Self-assembly of the Izh Jupiter 5 engine after its repair is a crucial operation. Inattention and errors during assembly will sooner or later lead to breakdowns during its operation. However, the attention and observation shown when disassembling it will avoid most mistakes.
It is necessary
a set of garage tools
Instructions
Step 1
Before starting the assembly, clean the surfaces of the parts at the joints of the parts from contamination. Throughout the entire process, pay special attention to the uniform tightening of the fastening screws, avoiding distortions. Grease the bearings well before pressing. Press the ball bearing into the right half of the crankcase, then install the locating ring in the left half. From the side of the crank chamber, press the oil seal into the crankcase, then install the second ring.
Step 2
Insert the locating rings into the grooves of the crank chamber covers, and press the ball bearings into them and put rubber O-rings on them. Install the left crankshaft. When doing this, be careful not to damage the oil seal. Press in the crankcase cover with a hammer and support. Then screw in the screws with lock washers. The tightening torque for these screws should be as high as possible.
Step 3
Insert the crankshaft into the right half of the crankcase. In the same way, using a hammer and support, press in the crankcase cover. Having installed oil seals on the crankshaft axle shaft and in the crank chamber covers, press them in. Next, insert the locating rings, press the ball bearing into the left half of the crankcase and fix the crankcase cover with screws with maximum tightening.
Step 4
On both halves of the crankcase, tighten the screws for securing the covers of the crank chambers to protect them from spontaneous turning. Put a gasket and a crankshaft oil seal cover on the right half of the crankcase. Fasten it with screws and fasten it in the same way.
Step 5
To assemble the cylinder-piston group of the engine, put the rings on the pistons using plates. In this case, the plate locks must coincide with the piston pins. Install a retaining ring on the piston bosses in one of the grooves, and a piston pin lubricated with machine oil on the opposite groove. Place the piston on the upper end of the connecting rod so that the arrow points to the rear and the piston ring retaining pins forward in the direction of travel of the motorcycle.
Step 6
Align the piston pin bore holes with the upper connecting rod bushing. Press in the piston pin using a mandrel and hammer. Then install the second circlip onto the piston. Assemble and install the second piston in the same order. Check the plane of the connectors before installing the cylinder. Clean these planes, install gaskets on them, put a wooden plank stand under the pistons. Lubricate the cylinder bore with oil. Slide the piston with studs onto the cylinder and carefully thread the piston rings.
Step 7
Remove the stand from under the piston. Slide the cylinder into place and secure. In this case, the locks of the rings should not fall into the cylinder windows. Replace the second cylinder in the same way, then install the carburetor pipe, gasket and head. Tighten the fasteners of the heads and the nozzle as follows: first of all, tighten the middle screws to the stop, then the outer ones. Tighten the outermost nuts evenly crosswise.
