Do-it-yourself overhaul of the Dnieper motor

In detail: do-it-yourself overhaul of the Dnieper motor from a real master for the site my.housecope.com.

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lanser_zareka
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Motorcycle: IMZ 8.103-30

Added: 18-02-2014 18:07:43

I also dream of a quiet ride in gear 5 at 120 km per hour. I'll put 10 or 9 on a pair, but I still want 5 gears. What solutions are there (inexpensive)?

Edited by lanser_zareka (18-02-2014 22:13:20)

Roma
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The crankshaft must be checked for backlash (away from you, towards yourself; right, left). The cylinders, if there is no wear (ovality, it is easy to check, you need to insert the ring into the cylinder and align with the piston, draw from top to bottom), you can not change.

on drakone
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if you want, change it. with carbs once and everything will not work out if you buy non-regulated

... heads, cylinders, rings, carbs, pistons, all this costs me 7000t.r. I think you also have not 20 and it will be shoveled if the knee is not dead, but it also costs only 2500, I think it will not reach that.
And the piston may not need to be changed, this time with savings. the cylinders you say change the jamb. well, you understand that things are not really worth it

lanser_zareka
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The crankshaft should be checked for backlash.

I will never believe that there are no backlashes. Even at the last run-in, I think there will be backlash. The question is how to determine if they are valid?
And in the cylinders, maybe the liners can be changed?

My question, apparently, is not understood) Of course, I want to change everything. But money does not fall from the sky) I would like to make it so that I do not climb into traffic at all for at least one season and go to any long distance without hesitation.

Video (click to play).

if the knee is not dead, but it is also only 2500

Do you know the golden saying of the English? We are not rich enough to buy cheap things. And here you can also add “I don’t have much money, time and only one life to buy the most responsible and loaded part in a motorcycle for 2500”. In general, I have a taboo on China. I will put only factory quality.

factory 5 mortar 14000 rubles

We start to go to extremes)

Added: 19-02-2014 16:16:49

Next week I'm going to the garden, I remove the engine with a box and take it home) I will start troubleshooting with your help

Roma
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There is always play on the crankshaft! But, to the right to the left, the allowable backlash is 1 - 2 mm. On your own, on yourself, there should be no backlash.

lanser_zareka
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What does it mean to the right to left, to yourself from yourself?

Sergei 472
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shake him in all directions!

Stierlitz
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Left / right - axial runout, from oneself / towards oneself - radial. Firshtein?

Roma
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Backlash 1 and Backlash 2 - right to left.
Backlash 3 and Backlash 4 - from yourself to yourself.

Backlash 1 and Backlash 2 approx. 2 mm tolerance.
Backlash 3 and Backlash 4 1 mm tolerance.

Sergei 472
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this is the rule of going to the men's toilet!

lanser_zareka
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Are there any tolerances for development?

Roma
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Added: 19-02-2014 23:02:43

You this, read the books. For starters, Kotova! Let Victor throw you off. Email him.

lanser_zareka
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Knees, of course. I hate reading electronically

Roma
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Print it out.

There must be a tight fit of the gear, the grooves for the keys (flywheel and gears) must be intact, not broken (imagine you crank the gear)

on drakone
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I hate reading electronically

Print it out.

finally killed

lanser_zareka
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Well! Priper I moved home, henceforth the spirit of opposites in the form of the smell of oil and benzene reigns in the air.
It's still a long way to the knee, not a single puller is missing while he drained the oil and removed the pots. What surprised me was that the oil turned black completely. And I drove on it no more than 100 km. This is a symptom of what?
Nobody said anything about the pots. Is it possible to recycle them, or is it better to have new ones right away? Both of them have some ruts in the mirror. In any case, I will sharpen for auto technology, but the notches will not go away.

Roma
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For pullers, you need a piece of a 36X32 wrench, a nut with a bolt and 2 fine-thread bolts. Here is such a puller, 2 holes for the flywheel and 2 holes for the KV cover!

lanser_zareka
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This is all good, of course, when there is welding and other delights of technical progress.

Bone1989
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For pullers, you need a piece of a 36X32 wrench, a nut with a bolt and 2 fine-thread bolts. Here is such a puller, 2 holes for the flywheel and 2 holes for the KV cover!

Interestingly, there were such factory keys.

Added: 27-02-2014 21:54:40

lanser_zareka
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I downloaded Kotov, but there is an emphasis on current repairs. Is there a literature about the cap specifically?

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"Dnepr" has been produced at the Kiev motorcycle plant since the middle of the twentieth century. In Soviet times, the Ural was popular along with the technology and was its direct competitor. Now the Irbit plant has stopped the production of its motorcycles, and the Kiev plant is still producing new models, such as Solo and KM38... They are popular for their reliability and power. Repair of the Dnipro engine is quite simple, which allows it to be done even on a trip.

All bikes of the Kiev plant have good dynamics and a pleasant sound, which is often compared to Harley. It was possible to attach a stroller to the main part, however, due to a reduction in production, models without additional seats or equipment for agriculture are currently being produced.

The most popular model is the Dnepr 11, engine tuning is presented in the 11M model, slightly modified with higher performance. Engine type - four-stroke carburetor, overhead valve with air cooling system. The two-cylinder Dnieper, with an engine displacement of 649 cm3, produces quite good power of 32 horsepower. The speed is 105 km / h according to the passport, but in fact it is about 120.

The box of the Soviet bike has a dry, two-disc clutch and four stages. Assembling the Dnepr 11 engine with such a gearbox is not a problem.Moreover, it is very reliable and rarely causes problems.

If your motor makes unnecessary noise during operation, it means that a problem has occurred in it that must be eliminated immediately. Everyone faced problems in the engine itself and more than once faced the fact that the assembly of the Dnepr engine is. However, few people encounter problems with the box. Therefore, let's talk about what questions may arise during the operation of the checkpoint and how to solve them.

At the first symptoms of self-shutdown, excessive noise of the gears or if the next gear is not turned on, jerks or jerks of the motorcycle occur. Doing repairs where necessary is impossible. Parts must be kept clean as dirt and dust have a very negative effect on engine performance.

Dnepr motorcycle engine repair directly related to the checkpoint... However, unlike many motorcycles, it is not necessary to remove both units. The box is removed separately. To do this, separate the clutch cable and neutral wire from the wheel, propeller shaft with rear axle. Then disconnect the air filter and drain the oil. Then you can disconnect the unit from the motor.

Wash the gearbox well with a cleaning agent and place it on a hard surface.
The kickstarter spring tension must be released first.
Disconnect the clutch lever and remove the slider with the rubberized ring.
Now you need to remove the kickstarter, with all its attachments (clutch tips, bearings and wedge).
Remove the cotter pin, then unscrew the disc nut on the rubber sleeve.
Unscrew the bolts securing the back cover of the box.
When the box is disassembled, it remains to find the problematic part and replace it, and then assemble it, having previously washed the gearbox from the inside.

As you can see, parsing the main elements is very simple and quick. But what if you wanted to make an engine tuning on Dnepr 11?

Many motorcycle enthusiasts like to improve the engine and they always have something to offer to increase the power. So, the modification of the Dnepr engine has several options. One of them: replacement of worn out parts and consumables that reduce the ability of the engine. Carrying out such manipulations will not greatly increase the indicators, but they will noticeably improve the work.

For greater effect, many owners put spare parts from foreign cars on their bikes. For example, the Dnepr 16 motorcycle, the revision of the engine of which is very difficult in stock condition, receives carburetors from other brands. Even a simple replacement of the exhaust pipe for any engine will add a drop of power to your pet. Feel free to experiment if you have a strong desire. Get involved in replacing the ignition and fuel supply system. This will help not only improve performance, but also significantly change the dynamics and handling of the motorcycle.

Image - Do-it-yourself overhaul of the Dnieper motor

On Sunrise 3, the engine worked well. But after the appearance of a gryma in it, I decided to make a cap. repair of the entire engine and gearbox.

It turned out that the crankshaft was rattling, the cams on the main gear were slightly beveled, there was a play in the bearings of the shaft knees, the clutch discs were broken, and the cylinder was worked out.

I ordered spare parts before they arrived, gave the cylinder for boring and bought something else for it.

Insufficient synchronization in engine operation means that one of the cylinders is showing more intensive work than the other. This can lead to the fact that the cylinder, which shows more powerful work, can very quickly wear out and fail. Do-it-yourself Ural engine repair. The timing of the carburetors is clearly visible when the motorcycle is idling. Synchronization of motorcycle carburettors occurs when the same operation of two cylinders is provided. Simply put, a motorcycle carburetor synchronizer is obtained by raising the throttle, both in the left and in the right carburetor, by switching ... >>> Read more

Adjusting the fork clearance is a fairly simple, but very important task in repair work. You can watch a video on fork repair in the Urals. In view of the fact that the wheel suspension on Dnepr motorcycles is made in the form of a telescopic fork, its correct adjustment will provide the necessary fork outreach for the normal movement of the motorcycle. Dismantling the front fork of the Dnepr motorcycle, like the Dnepr motorcycle, shows that a shock absorber is located inside the fork itself, and the distance between the upper part of the spring and the locknut is approximately 0.4 mm. The motorcycle fork is adjusted as follows: dismantle the front wheel, then unscrew the nut that secures the pipes to the motorcycle structure. We take out of this pipe ... >>> Read more

Adjusting the carburetors of the Ural and Dnepr motorcycle is not difficult, like the repair itself, but important. The brands, appearance, structure and details in motorcycles change from year to year. Including evolution affects carburetors, the constant improvement of which does not take long. I wonder where the carburetor is on the motorcycle?

The carburetor as a structural element is intended for mixing gasoline with air, as well as for the subsequent supply of an appropriate amount of it to the carburetors on the Dnepr motorcycle engine cylinder. The regulation process itself can be ... >>> Read more

During the life of the motorcycle, there is a possibility that the valves will need to be replaced. Lapping the valves in the Ural Motorcycle is an important matter. The question may arise, how to grind valves on a Dnepr motorcycle? The process of replacing the valve itself involves preliminary cleaning the cylinder head to such a state that it is possible to achieve the maximum tightness of its fit to the seat. These early tricks are essential for the correct operation of the engine.
To carry out this operation - cleaning the cylinder head, a certain algorithm of actions should be followed, step by step following it. First, the spring is put on the valve. The size of the spring is required to allow it to cope with ... >>> Read more

The most important point in which the adjustment of the valves of the Dnepr motorcycle and others lies is the correct setting of the clearances. If you overdid it a little and the gap turned out to be large, then there will be a clinking at the heads, if, on the contrary, the gap turned out to be too small, then the rods may begin to bend.The adjustment of the valves on the Dnepr motorcycle should be done after each manipulation of the assembly of the cylinders and heads, which must be securely fastened and tightened. Many people ask themselves how to set the valve to ... >>> Read more

The check of the ignition system, first of all, occurs from the initial check of the breaker performance. It is important to pay attention to the operation of the incendiary advance machine, in which the presence of various complaints is undesirable. The resistance of the primary winding, which is measured by the tester, must be at least 6 ohms. Next, the secondary winding is checked, for which the tester is connected to high voltage connections. The voltage of such a winding must be exactly ... >>> Read more

Repair and adjustment of ignition on a motorcycle Dnipro

Before starting all the manipulations to adjust the candles, you should pay attention to their external condition. They must be clean, without the slightest deposit of carbon deposits. Next, we make adjustments by alternately bending or unbending the candle contacts. With these actions, we reach the desired 0.5 mm in diameter - this is exactly the gap we need.

As in the case with candles, pay attention to the state of the breaker contacts. If there is any dirt on them ... >>> Read more

As soon as you are faced with the problem of lack of charging, you should not rush to dispose of the generator. The implementation of fairly simple, but effective methods will allow you to reanimate the generator without additional financial costs. By adhering to simple rules, you can quite effectively repair the device on your own.

First of all, you will need to dismantle the generator parts and clean them of dirt... This is followed by a check of the condition of the ball-type bearings: a test for the engagement of the armature to the stator. The course of the brushes must be free in the places where the brushes are held. The next stage - the production of rings is checked ... >>> Read more

Often, watching the engine overrun by my friends, it is not uncommon for a problem situation to arise: when I have already coped with the removal of parts from the engine and all that remains is to remove the crankshaft, unfortunately, this cannot be done. In reality, it is really difficult to remove it, and especially when there is no clear idea of how to implement it. In order to avoid this kind of problem, I will try to explain how to cope with the crankshaft.

To remove the crankshaft, you will need the following:
>>> Read more

The quality of the clutch is important for a motorcycle. This will require correct adjustment of the drive train. When the drive cable is taut enough, then the slipping of the clutch will be traced, if, on the contrary, the clutch is leading.

In the event of a failure of the starting device, as a rule, due to a breakdown of the starting spring or its exit from the bushing. In this situation, the clutch of a motorcycle Ural lever will not return automatically to its initial position, however, it can easily be resorted to a mechanical method of lifting up ... >>> Read more

Once you are faced with the problem of unsatisfactory gear shifting, then you should be on your guard. Probably, this can be attributed to the breakage of the gears of the box.... When the latter is not a problem, then you can turn to the adjustment of the gearbox with the screws located on the box near the base of the lever.

Here you shouldn't panic and rush to turn the screws. However, checking the condition of the balls and holes for the nature of breakdowns is still worth organizing a gearbox for a Ural motorcycle, do not forget to look at the health of the shift sector. If the situation inspires confidence in the reliability, then ... >>> Read more

As the saying goes, "We are responsible for what we have tamed."

The situation is the same with a motorcycle. Like any other technical device, the vehicle will require service.As a rule, services of this nature will be required every 2 thousand kilometers.

Services of a service nature can be performed, as a rule, at a service station, but it is always possible to perform them yourself. However, for this ... >>> Read more

It is often not uncommon when, during the operation of a two-wheeled friend, problems of various types are noticed in his work, for example, knocking, then you should not be afraid. The best solution in this situation is to carefully read the options below to fix the problem. The knocking pattern can be described as metallic or dry. The appearance of knocking can be triggered by starting the engine of the Dnieper motorcycle and decreasing as it warms up. This knock also appears in a situation where fingers are caught at the top ... >>> Read more

It is not uncommon for your "iron Horse" does not function as expected by the manufacturing plant, or even worse - refuses to work at all. However, "does not work" - the concept is quite cumulative, or as they say, the motorcycle does not start "every family is unhappy in its own way ...". In this regard, let's analyze problems of various kinds for faults ... >>> Read more

So, having assembled my long-suffering Ural in the spring of 2011, I rode it safely until the accident, which happened to me upon my return from Crimea.

A bursting rear wheel led to a fall at a speed of 110 km / h, a broken collarbone and a broken “chandelier” on a motorcycle.
Oh, what a chandelier it was! It's a pity. Now look for a new one.

Two weeks later, he was safely discharged from the hospital and went to work.

At the end of August, Nikita-Moro sends me a link to>, where, complete with the Ural 8.103-10, they give a liter engine from the Cross 1000.
I wouldn't be me if I missed this chance.
As a result, at the beginning of September, both the motorcycle (with a sidecar) and the "liter" are safely redeemed and transported to the VAZ 2104 from Dmitrov to my garage.

The engine is simply gorgeous, and practically new.

But there are several “buts” that interfere with its daily use.

1. The engine has no generator and no room for it.
2. The engine has nowhere to put the ignition.
3. The engine obviously did not run in, and that, God forbid, a thousand kilometers of its "run", was produced with obvious oil starvation and without an air filter, as a result of which the cylinders are badly damaged and are subject to boring.
4. From point 3 - production of new pistons with a diameter of 88.5 mm also follows.
5. The engine has a lightweight “to the edge” flywheel with 9 clutch springs. It is impossible to drive with such a flywheel on a daily basis. Idling around 1500 rpm, and starting off from 2500 rpm in the Urals is masochism.
6. The engine was designed for Dellorto carburetors with an accelerating pump with a diffuser of 36 mm, to put others on it - to lose all the "charms" of this engine.

In the course of parsing and communicating with Vasya, PP came to the following:

1. Install the Chudo Kilowatt of the original design on the engine
2. Thanks to Kilowatt there is a place for ignition.
3. Cylinders with 88.5 mm bore.
4. Pistons are ordered from NPO Avtotekhnologiya, rings from a foreign car.
5. Flywheel from the "economic council". Fortunately, the knee landing is similar.
6. We order carbs from Italy. Expensive, of course, but worth it.

At the moment, Comrade They threw us from Avtotekhnologiya….
They are not interested in whether you see making four pistons to order ...
Found an office in Zelenograd. According to rumors, they do it very efficiently. Soon I'll take everything to them.

Meanwhile, Vasily has almost completed Kilovatt.
Paid 25,000 rubles.

I have already found one flywheel, but it is defective - therefore I am still looking for it. Who has - respond.

While the court and business - attended to the arcs.
I'll leave the front ones with Voyazhevskie, just let them boil them wide.
Rear - from Ural Solo Classic.
Paid 3,000 rubles.

I gave it to the plant. There they carved new landing gears under the Wolf frame and welded them to the arches.
Paid 1,000 rubles.

Miracle Kilovatt at work.
VasilyPZ sprinkles over the engine day and night.

In the meantime, I have already bought new piston rings with a dimension of 88.5 mm.

I went to the glorious city of Kimry.

Price RUB 300

He also took the Miracle Wings from the early M-63.
All three fenders, rear, front and stroller. The condition is awesome, it looks like they did not stand on a motorcycle at all. A light bloom of rye only on the top, on the seamy side there is no dirt or rust at all.
I was painfully worn out with a deep wing without a wicket.
Now there will be a wonderful donor. And the yoke is very much in the subject of the Wolf-frame.

Rough assembly type with arcs.

Price RUB 1,000

Kilowatting of Liter continues!

Front engine cover after machining.

Italian Dellorto carburetors ordered, with 36mm diffuser and booster pump.
According to rumors, it was for these carburetors that the heads from my Liter were designed.

In the photo, the tubes of the cables are bent at 90 degrees, and the concentrators are lifted with a cable, but when ordering, all this can be changed. As a result, cable tubes similar to K68 were ordered, and the suction will be lifted by a lever.

Also ordered are the fixing of carbs to the heads.

Many thanks to Dmitry Night Rider Brunarsky for kicking the lazy Englishmen and generally taking over all the hemorrhoids of the checkout.

I took the cylinders and the piston to AMS-Service.

Two pistons - RUB 6,000
Boring 2,000 rubles

They said that the pistons would be made by January 21st.

He took new pistons at 88.5, and simultaneously bored the cylinders under them.

Two pistons, new and old, clad on one finger.

VasilyPZ prepared covers for sand / glass blasting.
Beauty!

I started checking the gas tank after sandblasting, which Kashchei organized for me
The price for sandblasting a tank and two wings is 3,000 rubles.

The tank is just a sieve. Tinkered for half a day. Like tinned it.

Yesterday I got the carburetors on my hands.

VasilyPZ also made me happy that the front covers of the Miracle Kilovatta are already ready.

I had to pay for two covers:

Yesterday I straightened the frame and the whole body kit in Dubna to Alexey (Beatle)

1. Unwelding the front arc in width under the "Liter"
2. Weld the base under the saddle.
3. Sealing the tank
4. Aligning the wings
5. Fitting the rear wing under the "sickles" Ural Wolf, welding extra holes, installing a brake light.
6. Installation of rear arcs
7. Remove the "eight" from the rear wheel.
8. Painting the entire motorcycle in two colors with the application of timing lines

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I gave up cotter pins for a long time, I use ABRO red thread lock with strong fixation.

and I put the connecting rods when the knee is already in the block with proper equipment, it takes 15-20 minutes for two connecting rods

I gave up cotter pins for a long time, I use ABRO red thread lock with strong fixation.
and I put the connecting rods when the knee is already in the block with proper equipment, it takes 15-20 minutes for two connecting rods

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Ruslan 18 Jan 2017

Despite the technical progress, I would not dare to put the connecting rod nuts without cotter pins. But I liked the idea, rationale and execution with a 209 rear bearing. I would make the engine now, put a ball on the rear neck 209. On my motor, before the repair and replacement of the KV, the axial play was about 1.5 mm due to the roller bearing and the worn out front journal of the KV. On the ball, this would not have happened. One of them would hold the HF in place. And for the thread lock, there are a bunch of other threaded connections.

Opposit4ik, you showed the roller bearing. In this case, the connecting rods fit to the crankshaft and then the knee is inserted into the crankcase without problems (as in the book). I showed a photo of how this is done in the second post in this thread. since there are oil seals in the guitar, it is more convenient to assemble so that nothing is cut off and crumpled

Video (click to play).

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