Voskhod engine tuning for a homemade all-terrain vehicle

In 1983, the Kavrovsky plant launched the modernized Voskhod 3M motorcycle. The purpose of the modernization was to improve the operational and technical characteristics of the Voskhod motorcycle. The platform for creating the motorcycle was the Voskhod 2M model. Since the early 90s, serial production of the Voskhod 3M 01 modification began. But still, many owners of this device are not satisfied with the appearance. Therefore, in this article we will talk about tuning sunrise 3m.

Engine tuning

The Voskhod 3m tuning engine which we will consider is a simple, 2-stroke engine with one cylinder. This engine is considered its own development, but has many similarities with motorcycles of Japanese origin. Experienced tuners assure that with the right approach, you can extract almost twice as much power from this engine as it comes from the factory. But you can’t do it with just one stroke; you need a careful approach and studying mountains of specialized literature. Let's look at what we can change to ride the Sunrise motorcycle faster:

Motorcycle improvement

Boosting the engine The Voskhod motorcycle has not been produced for a long time, but it does not lose popularity in our time. This is due to the low cost of Soviet equipment. But the old technology has several disadvantages: low power indicators, outdated design. Therefore, in order to get a high-speed and modern means of transportation from an old motorcycle, drivers carry out tuning of the sunrise 3m with their own hands.

Appearance tuning

As for appearance, the list of improvements can be divided into three groups:

Today, the most popular is restoring the factory appearance of a sunrise motorcycle. As we have already said, retro motorcycles, which have become fashionable, are very popular among both young people and older people. Moreover, literally every element is subject to recovery and restoration. The motorcycle is disassembled down to the bolts and then reassembled.

And in this article you can learn how to make an ATV in your garage. Manufacturing technology, selection of spare parts and many secrets of construction.

Those who chose this vehicle not as a tribute to fashion, but as a practical motorcycle, prefer to modify the appearance. The improvements include those elements that this motorcycle is so lacking: a dashboard, roll bars, panniers, high-quality lighting.

Last but not least is the radical tuning of the appearance of the Voskhod motorcycle. Here we will place improvements that affected major components and frame geometry. Some craftsmen manage to convert this road motorcycle into a full-fledged cross-country or enduro motorcycle. A new tank is installed, the tail of the motorcycle is lifted up, and sports shock absorbers are replaced. The most experienced Kulibins integrate a mono shock absorber from Japanese motorcycles into the rear suspension. On the other hand, modifications to the chopper style. Here, a long front fork and a thicker rear wheel invariably appear. Together with the high handlebars and forward footrests, the landing turns into a lordly one. All that remains is to get a huge seat and you can absorb kilometers of roads.

Parts of the cylinder-piston group

Tuning sunrise 3m begins with improving performance characteristics. The maximum speed of the Voskhod 3M motorcycle can be increased by lightening the CPG parts. To do this, we use a milling machine to bore those places that do not affect the strength.

We lighten the connecting rod in the same way. To play it safe, you can find foreign analogues. Next, you need to bore the purge, inlet and outlet channels. This is done in order to better mix and ignite the air-fuel mixture.

Complete disassembly of the Voskhod motorcycle engine - we do it ourselves

It is not clear why Voskhods have gained fame as unreliable and capricious motorcycles. You might think that Jupiter or Ant is much better than Sunrise. However, this opinion still exists in the motorcycle community. Well, okay, if there is such an opinion, then so be it.

Someone had already “overhauled” the engine before us, then we drove it a little, removed the cylinder for boring and rolled it into the garage for the winter. While the motorcycle was standing in the barn, water began to flow into the engine... And when spring came to the yard, the owner wanted some drive... Well, let's give him some drive.

Replacing clutch discs

Motorcycles Voskhod, Voshod-2(M) and Voshod-3(M) were produced from 1965 to 1993 and were distinguished by excellent technical and operational qualities for their time. All of them were equipped with 173 cc two-stroke engines, which had one air-cooled cylinder and carburetor power. This allowed the motorcycle, depending on the modification, to reach a maximum speed of 90-105 km/h with a fuel consumption of no more than 4.5-5.5 liters per 100 km. In general, Voskhod has established itself as a reliable and durable vehicle, capable of operating for many years with proper maintenance. However, time takes its toll, and the need to repair Soviet equipment arises more and more often. Let's try to figure out what features are characteristic of restoring the main components and assemblies in the process of repairing a Voskhod motorcycle.

Technical characteristics sunrise 3m.

Engine

The “heart” of a motorcycle, even with the most careful use, gradually wears out - this is facilitated by the abundance of heterogeneous mechanical loads in the cylinder-piston group and other moving parts, temperature effects on the metal, the chemical composition of the working mixture and exhaust gases. DIY motorcycle repair Voskhod most often includes the following engine work:

Engine repair, like the repair of other units, must be preceded by a comprehensive diagnosis of its technical condition, which includes an analysis of operational parameters (approximate indicators of developed power and speed, fuel consumption, sound of operation, color and character of the exhaust). If necessary, diagnostics are performed on the bench, and specialized instrumentation is used.

It is important to navigate the structure of a two-stroke internal combustion engine of a motorcycle and understand how each specific type of repair is performed. So, when replacing piston rings, you can do without removing the engine. It is enough to unscrew the stud nuts, remove the cylinder cover and, opening access to the piston, bring the piston to top dead center. Then the worn rings are removed and new ones are installed. The engine is assembled, not forgetting to replace the gasket. This completes the repair.

Photo report: Installing a piston on a motorcycle “Izh”, “Ant”, “Voskhod”

In matters of choosing one or another engine repair strategy. When it comes to repairing Soviet two-stroke motorcycles, it is advisable to adhere to a strategy that involves the complete restoration of original parts. And if this is not possible, with a creaky heart, you are forced to buy counterfeit goods or look for a used option.

There is little point in dwelling on the boring process in detail. Boring involves restoring the geometry of the cylinder by increasing its diameter. You don't need to know more about boring. There are turners, let them bother with these subtleties

Supply system

To make the bike go faster, you need to adjust the original carburetor for a higher fuel supply or replace it with a more efficient one. To install a new carburetor, you need to perform the following steps:

• we grind aluminum bushings under the flange of the pipe attaching the carburetor to the cylinders;
• cut off the edge of the inlet channel;
• take a flange from an old carburetor;
• We fasten all the elements using cold welding.

The assembled carburetor must line up exactly with the intake port.

Ignition and carburetor

It is these two components that, as a rule, determine the stability of the engine. Often, interruptions in the crankshaft rotation speed, loss of traction, and difficulties starting the engine are associated precisely with their malfunctions. Repairing the ignition and carburetor usually comes down to adjusting them. Setting the ignition includes setting the gap between the coil core and the sensor magnet within 0.295...0.305 mm. The piston ignition timing should be 3.5-5 mm to top dead center. Adjusting the carburetor is somewhat more difficult. If you are repairing a Voskhod-3M motorcycle, then you will have to deal with the K65V carburetor, and the main tools will be the quality and quantity screws included in its design. Using the first, you can lean or enrich the mixture - change the proportion of fuel and air entering the cylinder. The second determines its volume per working cycle. With the standard setting, the quality screw is screwed in completely and then unscrewed half a turn. Then the rotation of the quantity screw achieves the minimum stable speed and the quality of the mixture is re-adjusted. Finding the optimal adjustment balance is a search for maximum traction and stability with minimum fuel consumption.

Improved ride quality

Along with the growth of power comes the need for its full implementation. To do this, you need to carefully consider the current state of the chassis system and, if necessary, adjust or even replace some components.

• Rear shock absorbers. The standard suspension is quite soft, so if in your improvements you are aiming to increase the acceleration of the Voskhod motorcycle, then it is worth replacing the original shock absorbers with adjustable ones. Hard adjustment corresponds to improved acceleration, and on the contrary, soft adjustment slightly slows down acceleration.
• Front fork. First, you should check the condition of the fork as a whole; to do this, you need to check its maximum travel in both directions. For this model, the difference between the upper and lower indicators should be within 20 - 40 mm. Less - the fork is too tight, more - the fork is too soft. If configured correctly, replacement or upgrading of this unit is not necessary.
• Tires. A very important point is the type of tires. If you travel in rural areas or are a frequent visitor to off-road conditions, then it is better to choose tires with a developed pattern. To move along the highway you need special road tires, which perfectly hold the motorcycle on a straight line and in difficult turns.

Preparation

Russian is Russian, so until we process all the parts properly with a file before installation, nothing will work out...

Insert the cylinder rings and use a feeler gauge to measure the gap in the lock.

To reduce engine noise and speed up the ring grinding process, remove small chamfers on their working edges (preferably)

To improve lubrication of the piston pin, use a 5-6 mm drill to drill through holes in the piston bosses (optional)

We remove flashes and deposits of metal in the cylinder windows and round the edges along which the rings go

Tuning options

Refinement of the design involves internal or external tuning. During internal modifications, the engine is rebuilt, driving parameters, suspension, and brakes are optimized. When external modifications are made, the motor vehicle is given a sporty style or it is converted into a chopper.

Features of internal tuning

Owners often rework the Voskhod-3M engine. To increase engine thrust, the factory paper air filter is replaced with foam filter elements. This helps reduce air exhaust friction. Then the jets and diffusers are polished using an abrasive material, the diameter of which affects the volume of fuel entering the engine.

To improve the fuel exhaust system, a new modernized carburetor is installed. From the existing pipe, take flanges for mounting on the cylinders, grind out aluminum bushings, and cut off the flange from the exhaust pipe. In an old carburetor, take a second flange. Using cold welding, the parts are connected.

The design is adjusted until it fits perfectly into the exhaust channels. Internal gaps are filled using epoxy glue.

Often rear adjustable shock absorbers are installed and sports tires are installed. When performing such tuning, the motorcycle becomes more aggressive and sporty.

Performing external tuning

In a sporty style

With a low seating position and a high front fork, there is a desire to modify the motorcycle in accordance with the sporty style. To do this, raise the rear shock absorbers and replace the exhaust pipe elbow. This way the exhaust pipe is level with the rear axle. Exhaust pipes with a larger diameter will improve the design and increase the traction of the bike.

External modifications can include painting, chrome plating, installation of nickel-plated arches instead of the old factory protection, installation of large rear-view mirrors, stepped seats and wheel tuning.

At the end of the tuning, a sports fairing is installed.

Chopper

When performing tuning for a chopper, shortened rear shock absorbers are cut off or purchased. Thanks to this replacement, the rear of the motorcycle will be lowered by several centimeters. The rear fork and wheel are replaced with wider ones. The angle of inclination of the front fork axis is replaced, and the cylinder covers are equipped with chrome plated cups. The same style is followed when tuning the headlights, rear lights, and dashboard.

Tuning for Cafe-bike

With such a modification, to reduce costs, they weld the rear part of the frame with their own hands, shorten the fork, trim and adjust other parts. For the steering wheel and seat, your own strength may also be sufficient. A headlight with a brake light is installed from trucks.

Most owners can carry out tuning on their own using only purchased parts due to the simplicity of the designs and the low cost of spare parts.

Released models[ | ]

"Sunrise"[ | ]

"(1965-1971) had a single-cylinder two-stroke engine, a two-channel loop blower according to the Schnürle patent, and a four-speed gearbox. Unlike its predecessor (motorcycle K-175V), engine power has been increased to 10 hp. (at 5,200—5,400 rpm), torque up to 14 Nm (at 5,100 rpm), contact ignition, G-411 generator, the shape of the gas tank was changed, a trunk and knee pads appeared[1]. Maximum speed - 95 km/h[2], dry weight - 110 kg.

"Voskhod-2"[ | ]

"(1972-1977) differed from its predecessor in technical solutions aimed at improving performance, reliability and appearance. In 1976 it was modernized. Externally, it differed from its predecessor in round direction indicator lights (previously they were rectangular), a rear light, and new-shaped mufflers. New light signaling devices, an electronic non-contact ignition system with a G-427 generator, and a new muffler were used. The strength of the teeth in the gearbox has been increased, and more advanced drive discs have been used in the clutch, which has increased the clutch safety factor to 1.47[1]. Engine power was 10.5 hp. (at 5,400 rpm), torque 15 Nm (at 5,200 rpm). Maximum speed - 95 km/h, dry weight - 112 kg.

"Voskhod-2M"[ | ]

"(1976-1979) had a new engine increased to 14 hp. at 5,500—5,800 rpm power (while maintaining the same working volume of 173.7 cm3) and maximum torque up to 1.6 kgf m (16 N m) at 5600 rpm due to changes in the configuration of the channels in the crankcase and cylinder and a new cylinder head (compression ratio increased to 9.2, no decompressor, central location of the spark plug in the combustion chamber). The new engine was designed for high-octane gasoline AI-93, but could also run on A-76[1]. The front fork has been changed - the diameter of the pipes has been increased and the shock absorbers have been improved, the fork travel has increased by 20 mm and amounted to 160 mm. Maximum speed - 105 km/h, dry weight - 121 kg.

"Voskhod-3"[ | ]

"(1979-1983) differed from its predecessor in a different gas tank (holds 2 liters more fuel), an intake system, rear shock absorbers with adjustment and increased energy capacity (located at an angle of 12° to the vertical, providing a wheel travel of 105 mm), springs rear shock absorbers became open. Modernized brakes were used (the diameter of the brake drums was increased from 125 to 160 mm), wheels with stronger spokes, a G-427 generator (rated voltage 7 V), a rear gear driven sprocket damper was introduced, the saddle was improved, a lighter front wheel guard was installed, reel throttle handle. Maximum speed - 105 km/h, dry weight - 125 kg.

"Voskhod-3M"[ | ]

"(1983-1993)[3] represented a significant modernization of the previous model. It received such innovations as an enlarged cooling jacket, an external instrument panel instead of a speedometer and warning lamps mounted inside the headlight housing, and received a new tank, maintaining the same volume. From 1988, the under-seat plate was replaced with a shortened one, painted in the color of the motorcycle, and the aluminum instrument panel was replaced with a plastic one. Some engines were equipped with Czechoslovak-made carburetors. 12-volt electrical equipment was installed, an FG-137B headlight with a “European beam” diffuser, and a new rear light with side reflectors. Above the headlight there is a block of control devices made of plastic: ignition switch, speedometer, indicator lamps for direction indicators, low and high beams. In addition, an anti-theft lock was installed. The front shock absorbers received corrugated rubber covers. A brake lining wear indicator was installed on both wheels. The motorcycle received a new profiled front wheel guard, a kickstarter lever with a folding pedal instead of a solid one, folding driver's footrests, and two rear-view mirrors. The factory warranty for the model was 20 months[4].

Transmission

During transmission repairs, the following work may be required:

Most of them require high qualifications and are difficult to do at home. The exception is the repair and replacement of drive mechanisms. So, sometimes there is a need to restore the splines for the gearbox foot, replace the clutch cable or its jacket, or adjust the clutch. These works are carried out without disassembling the crankcase.

Repair and operation of the Voskhod motorcycle are closely interconnected due to the age of the model. However, with the proper approach to organizing and carrying out repairs, the motorcycle will remain your faithful friend and assistant for a long time.

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