Photo report: Repair of the clutch of the Voskhod and Minsk motorcycles

Coils B-300 and 2112.3705 are designed to work in “classic” ignition systems powered by an alternator G-401, G-411 and G-421. Such coils were installed on motorcycles K-58, “Kovrovets-175A”, “Kovrovets-175B”, “Kovrovets-175V”, “Voskhod”, “Voskhod-2” and motorcycles of the Minsk motorcycle plant M-103, M-104, M-105, M-106 and MMVZ-3.111.

Coils B-300B and 2102.3705 operate in contactless electronic ignition systems with generators G-427, 43.3701 and 80.3701. They were installed on motorcycles “Voskhod-2M”, “Voskhod-3″, Voshod-3M-01”, “Owl”, “Farmer”, “ZDK-175-4ShP” and motorcycles “Minsk” -MMVZ-3.115, MMVZ-3.112, MMVZ-3.113.

THE CAUSE OF THE BAD SPARK ON THE PLUG WAS AN INSUFFICIENTLY SEALED IGNITION COIL B-300. HOW TO CHECK IF THE COIL IS OPERATING AND CAN IT BE REPAIRED?

The presence of such a defect is easily verified. After drying the coil, sparking is restored. We offer a simple repair method. The gasket under the cover is replaced with a homemade one cut from thin rubber (for example, a tube from a bicycle tire). To ensure that the lid is tightly and reliably pulled to the body, install bracket 1 made from a steel rod with a diameter of 4-5 mm (Fig. 5.29).

Place a cracker 2 under it, made from the thinned part of the lid made of solid electrical insulating material. Secure the bracket with strap 3. Now the coil will not be afraid of moisture.

PROVIDE THE DATA OF THE DR-100 THROTTLE FOR THE “VOSKHOD-2” MOTORCYCLE. WHAT SHOULD BE THE WINDING RESISTANCE?

The DR-100 throttle core is assembled from non-standard strips 41 mm long and 0.5 to 1.0 mm thick. Thus, its cross-section (under the winding) is 7x8.6 mm. The inductor winding consists of 240 turns of PEV-2 wire with a diameter of 0.64 mm (copper). Winding resistance is 0.5-0.7 Ohm. inductance 2.3-2.6 Henry.

WHAT TO DO IF LIGHTING LAMPS FREQUENTLY BURN OUT?

With a correctly assembled motorcycle electrical circuit, the lamps burn out due to a malfunction of the P200 light switch or a breakdown in the connections between the headlight lamp and the socket due to oxidation of the lamp contacts. P-200 switches are not reliable, so owners of Voskhod motorcycles are recommended to slightly alter the electrical circuit by including a two-pole toggle switch TP1-2 and a DR-100 throttle (used on Voskhod-2), as shown in Fig. 5.30.

You can make the throttle yourself. 245 turns of PEV-2 wire with a diameter of 0.64-0.69 mm must be wound onto an open core with a cross-section of 0.65-0.7 cm 2 made of transformer iron. After alteration, lamp burnout for the above reasons is excluded.

THE SOUND SIGNAL TYPE 12.3721 INSTALLED ON MOTORCYCLES “ZDK” MAKES A HAZZY AND WEAK SOUND. IS THERE A WAY TO EQUIP VOSKHOD WITH A MORE POWERFUL HORN?

To do this, between terminal “01” of the BKS unit and “ground” you must connect an electrolytic capacitor (or a battery of capacitors) with a total capacity of at least 2000 microfarads, an operating voltage of at least 20 V. (“minus” to “ground”) After this, instead of signal 12.3721 You can install almost any car or motorcycle DC signal - S-39, S-205, S-304. It is best to place the capacitors under the filter air intake cover.

If the signal stops working, most likely the cause will be a break in the KD 202 diode connected between terminals “02” and “01” of the BKS unit. To eliminate the defect, it is enough to strengthen the diode outside the block (Fig. 5.31).

Generator Voskhod G-427

Generator G-427 alternating current with excitation from a permanent magnet with an inductive sensor of the electronic ignition system. In the grooves of the stator, made of stamped electrical steel plates, eight coils are placed, which form four independent circuits: - power supply to the ignition storage capacitor; — lighting and sound signal; — direction indicators; — braking signal.

Voltage regulation in the circuits of lighting loads is carried out according to the principle of parametric regulation, i.e. The winding data of the generator are selected in such a way that as the rotor speed increases, the voltage at the generator terminals changes within certain limits for a certain load. Attaching the generator stator to the engine crankcase provides adjustment of the ignition timing.

On the generator stator cover there are terminals: - charging coils of the power supply circuit of the Voskhod ignition storage capacitor; — direction indicators; — brake signal; — lighting; — sensor.

Which are marked accordingly: >, >, >, > and >.

The sensor is mounted on the generator stator cover using screws.

Generator rotor

The generator rotor with the sensor rotor located on it is mounted on the right axle axis of the engine crankshaft with a bolt and is secured against rotation by a key.

Assembly

I won’t rant too much on the topic of assembly since assembly is done in the reverse order of disassembly. I will dwell only on the most important points.

We put the sprocket on the crankshaft journal and tighten the nut; we put adjusting washers on the gearbox shaft and then put the basket there along with the spacer sleeve; position the engine relative to yourself so that you can clearly see how aligned the teeth of the motor chain sprockets are relative to each other

In my case, the misalignment of the teeth was about 7 mm. The norm is within a millimeter. For clarity, I attached a ruler to the star. If you have the same situation with the alignment of the teeth, place adjusting washers under the spacer sleeve until the teeth are exactly opposite each other. If this point is neglected, the chain will work skewed, and this will lead to rapid wear of both the chain itself and the teeth of the basket and sprocket.

After installing two additional shims, the tooth misalignment situation was completely resolved.

We install the clutch parts in their places, tighten the nuts and secure them with washers.

We look for the thickest one among the metal disks and install it on the inner drum - with the chamfer facing the engine.

Next, we put the plastic disk behind it with the metal one, and so alternating the disks with each other, we assemble the basket.

We put the clutch rod in place.

We install the pressure plate, tension the springs, adjust the clutch and screw on the cover

Caring for a sunrise motorcycle generator - how to remove, what to check and install correctly

Generator maintenance mainly comes down to tightening the threaded fasteners of the generator stator and rotor, as well as the wire terminals.

In order to remove the generator, you must:

• disconnect the wires of the ignition circuit, sensor, brake light and direction indicators from the generator terminals;
• unscrew the three screws securing the stator to the crankcase and remove the stator;
• Unscrew the bolt securing the generator rotor and, with light, careful blows of a wooden hammer on opposite sides of the rotor, remove it from the trunnion and remove the key.

Checking the removed parts

After removing the generator stator and rotor, wash the parts with clean gasoline and carefully inspect them. Disassemble the wire fastening terminals on the stator. Wipe dry all insulating parts of the terminals.

Generator installation

Installation is carried out in the reverse order, in this case it is necessary:

• check the runout of the generator rotor, which should be no more than 0.1 mm with the bolt secured;
• tighten the generator stator without distortions, ensuring a tight fit to all three supports;
• install the ignition correctly;
• The generator wires must be securely fastened and well insulated from each other.

Ignition adjustment Voskhod

The ignition timing is set by turning the generator stator after first loosening the three screws securing the stator to the crankcase. For normal engine operation, it is necessary that the moment of spark formation (on the generator, this moment is determined by the coincidence of the sensor rotor groove with the protrusion on the sensor coil frame. Fig.) coincides with the moment when the piston does not reach the top dead center of 2.5-3.0 mm (at running the engine on gasoline with an octane rating of 92).

The gap between the rotor and the core of the sensor coil should be within 0.3±0.05mm.

The gap should be set as follows:

• loosen the screws securing the sensor stator to the generator stator cover;
• By moving the sensor stator in the grooves of the generator stator cover, set the required gap, and then tighten the fastening screws.

For more accurate ignition installation, it is recommended to determine the piston position with the cylinder head removed.

Switch Voskhod - electronic KET-1

The electronic switch KET-1 is designed to work in the ignition system complete with the G-427 generator and the B-300B high-voltage transformer. Allows you to obtain a secondary voltage of up to 18 kV, at a generator rotor speed of 250 to 7500 rpm. The switch is installed in the right toolbox. The base of the commutator is connected to the ground of the motorcycle. If the switch fails, it can be disassembled and repaired

The electronic switch has three output terminals with letter markings on the body >, > and >. The ground terminal is the base of the switch.

Maintaining the switch during operation comes down mainly to tightening the threaded connections, while avoiding stripping the threads. It is necessary to protect the switch from moisture getting inside it and onto the terminals from sudden shocks and exposure to high temperatures. You should also systematically check the reliability of the electrical connection of the switch base with >, because If this condition is violated, sparking on the spark plug stops.

Spark plug Voskhod - spark ignition type A-23

During operation, the spark plug must be periodically cleaned of carbon deposits and the gap between the electrodes must be adjusted, which should be within 0.6-0.7 mm, which is ensured by bending the outer electrode. To seal, a copper-asbestos gasket is placed between the spark plug and the cylinder head. To eliminate radio interference created by the ignition system, a shielded tip of type A-4 is placed on the spark plug.

Ignition switch Voskhod - central switch

Switch 124005490201 is used as a central software switch that provides the necessary switching of lighting equipment on a motorcycle. The switch has three operating positions >, >, > in accordance with the following operating modes:

• in position > - the generator sensor circuit is shorted to ground, which ensures the engine stops.
• in the > position (driving during the day) - the ignition circuit is turned on, the direction indicator circuit operates (when the direction indicator switch is on) and the brake signal circuit (when the brake pedal is pressed);
• in position > (driving at night), two circuits are switched on:
• a) a circuit of speedometer backlight lamps, license plate lighting and city driving (through a throttle, which serves as a device that complements the parametric control of the generator);
• b) headlight lamp circuit A6-32+32 (via the light switch on the steering wheel).

Caring for the central switch comes down to periodically checking the reliability of the switch in the headlight and cleaning the moving and fixed contacts from dust and dirt by washing them in gasoline.

Model overview

The motorcycle was built on the basis of the Voskhod-3M-01 model, the start of sales was announced in 1993. The Owl was included in the light class of road motorcycles.

The plant produced two versions: initially motorcyclists could only purchase the “Sova-175” version, but after a short period of time the “Sova-200” appeared, which had a new and more powerful engine.

In appearance, the Sova motorcycle differed from the Voskhod in its more modern design, which could help attract Russian buyers who had already seen Japanese and American equipment.

Despite the changed design, the designers managed to preserve the flavor of old Soviet motorcycles. The photo shows that the motorcycle has compact dimensions, it has a comfortable seat and an ergonomic dashboard.

It is also worth highlighting that the Sova , in comparison with the Voskhod, received a new sports steering wheel , equipped with roll bars, a jumper and two rear-view mirrors. Touring equipment appeared on the motorcycle:

• Side bags made of leather substitute;
• A tablet bag mounted on the fuel tank;
• Rear luggage compartment equipped with side sections.

Stickers made of lavsan film appeared on the model - “Owl”.

The appearance turned out to be quite successful, since in the first years of sales the Owl motorcycle was very popular.

All motorists have already purchased, it’s time for us to purchase DVRs for our motorcycles. It's nice to see how you push the maximum, and to feel everything again.

We will share with you interesting thoughts about buying your first motorcycle on this page.

Switch P-200

Light switch with horn button (located on the left side of the steering wheel). To switch the low and high beam circuit, a P-200 type switch is used with a built-in push-button horn switch for three operating positions: neutral - the headlight lamp is off; far right - low beam is on; far left - high beam is on.

The horn button has a movable contact connected to ground and a fixed contact connected to one of the wires coming from the horn terminal. When you press the button, the contacts close and the signal circuit is completed.

Video

We present to your attention a video featuring the Owl motorcycle, once so popular and desirable.
Look what he can do! Did you like the article? Tell your friends!

Comments (6)

1. Sergey:
   02/28/2015 at 00:12

   A good, simple motorcycle in its class that does not require special or special care, and is unpretentious. Very affordable to repair.

   Answer

2. savnatra:

   02/28/2015 at 10:25

   Well, of course, I wasn’t familiar with this Owl, but the old Voskhod was still that problematic motorcycle. At least for me. I think Minsk is better too

   Answer

3. Andrey Dobryansky:

   03/01/2015 at 10:14

   I remembered my distant childhood. My brother took me for a ride on VOSKHOD. I think now is the time for manufacturers to increase production of this model. Economic instability will lead to an increase in the cost of imported analogues. A little work in the field of fuel economy (4 liters is somehow too much for a motorcycle), the design is almost brought to the world level - and you can safely flood the market with domestic models. After all, ours have learned to do it too!

   Answer

4. Alexander:

   12/17/2015 at 18:59

   I had a motorcycle like this) Yes, the design was cool for that time, all the girls were mine.. But it could only ride normally with one person, there was no traction with a passenger. Very weak, and never started the first time

   Answer

5. Dimas:

   06/06/2016 at 11:53

   I had to set it up, I still have 2 people, it pulls easily, it starts with one poke

   Answer

6. Basil:

   06/14/2016 at 14:45

   I had 1 - a Kovrovets, which outperformed all sunrises in its use, then I bought 2 - an M-106 motorcycle (Minsk blue motorcycle with a white tank, 4 speed) there were no complaints about it at all, an excellent motorcycle, the 3rd motorcycle was an IZH-Jupiter 3-02, when it was new, everything worked on 4, but the adjustment was not very good, 5 motorcycle - Izh-P-5, I consider this the best of all. 6 was Dnepr, MT-11 is just a nightmare. In general, the engines should be made 4-stroke and with electric start, if possible, an injection system, and of course the price is adequate, and not like quadrics are sold at the price of a car, in short, the pricing policy is a complete mess, and motorcycles are more expensive than cars, although production is much cheaper.

   Answer

Electrical circuit of the Voskhod motorcycle

Central switch. 2. speedometer. 3. Speedometer light. 4. Headlight. 5. Headlight lamp. 6. City driving lamp. 7. Sound signal. 8. Direction indicator lamp. 9. Direction indicators. 10. Direction indicator switch. 11. Electronic switch. (D - sensor terminal, K - ignition coil terminal, G - generator terminal.) 12. Throttle. 13. Relay breaker. 14. Generator. 15. License plate lamp. 16. Brake signal lamp. 17. Rear light. 18. Wire connection block. 19. Brake light switch. 20. Shielded spark plug cap. 21. Spark plug. 22. High voltage wire. 23. Ignition coil. 24. Light switch.

Wire colors: sn. - blue, cf. - gray, g. - blue, g. - yellow, h. - green, k. - red, kor. - brown, op. - orange, f. - violet, h. - black.

The landing dimensions and dimensions allow this to be done. However, the electrical circuit needs to be modified: connect the KET or BCS. Increased spark energy will require another reel - B-300 B, interchangeable in terms of landing dimensions with the previously used B-300.

Externally, the old and new reels are no different. However, numerous attempts not to change the old unit sooner or later ended with the windings burning out. Those who like to improve the performance of power systems can be advised to install a bobbin from IZH (7.109-37.05.010). Its use increases the duration of the spark pulse by approximately 15% and its energy by 60%. As a result, starting the engine is noticeably easier.

IS IT POSSIBLE TO CONVERT THE “VOSKHOD-2” MOTORCYCLE WITH ELECTRONIC IGNITION SYSTEM DEVICES WITHOUT REPLACING THE ENGINE?

Such a change is possible. To do this, instead of the G-421 generator, it is necessary to mount a G-427 on Voskhod-2. It should be borne in mind that to fasten the rotor of the G-427 generator, a bolt with an M7x1 thread 85 mm long is required, that is, 10 mm longer. After installing electronic system devices on the motorcycle, it is necessary to adjust the ignition timing - it is 2.5-3 mm for the piston. m.t. The moment of sparking corresponds to the coincidence of the groove of the sensor rotor, available on the G-427 generator, with the protrusion on the frame of the sensor coil (Fig. 5.23), while the gap between the coil core and the sensor magnet must be set within 0.3 ± 0, 05 mm.

To do this, first loosen the screws tilting the sensor stator in the grooves of the cover, set the required gap, and then tighten the fastening screws. It is somewhat more difficult to install the Voskhod-2M engine or electronic ignition system devices on the Voskhod and Kovrovets motorcycles. There, in addition to the work listed above, you will have to mount a central switch. To do this, it is necessary to make a hole with a diameter of 27 mm in the headlight housing on the left side (Fig. 5.24) in order to secure the central switch in it.

You can also replace the FG-138 headlight with an FG-133, and drill holes in the left casing of the front shock absorber to access the switch (Fig. 5.25).

The connection diagram for electrical components to the central switch is shown in Fig. 5.26. If your motorcycle is not equipped with turn signals, the coil of the G-427 generator, which operates on their circuit, remains unloaded.

THE ENGINE OF THE MOTORCYCLE “VOSKHOD-3” WITH ELECTRONIC IGNITION CONTINUES TO WORK AFTER IT IS SHUT DOWN. SWITCH IS OK. WHERE TO LOOK FOR THE REASON?

As practice shows, most often the reason lies in the sensor circuit. If the wire in terminal (4) of the ignition switch becomes loose, then in the “Off” position the sensor does not close to “Ground”.

ON THE MOTORCYCLE “VOSKHOD” WITH GENERATOR G-427, THE ANCHOR OF THE INDUCTIONAL CONTACTLESS SENSOR FRONTED. CAN IT BE REPAIRED?

When such a malfunction occurs, the ignition timing first becomes unstable, and then the armature can become so loose that the rotor protrusion hits it. As a result of such an impact, the sensor is significantly damaged.

If the sensor winding is damaged, it will have to be replaced with a new one.

If the winding is not damaged, then the sensor can be repaired.

To do this, you need to use pliers to return the armature to its original position and, having thoroughly degreased the adjacent surfaces, glue the armature to the sensor base plate and the coil with epoxy resin. After the resin has hardened, the damaged surface of the armature must be carefully processed with a file so that its surface becomes parallel to the component surface of the rotor. If you put the resin in a thick layer, then its excess must be removed so that it does not interfere with adjusting the gap between the rotor and the sensor. It is best to glue the anchor immediately on the new engine, without waiting for its failure, which, as usual, happens at the most inopportune moment.

THE MODERN IGNITION SYSTEM OF KOVROV MOTORCYCLES IS QUITE RELIABLE, BUT SOMETIMES IT FAILS. HOW TO CHECK AND ELIMINATE IGNITION FAULTS IN “OWL” AND “PILOT” MOTORCYCLES?

Before starting repairs, you should check for breakdown of the spark without a spark plug cap. Set a gap of 6-7 mm between the high-voltage wire and the cylinder head ground. If there is no spark. start searching for it more methodically. You probably did not connect the plug connectors tightly. Poor contact of the base of the BCS housing with the “ground” does not have any effect on the operation of the system - the “ground” is output by a separate wire. But in old KETs, the “mass” was brought out to the body, and its contact with the frame is necessary.

Motorcycle Specifications

Cooling in both versions is the same - air, which occurs through the flow of incoming air.

The air filter has not changed either - it is a contact-oil model, equipped with a polyurethane interlayer insert.

The chassis, design - everything is identical in the Sova-175 and Sova-200 motorcycles.

40 years of evolution and technical progress have given us today a technically well-equipped middle-class motorcycle - the Honda CB 400, the price of which is in our article.

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