Replacing shock absorbing fluid. Telescopic plug -Construction, disassembly, assembly and installation

\u003e\u003e Telescopic fork. Telescopic plug -Construction, disassembly, assembly and installation. Replacing shock absorbing fluid

LLC "Mir Avtoknig"

Telescopic plug -Construction, disassembly, assembly and installation. Replacing shock absorbing fluid

Removal

The telescopic plug has to be removed and disassembled with the appearance of knocks in motion, deterioration of oscillations, leaks, as well as the planned replacement of the amortic liquid.

1. Remove the front wheel with a brake drum cover (see p. 98).

2. Disconnect the fastening of the mud shield of the front wheel from the left sliding plug.

3. The key to 14 mm weakening the tightening of the screw bolt of the top traverse of the steering column.

4. 27 mm key turns into several revolutions shock absorber.

5. The key to 17 mm weakening the tightening of the nuts of the tight bolt of the lower bridge (traverse).

6. With light blows of the hammer through a wooden spacer, we knock out the carrier pipe from the top and bottom traverse.

7. Take out the feather forks from the bottom traverse.

Similarly, we remove the second feather forks.

Installation

Install the plug in the reverse order.

Disassembly

1. Remove the feather forks from the motorcycle (see above).

2. Soak the shock absorber plug completely.

3. Inverting the feather of the fork, drain the depreciation liquid.

4. Pulling the pen in the vice for the lower tip, the protaded key of 11 mm with the extension, turn the bolt of fastening the hydraulic shock absorber.

5. Take out the shock absorber along with the spring.

6. Special ring or "gas" key turns around the housing of the gland.

7. We take out the sliding tube from the carrier pipe.

8. Press the shock absorber in the vice through the gasket for the bottom tip.

9. The key to 13 mm turns away the nut and the rod lock nut, pre-remembering (writing) the magnitude of the protruding thread side.

10. Remove nuts, washer and spring.

11. Caid key on 12 mm turn the rod tip.

12. Take out the rod assembly from the shock absorber.

13. We rinse all parts of the removed shock absorber in kerosene or White Spirit.

14. After washing, we examine the details of the shock absorber. Damaged parts replace.

15. We check the state of rubber seals. Strong wear of their edges, cracks and elasticity loss should not be.

In case of malfunctional detection, we replace the package of the gland assembly.

16. We subsequent a screwdriver with a felt gland, (the gland has an oblique section) and take it out of the housing.

17. Schunzirkul or micrometer measuring the outer diameter of the support pipe.

18. The chute meter measure the inner diameter of the rings of the sliding pipe.

The difference between the outer diameter of the support pipe (see paragraph 17) and the inner diameter of the ring (clearance) should not exceed 0.3 mm.

19. Measure the outer diameter of the ring.

20. The chute meter measure the inner diameter of the sliding tube. The difference in diameters (see paragraph 19) of these parts (clearance) should not exceed 0.25 mm.

In the case of increased wear (enlarged gaps), we replace the worn parts or the feather forks assembly.

Attention!

The chrome surface of the sliding tube (mirror) should be completely smooth. With bulhira, fears and other damage to the surface layer we replace the pipe or feather forks assembly.

Assembly

1. We collect the shock absorber in the reverse order, turning attention to the position of the pitch's pin pin. The pin should get into the hole of the sliding tube.

For this hand rotate the shock absorber, holding the rod nuts. Only after that you can tighten the bolt with a protes key by 11 mm.

2. We wash the felt gland in gasoline, press, then soak it with a motor oil, press the slightly again and install it into the housing.

Replacing depreciation fluid

Liquid replace simultaneously in both feathers forks.

Install a motorcycle on the central stand. We take out the axis of the front wheel (see. 98). Brake cables and speedometer drives to disconnect from the wheel is not necessary.

1. The key to 14 mm weakening the tightening of the nuts of the tightest bolts on both sides of the top traverse fork.

6. Watch the bolts.

7. Pour 200 cm3 cerosene or White spirit in the upper part of each shock absorber and wrap the plugs. Low under the lower ends of the fork wooden bar.

8. Energetic movements, by pressing the steering wheel several times down, pump the shock absorbers, washing them.

9. Afterverting the lower bolts, drain the washing liquid (if it is strongly contaminated, you should pour a clean liquid to the flushing one and repeat the flushing).

10. Watch the lower bolts and fill in the shock absorbers of 175 cubic meters. See fresh shock absorbing fluid. As a shock absorbing liquid, you can apply oil for power steering, oil for automatic gearboxes (ATF) or spontaneous oil (AU). The first two species are preferable, due to the content of antifriction and anti-anti-antipid additives. This allows you to increase the duration of the replacement of the liquid and reduces wear of parts. Motor, and even more so the transmission oil for the front fork is unsuitable, it is too viscous, because of this, the suspension will be tough, especially in cold weather. Attention!

The shock absorbers should be filled with a liquid of one species (stamps).

11. Watch the shock absorbers and nuts of the top traverse bolts in reverse sequence.

12. We check the tightness of the shock absorber. Even the slightest leak of shock absorber fluid is unacceptable! If necessary, you can "put" the lower bolts on the oil-resistant sealant, but so that the sealant particles do not get inside the shock absorber.

13. Similarly, replace fluid in another shock absorber.

14. After assembling and installing a telescopic plug (see above), we experience it when the motorcycle is moving at a small speed along the uneven road. The stroke of the shock absorbers should be smooth, without knocks, clicks and jams. The quenching of oscillations should occur quickly and fully, the front wheel of the motorcycle should not bounce on the irregularities.

January 15th, 2013

To mitigate reverse strikes, rubber buffers 3 installed in the lower part.

In the IZH-49 motorcycle, an elastic rear wheel suspension with hydraulic shock absorbers is applied; Such a suspension is the most modern. It provides smooth ride even at rough terrain.

The IL-49 Motorcycle Rear Wheel Suspension (Fig. 273) consists of a fixed part associated with the back fork of the frame, and the movable part associated with the rear wheel. The fixed part consists of two brackets located at the ends of the rear fork; Each of the brackets has two split tips with tight bolts. In the tips of the brackets, tubular steel suspension rods are fixed, in addition, the support sleeves with worm cutting on the outer surface are installed in the upper tips on the outer surface on which the upper ends of the suspension springs are screwed. Tubular steel rods also perform the role of the case ( cylinder) Hydraulic shock absorber. 30 cm 3 low-grade oil (automotive) is flooded in the shock absorber housing (automotive), the level of which should be below the top end of the stem.

The movable part of the suspension consists of a housing 1, springs 2, stem 13 of the hydraulic shock absorber with a buster 4 and cuffs 12 and stiffness plugs 8.

The suspension body has a shape of a long sleeve with cutting along the outer surface for fastening the lower end of the spring.

The rod 13 of the hydraulic shock absorber is inserted into the tubular housing of the shock absorber and at the same time into the housing 1 of the suspension, with which is connected by a bolt.

Suspension springs are installed between the upper support sleeve and the suspension housing.

The rigidity plug connects the rear wheel of a motorcycle with a suspension and with a motorcycle frame in such a way that both shock absorbers work simultaneously. This plug is the front end of a hinged mosquito on the motorcycle frame; At the bottom of the other end of the plug installed the rear wheel axis. Through the bolt 9 and the connective sleeve 10, the stiffness plug is associated with the suspension housing.

At the occasion on the obstacle rear wheel moves up along with movable parts of the suspension. Due to the fact that the oil is located at the bottom of the shock absorber, its rod moves up without resistance, and mitigation will occur only due to elasticity springs. Thanks to a small jiggle, the oil slowly flows up and moves slowly.

Owners of the Motorcycle Izh 49, who do not want to part with these old, but, according to them, "wonderful machines" are asked to tell than and how to replace the wheels of the wheel. This is what the designer of the Izhevsk plant Viktor Aleksandrovich Starks is recommended.

You can install the rear wheel (IL-56 - Sat. 4-2) to the IL 49 motorcycle (IL-56 - Sat. 4-2) together with the brake device and the slave asterisk (IL-56-Sat. 4-21-2), which is now produced as a spare , Izh Planet, Izh Jupiter. To do this, make a few additional details and remake some nodes.

1 - sleeve (2 pcs.):
2 - sleeve (6 pcs.);
3 - hairpin;
4 - bolt;
5, 6 - Studs.
Bolt and studs made of steel 35 or 40, sleeves - from steel 20 or 30.

The back of the frame (Fig. 1) is expanding by 22 mm due to the installation of new sleeves 1 and 2, studs 3, 5 and 6, bolts 4. Feathers of the swinging plug (Fig. 2) Wheels are extending to size 212 mm (heated by the burner in places circled in the figure with circles) and separate the grooves under the axis and semi-axle (from the left side to size 17.2 mm, with the right - up to 20.2 mm), the axis passing through these grooves should be parallel to the axis of the plug suspension, otherwise The wheel will not lie in the motorcycle plane, which is why the stability and control of the machine will violate. The check can be carried out on a plate or glass with a scholars or templates.

To attach the right shock absorber, we produce a bolt according to rice. 3 and we screw it up so that the long edges of the head (entered in the groove of the sprocket cover) are located along the axis of the fork, preventing the sprinkler's casing.

The semi-axes (Fig. 4) and the washer (Fig. 5) are needed to install the rear-wheel sprocket housing (IL-56 - Sat.4-21-2). To this node still acquire the axis with the chain tension nut, the half-axis nut and the spacer station from the IL-56 motorcycle (IL Planet, Izh Jupiter).

To protect the chain from dirt, you can use rubber covers used on the latest IFA models, with the simultaneous replacement of the left and right Carter covers. At the same time, dismantle the manual gear mechanism.
In the rear-wheel brake drive, we shorten the craving to 185 mm and put the transition bracket as shown in Fig. 6.

The front fork and the wheel from the Motorcycle IZh 56 (IL Planet, Izh Jupiter) can be put on the IZH 49 motorcycle together with the following details: the brake drum cover, mud shield, speedometer gear gear, wheel axis and hand brake cable.

V. Starkov, Engineer

izhevsk

"IL-49" - a middle class motorcycle for roads with a solid coating, was produced by the plant "Izhmash" in the period from 1951 to 1958. A total of 507 two-wheeled machines left the conveyor. Since "IL-49" is a motorcycle with a multi-year story, he became the exhibit of the Museum of Avtomotorin in Vladivostok. The exhibition area in the Primorsky Territory is not the only place where this long-lived is demonstrated. Classic equipment of the legendary two-wheeled car can be found in Moscow, St. Petersburg, Riga, Minsk. The regions in which a motorcycle appeared is not to account, in fact, it is most of the territory of the former USSR.

History

After graduating from the Great Patriotic War from defeated Germany, the Dampf Kraft Wagen (DKW) motorcycle plant (DKW) was taken within the framework of the Reparation Agreements. The action was large-scale, in the USSR there were whole production lines, and at one time Soviet engineers did not know what to do with unique German equipment. In the end, all the technical means were decided to send to Izhevsk, to the plant "Izhmash".

After several years of arrangement and release of the trial model, DKW NZ 350 became clear: German equipment is quite viable. Factory experts began to prepare a technological line for the release of the middle class road motorcycle. The Enthusiasts of the Soviet Avtomotoproh tried to create an exclusive copy with domestic characteristics. However, German equipment somehow forced specialists to follow German technologies.

Start of release

In 1951, the model "IL-49" was launched into mass production - a motorcycle created on the basis of the German prototype. The car as a whole turned out to be successful, for seven years of continuous release, she won wide recognition. The 49th "Izh", a motorcycle with excellent characteristics, was removed from production in 1958, since the release of new generation motorcycles was already beginning - "IL-56". And soon the last 49th came off the conveyor.

It is characteristic that even for a long time "IL-49" dominated the market. His successor, the 56th, did not have success. In addition, the new motorcycle was unsuccessfully designed and literally stuck in endless improvements.

Characteristics of the Motorcycle "IL-49"

Overall and weight parameters:

• 2120 mm - Motorcycle length;
• 980 mm - height;
• 770 mm - width; weight dry - 150 kg;
• full weight is equipped - 165 kg;
• maximum load capacity - 160 kg.

Driving performance:

• Without a passenger - 90 km / h;
• power reserve on the track with one refueling - 170-180 kilometers;
• depth of overcomed by fusion - 300 millimeters;
• fuel consumption when driving on the highway - 4.5 liters per 100 km;
• - drum mechanisms on both wheels;
• the front fork telescopic, spring, with hydraulic depreciation;
• pendulum, spring, with hydraulic shock absorbers;
• multi-disc clutch, oil bath;
• transmission - CPP four-stage with foot switching speeds;
• tire size - 3.25/19 ";
• drive on the rear wheel by means of a roller chain at the transfer number of 2.33.

Engine

• Engine "IL-49" two-stroke, single-cylinder;
• piston stroke - 85 mm;
• cylinder diameter - 72 mm;
• the volume of the cylinder is 346 cubic meters. cm;
• the degree of compression is 5.8;
• maximum power - at 4000 rpm 11.5 hp;
• lubrication system - a mixture of oil with a flammable in proportion 1:25 for a rolled motor;
• air cooling.

The engine design allowed its operation in any conditions: the unit worked smoothly and measured.

Motor Carter "IL-49" Block, consists of two longitudinal half, in front of the front part there is a crank chamber with a crankshaft, in the rear section - the gearbox. The kick starter and gear lever are on the same axis, on the left side of the engine.

Chassis

The telescopic plug is combined with a protective shield, which is usually called the wing, the brakes are mounted there. At the top of the steering wheel, parabolic headlights with built-in and speedometer is placed. There are also two light bulbs, red and green, reacting to changes in the power grid. "IL-49" - a motorcycle that does not need a battery, the whole scheme can work from magneto.

Steering wheel is possible within 35 degrees both to the left and right. The steering rod is adjustable in height and is fixed with the growth of the motorcyclist. On the right sidewall of the gas tank mounted a manual switching lever, duplicating foot. Both transfers are equivalent, the motorcycle driver chooses the most convenient for himself.

Seat

Since the 49th "Izh" - a motorcycle is not high-speed, its seats are designed for a comfortable driving, the seat area is quite large, the surface is rifled, with good depreciation properties, the springs are mounted under the plate that take the load and significantly soften shake. On some motorcycles, the rear passenger seat of the same form and with the same parameters, but less in size. On other copies, ordinary foam pillows are installed, covered with dense tissue.

Some owners upgrade the back seat to taste their regular passengers to make friends and relatives to be comfortable. For a child who regularly travels in the back seat, you need to make a back, about the same, like a chair, but it should be stronger. The material can serve as a metal bar with a cross section of 8-10 millimeters. Several racks are welded to the base, and the horizontal bundle is created at the top, which will play the role of support.

Of course, the improvised baby seat should be removable, so that he can sit in the passenger seat. The options for arranging the back can be set, it all depends on the creative approach of the owner.

Raretric value

Motorcycle "IL-49" (photos, represented on the page, demonstrate it in all its glory) is a fairly elegant car from the distant past, and it can decorate any collection of automotive equipment. The model is practically absent on the market. If you manage to find an instance, then it is not subject to restoration. Motorcycle "IL-49", the price of which today comes to three thousand dollars, is the dream of many connoisseurs of two-wheeled rarities.

Tuning In most cases, the "IL-49" does not apply, since this is a machine of this class, when it is better to restore a motorcycle than to modify it in favor of the owner's fantasy. The best reward owner will be the talented renovated motorcycle "IL-49". The photo of the car, which received the second life, will become a memory for descendants.

I will add a post about your favorite Motorcycle IL-49. At the time of recovery did not have the experience of repair and restoration of motorcycles, and catastrophically there is no time, I work on business trips. Therefore, strictly do not judge! All shortcomings and inconsistencies are known to me.
Written review in 2014 and posted on another Internet resource. Go…
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What is IZH-49, I knew, but even in my thoughts it was not to buy it, the owners of these motorcycles in the mania of greatness and from the awareness of the ownership of the rarity, survived the owners of all Izhia combined. Moreover, the state of the motorcycle for them does not mean anything. It does not matter whether it is a Solyanka of all planets of a local collective farm + Tractor Magneto, or a rusty cable, which was left to the advice of a drunken neighbor, who, in turn, strongly dismantled in Retro and convinced the owner not to give it to Sadzhevo, but to wait for this trash From Moscow itself.
Paint ads and you will understand what I mean ...

Shaking, I decided to call. The photo of the motorcycle in the ad was not. The voice in the tube voiced the price of 10 tr.
All that I was at that time knew that the IL-49, there should be a switching of speeds on the tank and silencers with fish at the end. Finding out that all this is and a motorcycle seems to be on the go, but without documents, is from us for 50 km. - He said that I take and come tomorrow.
It was January, time 15:00. I called my father, asked for tomorrow Gazelle. Father says - "We drove away today, what to expect that." And rightly done, while they were on the road, two more called the owner and wanted to pick up, but did not have time.
They were strung up to 8 tr., Loaded it into the gazelle and went back home. I was glad, as a child who had the most dream and not believed, was 1.5 years old, I still also rejoice at him, I can't help you to drive on the weekend.

In the morning run to him, consider it. They took it in the dark, in the garage there was a light bulb, Ilyich, there was nothing to look. I look at the whole, on the move conditionally - "someone, once, recently, drove on it, having a male magneto." Rust, poverty, everything is in line with their age and habitat.
It was completely deprived of all electrics and wiring. It turned out to be painted in a dark blue, but obviously once repainted, and high quality, not a tassel in the garage and completely. But apparently it was a long time ago, and for all it was a piece of old iron, but not for me.
Smoking on the Internet, immediately found himself on the Motorcycle Forum IZH-49 and a little closely by age motorcycles for those years, from that time no longer came out of it. Always help with advice, detail, reference, very friendly and friendly forum.

On this lyrics ended.
Practice.
I will start with the fact that for your 30 years, I have never been engaged in the repair and operation of the motorcycle. Jupiter 2 at 16 years old does not count, only went, picking up a screwdriver and a key to 10, is not considered.
Again I will make a reservation, there are no motorcycles, but with machines yes. All that you need to be able to do a man with a domestic machine, did everything and did not cause difficulties. The service in the army on UAZ supplemented skills, and life in general, it did not indulge the presence of new cars, and more so much more. Anyway.
Armed with a book, prints from the Internet, from the forum settled in the garage, in conditions below zero. I decided to make it and ride along the street before full disassembly.
Heart of the IZH-49 motorcycle, I consider the distribution. Box. This is a small black box in which the ignition coil is hidden, the relay controller, the ignition castle and the charging control light. All this is turned on by the key of the bizarre form. On the following models of Izhevsk Motosable, there was no longer anything like this.
Assembled for a trial launch of electric - a scheme from Izh Planet. Ignition Coil 6V + RP1 + Battery + Generator. The time was in search of familiar, I gave something, I bought something in the store (an empty waste of money, nothing works, because Made by China and very poor quality).
Finally came the day when he wound like a miracle! Sitting in the yard, I tried to turn on the speed, turned on, but the motorcycle went ...... back.

Too early ignition, crankshaft scrolled in the opposite direction! It was not going to start up and frost on the street in -18, I did not add desire.
On the next weekend, I started it again and tried to leave on it, but the chain broke. The chain was larger than usual, or from the combine, or with the conveyor belt, it does not matter. The new chain costs 300 rubles, put. Forward! But no, having drove 2 more meters, the gas cable broke.
Everything! Stop! In disassembly for repair!
I decided to cleanse from the old paint with the help of a brush-nozzle on the grinder. This is hell! Only thanks to the enthusiasm and desire to leave in the spring, caught up. The process is completely disgusting. All sides fly the wire from the brush, pushing into clothes (worked strictly in glasses), paint turns into dust, Bulgarian strives to pull out of the hands on each irregularity of the part.
And the number of parts frame and body kit! During painting, I counted - about 60 pieces and mostly trifle! .. All subframes, spacers for the central footboard, spacers for a signal, strut, seats are disassembled to the components, etc.

I will never do this anymore. Better to pay, wait, negotiate on sandblast, but not it is!
The engine in the overhaul of the acquaintance was given to the Balakovo Speedway Club "Turbine". Mechanics Vitaly - Thank you!
Despite the 60-year-old age, only bearings, glades and rings went under the replacement.

The tank and wings gave to the car, the rest all painted himself, mastering it for the first time this craft. Recovered, reopened, dykened. It turned out normally.

The most difficult thing is to paint chings (thin lines on the frame, tank, wings).
At the factory, women were engaged in a solid hand and a brush with a long end of natural hair from the first time, standard lines approved by approved by the State Commission of the RSFSR. Nowadays it is an art and is called a wonderful word Pinstrapping and popular in America on a par with airbrushing.
Since the owners of Izhey, there are no pinstreps, then everyone does, as can. The best way is the way, it is a disconnection of circuit circuits by contour tape zm., Closing the rest of the surface and painting with a spray gun.
In my case, it was cut across the tape, and painting with a tassel. The result was different. Somewhere very good, somewhere curved.

The first experience in painting authemal.

Motorcycle assembly