housing, a couple of washers may fall out. The second element is slightly thicker and is mounted on the copy shaft. They must be signed and put away with the rest of the spare parts.

Features of electrical equipment

The wiring diagram of IZH Planet 4 is almost completely copied from the Jupiter model that was the first to appear on the factory assembly line.

The only differences are that:

1. The Planet family has one working cylinder, and accordingly the ignition system is designed to ensure its operation;
2. The IZ Jupiter family, unlike the Planet, has 2 working cylinders; accordingly, the wiring diagram has additional repeating elements.

Headlight

IZH Planet 4 is equipped with more advanced lighting devices:

1. Headlight type "European beam" FG137V with glass with an asymmetrical pattern;
2. Low beam mode with lamp A12-45 + 40 W;
3. Modern direction indicators type 16.3726 (lamp power - 25 W).

Photo of IZH Planet 4 model 1986

Thanks to the modernization of the lighting system, as well as the configuration of the motorcycle:

1. battery 6MTS-9;
2. high power alternating current generator 100 W,

The illumination of the road in the flow of traffic has significantly improved, and traffic on public roads has become safer. At the same time, the price of the motorcycle did not change significantly, which brought its sales to a new level of popularity.

Contactless ignition system

The motorcycle used a new contactless ignition system, the operating principle of which was based on the following operating algorithm:

1. The generator rotor generates pulses when rotating;
2. The storage capacitor is charged through diodes (in the diagram below indicated as VI, V5), as well as through a limiting resistor (R1);
3. Passing through the diode (V6), the electrical signal from the sensor winding (3) enters the thyristor (V4);
4. After it opens, the charged capacitor (C1) transfers the accumulated charge to the ignition coil (primary winding - 4);
5. Under its influence, a high voltage pulse is induced in the secondary winding;
6. Through the high-voltage wire, the central electrode of the spark plug receives a charge;
7. A spark between the electrodes ignites the air-fuel mixture in the motorcycle engine cylinder.

The factory instructions contain the original diagram of the contactless ignition system

The electrical wiring of the IZH Planet 4 motorcycle, due to the peculiarity of the contactless ignition system, has differences in the layout of the main components:

1. The electronic unit of the stabilizer and ignition system is placed in a single housing;
2. It is equipped with two plug connectors;
3. In order to increase reliability, the block is filled with polyurethane foam (non-separable version);
4. Its operating parameters are designed to provide a light signal circuit voltage in the range of 11.5 – 14.5 V.

In addition, the use of a 12-volt circuit led to the division of the ignition system into three electrical circuits that differ in voltage levels:

1. A high-voltage circuit consisting of an ignition coil, a spark plug, a spark plug tip and a high-voltage wire;
2. Storage capacitor charging circuit, consisting of a charging winding, connecting wires with plug connectors, BCS and the primary winding of the ignition coil;
3. The sensor circuit, consisting of its winding, connecting wires and plug connectors.

Generator IZH Planet 4

A more advanced generator began to be installed on the new model of the Izhevsk Motor Plant, capable of serving the increased needs of the electrical equipment system, in contrast to the wiring diagram of the IZH Planet 3.

Original factory circuit diagram of the IZH Planet 4 motorcycle generator

Among the design features it is worth highlighting:

1. Eight coils placed in the stator slots;
2. Serial connection diagram;
3. Coating of coil windings with insulating varnish;
4. Original fastening to the stator, made using washers and bent petals.

To identify faults with your own hands, you need an ohmmeter or a universal tester, which can be used to measure the resistance of the windings:

1. If the values ​​of the measured resistances differ significantly, it is necessary to inspect the generator stator to detect broken winding leads;
2. The reason for unstable operation may also be their short circuit. If possible, identified faults are eliminated by soldering.

Main stage

As noted in the assembly diagram of the Izh-Planet 5 box, further disassembly operations are carried out above the insides of the roof of the unit, since the secondary shaft and sector could remain in it. If it is necessary to remove them, you need to straighten the petals of the lock washer, unscrew the nut, remove the star and washer. Holding the gear very carefully to prevent the shaft from jumping out, the cover is moved to a clean and flat surface with the gear facing up.

It is worth noting that the bearing of this part of the assembly does not have a retaining ring. Therefore, when removing the shaft with bearing, the rollers may fall out, so be careful. If the specified element has exhausted a decent service life, there is a risk that when dismantling the secondary shaft, the outer ring may jump out of the seat and remain on the rollers. Next you need to start pressing out the oil seal. To do this, the installation rings are removed from the hole in the cover, after which the outer ring of the bearing is removed.

Maintenance Features

Often during operation it is necessary to correctly set the gap between the contacts of the breaker. To do this, you need tools and a diagram to see which elements need to be dismantled.

Tip: a video on servicing a particular motorcycle component is a good help these days. For example, on our website there are materials on servicing several brands and models, and you can glean the information you need from them (see, for example, the article on Java 350 wiring).

The algorithm of actions is as follows:

1. place the motorcycle on the stand;
2. turn on neutral;
3. unscrew the spark plug from the cylinder;
4. remove the engine crankcase cover;

1. turn the crankshaft until the contacts are as open as possible;
2. using a screwdriver, loosen the locking screw;
3. using a special feeler gauge, set the gap to 0.35-0.45 mm and fix it with a screw;
4. we collect everything in reverse sequence;

1. turn on the ignition and start the engine. Its stable operation at idle indicates that the adjustment has been correctly performed.

In general, all the wiring of IZH Planet 5 is very easy to do with your own hands.

The need for such work often arises when operating a motorcycle:

1. in wet weather, driving in the rain for a long time (oxidation or dampness of electrical contacts);
2. when traveling over rough terrain, replete with vegetation and bushes (mechanical damage to wiring);
3. when used in winter (snow and slush stick to the wires and can damage them).

Often the sound signal suffers during operation. Its malfunctions manifest themselves in the form of deterioration in sound quality.

To restore its functionality, you must perform the following procedure:

1. loosen the locknut using an open-end wrench;
2. turn on the ignition;
3. press the button to turn on the sound signal;
4. use a screwdriver to adjust the tone;
5. repeat the procedure until we get a clear and loud sound;
6. tighten the control nut.

Conclusions: we are confident that this article will help you in servicing motorcycles of the IZH family (see also the article on the IZ Jupiter 5 wiring diagram). Both the attached diagrams and description will help you avoid making mistakes during operation.

Final stage

Next, the second and third speed gears are removed from the input shaft, after which the input shaft is dismantled. To do this, you will need to carefully knock it out using a stopper and a light hammer. The upper and lower forks are removed.

Next comes the intermediate shaft assembly. Using a screwdriver or other suitable tool, bend the clamp with the neutral indicator and carefully pull out the worm wheel. On its far side there are shims that could stick to the crankcase. They need to be collected and stored with the rest of the removed parts. Next is the turn of the copy shaft. Check the edges of the shaped sockets in which the guide forks move. They should not have chips or dents. We unscrew a couple of screws securing the switching mechanism, which is also removed. Now you can replace unusable parts and assemble the Izh-Planet 5 gearbox according to the scheme. The figure below shows: retaining cap (1), bolt (2), crankshaft sprocket (3), double-row chain (4), clutch drum (5), input shaft (6).

Retro style

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Nowadays, the fashion for old and vintage cars and motorcycles is actively developing. Models from 30 to 50 years ago are kept in barns and distant villages to be restored to their original form. The idea of ​​this style is a complete or partial restoration of the motorcycle to its factory appearance. The closer and better the work is done, the better the tuning of IZH Planet 5 with your own hands looks photo:

Do not think that it is so simple, because even for such a relatively new model, it is becoming increasingly difficult to find original spare parts. Particularly expensive are fragile dashboards, original trunks and dented gas tanks. You'll have to hunt for these details. It will be very expensive to restore Soviet chrome and paint all chips and scratches. This style is suitable for true connoisseurs of the brand and those who prefer to spend hours and days in the garage.

Repair

Once the unit has been gutted, you can begin to determine the parts that need to be replaced. As a rule, you have to buy a set of shims, a set of gaskets and sealant. This is the case if there are no more serious damage. Once you have decided on the elements to be replaced, you will need to adjust the worm shaft axis, and after final assembly, the clearance along the axis of the primary, intermediate and secondary shafts.

Adjusting washers are placed on the far ledge of the copy roller; they should be lubricated with a special compound. A support washer is mounted on the near edge, and the shaft is put in place. It should be turned so that the neutral sensor with its protrusion fits into the deepest groove. Then, using a ruler (without the gearbox cover yet) on the plane of the crankcase, measure the gap between the washer and the dipstick. It should be no more than 0.2 mm. Depending on the indicator, regulators are added or removed. If it is impossible to accurately set the gap, it is better to make it smaller.

Installation of bearings and seals

We install a retaining ring in the left half of the crankcase.

Depending on the model of the main oil seal, we install a spacer sleeve in the mounting hole of the main bearing, or, if the oil seal was initially wide (there are some), we heat the crankcase and, on the inside of the crankcase, place the oil seal until it stops against the retaining ring.

My engine had a regular narrow oil seal, so I put in a bushing.

Using a mandrel, install the main oil seal into the preheated crankcase.

Quickly, before the crankcase cools down, place the oil guide washer on the oil seal. The oil guide washer has a saucer-shaped profile. We place it on the oil seal so that the concave side faces us, and the curved side faces the clutch basket.

While the crankcase has not cooled down, we press the outer race of the main bearing into it using a mandrel.

If you are going to replace the main bearings with new ones, don’t be lazy: find a sheet of iron 7-8 mm thick, cut a wedge in it for the connecting rod, pass the sheet of iron between the cheeks of the crankshaft and use a mandrel to drive the main bearing onto the axle.

This way you will protect yourself from damage to the crankshaft. The main bearing has a very high interference and fits into the axle with a very large force. It is not uncommon for people to simply knock out the axle (the axle on the planetary crankshaft is pressed into the cheek) inside the crankshaft, but they were never able to put the bearing on.

Source

Assembling the box on the Izh-Planet 5 motorcycle

For proper assembly, you first need to install the input shaft, then the first gear gear with the groove down. Then the return spring is mounted with the range shift shaft; first, put on the spring mechanism and place the block in the seat. After this, a worm shaft with adjusting washers is installed. To make installation easier, lubricate the moving mechanisms with Lithol.

When installing the unit, care must be taken not to damage the neutral speed sensor. To get the shaft into place, use a screwdriver to bend this indicator slightly. When installing, remember the small washer, which eliminates play. A similar part is installed on the copy shaft. After this, the gear shift compartment is installed.

Characteristics of the IZH-P5 motor

Important

When performing these operations, follow the mark in the middle part of the sector. It should coincide with a similar mark on the shaft. The last step is to install the crankcase cover. If the work is carried out correctly, it will sit in its place without problems.

It is necessary to ensure that all rods and shafts coincide with their original mounting sockets. They should rotate freely without creaking or jamming. Use moderate force when tightening the screws as the threads in a soft metal crankcase can easily be stripped. All fasteners are tightened evenly to avoid distortion.

Familiar problems

"Gazelle": disassembling the box. “Gazelle Next”: disassembling and assembling the gearbox

Reviews from owners indicate that, regardless of the version and year of manufacture, the Izh Planet-3 motorcycle had the same disadvantages:

• Engine vibration associated with its design features. Almost all single-cylinder engines suffer from this.
• Problematic electrical equipment. Almost identical to the Jupiter of the same years of production, the 6-volt wiring installed on Izh Planet-3 was not of very high quality. An insufficiently powerful generator created problems when driving at night.

Completely eliminating engine vibrations is almost impossible. Even serious engine tuning does not completely solve the problem. You have to put up with this feature of technology. As for electrics, motorcycle lovers who are interested in tuning Izh Planet-3 often ask the same questions:

• How to detect ignition system malfunctions?
• What to do if charging is lost?
• How to replace the relay regulator?
• Does it make sense to install electronic ignition?
• How to replace a failed generator?
• Where can I find the wiring diagram for Izh Planet-3 at 6 volts?
• How to install BSZ?

These questions are countless and it is simply impossible to answer them in one review article. This requires digging deeper. And therefore we will try to answer as briefly as possible.

1. Since the wiring diagram on Izh Planet-3 was repeatedly changed even depending on individual series, one cannot count on an exact match of its description. Sad but true.
2. Replacing electrical wiring, switching electrical equipment operating from 6 volts to 12 volts and installing contactless ignition are completely justified steps to improve the performance of a motorcycle. After such modernization, ignition installation is simplified, and engine operation becomes more stable. At the same time, you will know exactly how the electrical circuit of your Izh Planet-3 works!

But it’s clearly not worth getting down to business without the necessary skills or suitable tools. As for DIY tuning enthusiasts, for them the Izh Planeta-3 motorcycle is an unplowed field for activity. There is room to expand here. Go for it!

You'll find some, you'll lose some.

The Third Planet, due to its lower motor power, was somewhat inferior to Jupiter in dynamics. Owner reviews indicate that this shortcoming was compensated for by better traction at low speeds. This gave certain advantages when driving over rough terrain.

But, despite the fact that the engine capacity of the Izh Planet-3 remained almost the same as that of the two-cylinder unit of the older model, fuel consumption increased significantly. At high speeds it reached 5 liters per 100 km. But the ignition adjustment has been simplified.

Izh Planeta-3 was produced from 1971 to 1977. During this time, 478,496 vehicles of this modification were manufactured. They had minor differences, such as the color of the seat upholstery materials and the side trims on the tank.

First changes

In 1977, the next version of the motorcycle went into production - Izh Planet 3 01. When creating this model, the developers followed the same path as when modifying the Izh Jupiter. The changes affected:

• Front fender, height-adjustable above the wheel.
• Rear shock absorbers, the design of which has been significantly improved, adding the ability to change the spring preload.
• Power unit. Boosting the engine by increasing the compression ratio made it possible to increase power to 20 hp. With. But this required installing a spark plug with a different heat rating - A-23, increasing the area of ​​the cooling fins and changing their shape.
• The design of the steering wheel, on which rear-view mirrors appeared, and the ends of the control handles received protection for hands in case of a fall in the form of rubber balls.
• Front brake that got a brake light frog.
• Installed standard safety bars that protected the motorcyclist in an accident

The last motorcycle Izh Planeta-3 01 rolled off the assembly line in 1981. By this time, 400,845 copies of this modification had been produced.

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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...

An example of worn teeth.

It is not uncommon for the basket body to burst. Unfortunately, the body is made of cast iron and welding it will be problematic. If you find cracks on the body, try to find a welder who welds non-ferrous metals, the so-called “argon welder”; they usually take on welding cast iron.

An example of cracks in the basket body. By and large, this basket can still be saved: chamfer the cracks, weld and turn the seams on a lathe. But the teeth under the motor chain were worn out and I threw it away.