8-valve 1.6 MPI engines of the EA113 family were produced from the mid-1990s until 2013. They have been repeatedly upgraded and modified to comply with stricter environmental regulations.
On our YouTube channel you can watch a disassembly of the 1.6 MPI engine - a very common BSE engine removed from a 2009 Seat Leon.
This engine was installed on two dozen VAG models. These are all co-platform models of Golf 5 and Golf 6 such as Jetta, Touran, Caddy, Skoda Octavia A5, Seat Toledo and Altea. This engine was also used in the Audi A3 and Passat B6.
The 1.6 MPI (BSE) engine has a lightweight piston group and has lost the EGR valve. Otherwise, it is the same old engine of the EA113 family with a lined aluminum cylinder block, timing belt drive, and a plastic intake manifold with variable geometry. This engine also has a “secondary air” supply pump to speed up the heating of the catalyst.
You can choose and buy an engine for Audi, an engine for Volkswagen, an engine for Seat, an engine for Skoda in our catalog of contract engines.
Gasoline pump
A fairly common malfunction on VAG cars is a clogged mesh of the submersible fuel pump. Because of this, the pump does not provide sufficient fuel pressure, which is felt at high loads. Those. The engine starts normally, but when accelerating with the gas pedal to the floor or at high speeds, a failure occurs. In most cases, replacing the fuel pump strainer is sufficient.
The fuel pump itself may also fail or it will work intermittently. Accordingly, the engine will not start or will stall randomly.
You can choose and buy a fuel pump for Audi, a fuel pump for VW, a fuel pump for Skoda, a fuel pump for Seat in our catalog of contract engines.
Jerking at idle
The 1.6 MPI engine is characterized by slight jerking when idling. This is considered a feature of this engine, which is associated with a low idle speed of 640 rpm. Usually, twitching or dips are associated with an increase in the load on the engine when turning on electrical consumers, the air conditioning compressor, or turning the steering wheel (in this case, the load is supplied by the power steering pump).
If the engine shaking does not suit the owner at all, and there are no signs of malfunctions or misfires, then, according to the manufacturer’s recommendation, you can increase the idle speed to 730-750 rpm. This is done by the diagnostic software in one of the adaptation parameters.
Honda XR250 R
The airborne “Ikser-Chekushka” became a training desk for “millions of rural motorcyclists”; it was through it that they came to conquer off-road terrain and promote the slogan “everyone will ride an enduro.” An unpretentious, attractive and “indestructible” device is able to endure the hardships of off-road hardships for years: operation in brutal conditions, rare washes, even more rare maintenance, replacement of components only after their complete failure, repairs with a hammer, pliers and a screwdriver in the field, regular falls, overturns , flooding and hard contacts with stationary parts of the relief. I think the XR 250 R will definitely take first place in the Most Abused Motorcycle category. “Unkillable” is put in quotes because it is still possible to kill a Honda, nothing lasts forever in this world, but it can also be repaired - spare parts are available, mechanics are familiar with this engine, and there are no difficulties with its resuscitation and complete overhaul.
What does the 14-year-old XR 250 R represent at the moment? Maybe, by the standards of 2001, it would be a stretch to call it a sports enduro, but at the moment it is a soft and plush dual-purpose motorcycle for beginners and girls, with a not very high saddle, a soft engine, low-end traction and good handling. On it you can quietly puke through the forest, without being particularly bothered by the choice of the quality of the coating under the wheels, cross puddles and ruts, climb mountains and even jump over logs lying on the road. It performs well the basic elements of enduro, you just need to make allowances for the low engine power, the inertia in spinning the crankshaft and the fairly large mass of the motorcycle itself.
The ground clearance of 315 mm indicated in the manual does not correspond to reality, because the soft suspensions have sagged greatly over time, because gravity cannot be defeated. The motorcycle seems low, and the distance from the engine to the ground is unusually small. The engine is covered from below with frame pipes and aluminum crankcase protection, so there are no special problems with forcing logs and driving over rocks, but it strikes the protection over the terrain more often than modern sports enduros.
The suspensions themselves are soft and not very energy-intensive; when landing after jumps, they are often completely pierced. The existing adjustments are not enough; the springs need to be changed. There is no compression resistance adjustment, and you can adjust this parameter to suit yourself only by selecting the viscosity of the oil in the fork legs.
The seat is wide and comfortable by sporting standards, which allows you to use the Iksera as a touring motorcycle, even going around the world on it. You just need to find and install a larger gas tank from the Baja version.
A simple route computer can show the distance traveled and the time taken for two routes, as well as the current speed. In principle, there is enough information in the forest.
Cracks in the exhaust manifold
The 1.6 BSE engine has an old problem with exhaust manifold cracking. All VAG 8-valve MPI engines have suffered from this problem since the mid-1990s. As a rule, a crack appears near the 3rd and 4th cylinders. It is useless to weld it, the exhaust manifold needs to be replaced with an uncracked used one.
You can select and buy an exhaust manifold for an Audi 1.6 engine or an exhaust manifold for a Volkswagen 1.6 engine in our catalog of contract spare parts.
Aces up your sleeve
Jumping from saddle to saddle, you become imbued with love for the fresh “Chinese” and a sense of respect for the elderly “Japanese”, who is not ready to give up his position as the people’s favorite without a fight. Yes, the BSE rides much more fun, it has a more powerful engine, less weight, better handling, more energy-intensive and long-travel suspensions with a wider range of adjustments, and higher ground clearance. On the J 5-250 E you can and want to go fast, while on the XR 250 R you just want to go to get there. Despite the same engine power and torque values indicated in the technical specifications, the BSE is much more willing to lift the front wheel off the ground, allowing you to jump over a hole that suddenly appears on the way only by using the gas, while on the Honda you have to actively use the clutch lever to performing such maneuvers.
After the springboard, the suspension of the Chinese motorcycle works well for landing, while the “Japanese” one breaks through almost until the crankcase hits the ground. In ruts, the XR's low-mounted footpegs begin to catch on the side walls, while the J5's higher ones still stick out from above, leaving more room for maneuver. That is, in all driving parameters, China is ahead, and Japan is behind. But there is one “BUT”. The old samurai slowly and majestically pulls out an ace from his sleeve, which easily beats small Chinese trump cards: the presence of a title and the ability to register a motorcycle. While on the BSE you can only move along forest paths, and even then on a bird’s license, and you may experience big problems when exporting equipment abroad to Russia, on the XR you can safely and legally get to the forest along the road, without fear of running into to an ambush by paunchy guys from the traffic police. This also expands the scope of application of the motorcycle, allowing you to install 50/50 tires, and ride a motorcycle on weekdays to work, and on weekends in nature, albeit in the “light” style without mud and swamps, where such tires will be absolutely useless.
If you want versatility, then “Japanese”. Unpretentious, reliable, not the fastest, but ideal for learning the basics and acquiring skills. If you get tired of it, you’ll sell it in a few years, with almost no loss in price. If you want to be closer to sports, then “Chinese”. Sharper and faster, no reliability problems, but incompatible with public roads. You feel the prospect and growth of skill, then change it to a sports “European” or “Japanese”.
Of course, the BSE J5-250 could be cleared through customs as a motorcycle, fortunately, a full set of lighting devices is present, but this would further increase the cost, reducing the “availability” parameter: the price of under 200 kilo rubles seems humane only against the backdrop of 400+ for the “Japanese” and “Europeans”, but the figure itself is not amazing, unfortunately.
The BSE motorcycle was provided for testing, https://www.velocityk.ru, tel. +7 (499) 922-43-34. Honda motorcycle provided by a private individual. The editors would like to thank the SVR Team enduro school for their assistance in creating the material, https://svrmoto.ru, tel.+7.
Resize > 7 June 2015 10:59 Denis DEAN Panferov
Intake manifold
The intake manifold of the 1.6 BSE engine, like many of its close relatives, has a variable geometry intake manifold. Switching between long and short intake channels is carried out by a rotating spool drum.
On early 8-valve engines of the EA113 family, this drum causes knocking due to wear on its guide rings. But BSE engines and other more recent 8-valve VAG engines, as a rule, do not have problems with either the geometry drum or its drive.
You can choose and buy an intake manifold for an Audi engine, an intake manifold for a Volkswagen, an intake manifold for a Seat, an intake manifold for a Skoda in our catalog of contract spare parts.
Hello everyone, I’ll share my joy and perhaps my experience. Last year I bought my first motorcycle (Honda NC750X), and then a moped (Yamaha Jog). My birthday was approaching and my soul longed for change... I didn’t look for inspiration for a long time! I watched a bunch of videos and it was decided to bomb the family budget for a new endurik and, of course, full equipment! To get the initial skill and find the answer: “Why the hell do I need this!?”, with minimal financial costs (was spent: 180,000 rubles - mot; equipment - about 80,000 rubles) I made all my planned purchases on my birthday! What's the bottom line: - Equipment (the whole set) - maybe I'll write about it later... - BSE Z5 motorcycle, 2021, new (all right in cellophane). — Consumables, stands, etc. - another 10,000 rub.
In general, more about the motorcycle! On the day of purchase, they brought it straight to my garage.
The shipping oil was immediately drained and then the run-in at the garage cooperative began. After 5 engine hours I decided to completely disassemble it, finish it and service it.
Now, in order (I did all the work myself in my garage): — Disassembling and lubricating the rear suspension. There was almost no lubrication in it (in fact, like in other components).
— Opening the wheel bearing seals. The story is similar to the previous one...
— Opening the steering bearings. There was lubrication, but (see for yourself)...
— Pulling the spokes. The spokes from the magazine were almost dangling, and both rims had a slight figure eight. Using a simple device, it was possible to restore the geometry (there are plenty of videos on the Internet explaining the physics of the process - there are no difficulties).
— Drain the oil. The grid turned out to be clean. After 5 engine hours, the oil really got tired, and without frying...
— Removing the motor to check the gaskets and, of course, tighten all the bolts. The reason for opening the engine was that the gasket and seal of the cylinder head cover were damaged at the factory, as well as an incorrectly installed timing chain star. HORROR!!! Next, the valves were adjusted (intake - 0.06, exhaust - 0.08). Assembly and oil change (1 liter included).
— Fitting the main bolts onto the thread locker is a must!!!
— Relocation of electrical wiring and its “corrugation”.
— Lubricate the air filter and place it in a medical cap.
— Relaying the clutch cable (seen in the photo above, where the container with oil is) and reinforcing it with a rubber hose.
Overall, I'm happy with the purchase of this designer! Operation is already in full swing! Lots of emotions!
If you are thinking of buying similar equipment from China, then be prepared for the mandatory procedures indicated above, otherwise the motorcycle may simply begin to regurgitate individual components in the medium term.
Please do not judge the choice; I am not going to enter into controversy on this issue!
Throttle valve
The throttle valve on the 1.6 MPI engine is reliable and does not cause problems. But an error may appear indicating an unreliable signal from the throttle position sensor. In this case, it's all about poor contact in the electrical connector of the damper. As it turned out, the manufacturer saved on pins and then offered replacements with higher quality gold-plated pins, which need to be changed along with the wires. New wires must be soldered to the standard harness.
You can choose and buy a throttle valve for an Audi engine, a throttle valve for Volkswagen, a throttle valve for Seat, a throttle valve for Skoda in our catalog of contract spare parts.
Ignition coil
The 1.6 MPI engines use a dual ignition coil. It serves well, but over long runs its plastic body dries out and cracks, which causes misfires. Therefore, if there are any problems with the ignition system, you should inspect the coil body - perhaps it’s time to replace it too.
If you neglect to replace spark plugs every 45,000-60,000 km, the load on the coil increases and it may fail prematurely.
The spark plugs of cylinders 2 and 3 are located under the intake manifold, however, you can remove the tips of the high-voltage wires from them and unscrew the spark plugs using spark plug wrenches with a universal joint.
You should also inspect the contacts of high-voltage wires and the ignition coil once every couple of years - often a white or green coating forms on the contacts, which also leads to misfires.
You can choose and buy an ignition coil for an Audi engine, an ignition coil for a Skoda engine, an ignition coil for a Seat engine or an ignition coil for Volkswagen in our catalog of contract spare parts.
Injectors
Fuel injectors usually last a very long time and do not attract attention to themselves. However, the following malfunction is known: one of the nozzles may lose its seal along the spray needle. In this case, the engine will have difficulty starting after a long period of parking in hot weather. To accurately diagnose fuel draining from the rail, you need to check the pressure drop in the rail after stopping the engine. The measurement is carried out with a pressure gauge; the fuel pressure in the rail must be maintained at 4 bar with the engine turned off.
And to specifically find the pouring nozzle, it is best to use an endoscope: the pouring nozzle leaves a puddle of fuel on the piston.
A worn injector must be replaced with a new, working one.
You can select and buy fuel injectors with a ramp for an Audi engine, fuel injectors with a ramp for a Seat engine, fuel injectors with a ramp for a Skoda engine or fuel injectors with a ramp for a Volkswagen engine in our catalog of contract spare parts.
Position of piston rings
A good half of 1.6 BSE engines have rather indecent oil consumption - up to a liter per 1000 km. As a rule, increased oil consumption appeared already at a mileage of 150,000 km. Although some owners reported that the BSE engine consumed oil from the very first kilometers.
Typically, this engine does not consume oil during city driving, but actively “bursts” it when driving on the highway. The fact is that the 1.6 BSE works in tandem with a rather “short” 5-speed. The manual transmission also operates at high speeds in fifth gear in highway mode. In this mode, the oil scraper rings, whose height is 2 mm, do not cope with their task.
Oil burns appear due to coking and loss of mobility of the oil scraper rings. In addition to a decrease in the oil level in the sump, oil build-up is indicated by the appearance of oil deposits in the intake manifold, as well as oil deposits or wet oil on the spark plug of the 4th cylinder. It has been noticed that most often it is the spark plug of the 4th cylinder that becomes clogged with carbon deposits.
If oil consumption has just appeared and is not measured in liters per thousand kilometers, then decarbonizing the engine can help. If oil consumption is significant due to waste, you have to remove the pistons and change all the piston rings. In practice, the cylinders do not wear out or wear out.
The main reason for stuck oil scraper rings is considered to be low-quality oil, including that which was filled and recommended by dealers. There are also versions that some 1.6 BSE engines received defective piston rings, which initially had poor preload.
Also, those 1.6 BSE engines in which the oil was changed less than once every 10,000 km have noticeable oil consumption due to waste.
BSE J 5-250 E
A direct comparison shows that this is a motorcycle of a different generation. It has an inverted fork, a water-cooled engine, more modern shapes in the plastic and exhaust, and longer suspension travel. This orange and white motorcycle is much closer to the modern interpretation of the term “sports enduro” than its elderly ancestor.
As is usual in the Celestial Empire, there were some borrowings. The headlight mask and front fender clearly hint that the Chinese designer really likes Austrian off-road motorcycles. It’s good that they didn’t go so far as to directly copy engines and frames - it’s not so easy to apply European developments to Chinese production technologies. Outwardly it will be similar, but problems may arise with the resource. Therefore, we took our own motor, a water-cooled four-valve single-shaft that has proven itself well on the Kayo T6 and Bal t motors Dakar 250. It has a good balance of power and reliability that allows you to enjoy dynamic off-road driving without having to climb inside to rebuild it every third session.
The travel of the suspension, undamaged by time, and the height of the saddle, which is not nailed to the ground by gravity, also match the newer concept. In terms of size, this is a full-fledged men's motorcycle, and not a training desk for beginners and girls.
The seat has a clearly defined step, which even allows us to talk about lumbar support when riding while sitting, but the seat itself is not padded with comfort from the inside - it is a sports one, and according to the designers, you can sit in it only on the liaisons between special stages, and for most of the time you can drive in the rack.
The absence of a side stand also comes from the world of big-time sports. Like a cross-country motorcycle, the BSE comes with a steel triangle, which is inserted into the hollow axle of the rear wheel and serves as a stand, but it’s completely inconvenient to carry it with you through the forest; every time you have to rest, you have to look for something to lean the motorcycle against.
The instrument panel shows engine speed and rpm, a resettable trip odometer, and the number of the selected gear. A pictogram on the screen warns of low gasoline levels in the small 5.2-liter tank.
