Assembling the box "Izh-Planet 5": detailed instructions, diagram and recommendations

2024 Author: Erin Ralphs | [email protected]. Last modified: 2024-02-19 11:42

The assembly of the Izh-Planet 5 box is often carried out during its repair or replacement of parts. This node is not very reliable. This is due to the low quality of components, poor assembly, poor requirements for the accuracy of manufacturing bearings, crankcase and other mechanisms. You can also find your benefits. First, it is cheap production. Secondly, it is subject to repair with your own hands. Consider what the part is and how to assemble the Izh-Planet 5 box, as well as learn useful recommendations.

Most common problems

Most often, the motorcycle in question loses or shifts poorly in second gear. This may be due to careless inclusion of speeds. For example, when gaining high speed in first gear without neutral, when engaging with the second speed gear, a blow occurs, which contributes to intensive wear of the assembly. Therefore, it is not recommended to strongly "unwind" the first speed. If, nevertheless, problems with the second position continue, there are several options for resolving them.

In some cases, the simplestmethod, without complete disassembly and subsequent assembly of the Izh-Planet 5 box. It is necessary to put the motorcycle on the right side, and then remove the kick starter and the gearshift foot along with the shaft. Next, the crankcase cover and clutch basket are dismantled along with the discs.

During the production of the gears of the box, the gearing of the teeth deteriorates. In turn, this leads to slippage, jerking and failure of the second gear. Another reason could be worn input shaft bearings. Since it goes a little to the left from vibration, it is necessary to move it with light blows into place with a mallet. Fixing the element in the desired position will allow the installation of washers suitable for the diameter. Then the bearing stopper and other dismantled parts are mounted in reverse order.

Other malfunctions

It happens that the disassembly / assembly of the box "Izh-Planet 5" may be necessary in case of loss of the fourth speed. This is often associated with broken bearings on the output shaft. Such a nuisance happens due to the presence of axial play, displacement of the bearing assembly or its failure. You can try to fix the problem in the same way as repairing the second gear. If it does not help, a complete disassembly of the block will be required.

When the speed switch is jammed from the high range to the low mode, the spring system of the switching mechanism is out of order. It needs to be replaced. The strained operation of the assembly after the assembly of the Izh-Planet 5 gearbox indicatesincorrect installation of shims. To avoid this, it is necessary to mark and fix the previous placement of these elements in the process.

Disassembly and assembly of the Izh-Planet 5 box

First, you will need to completely dismantle the clutch, starting device and motor transmission, and drain the oil. After these manipulations are carried out, you can proceed to the removal of the gearbox. In the area of the right side of the motor, unscrew the eight fastening screws. The footrests of the driver, the foot brake lever, the crankcase cover on the right side are removed. The clutch cable is disconnected, the ball and the pusher of the input shaft are taken out. After that, the chain is disconnected. Symbols in the photo below: clutch discs (1, 3), lower disc (2), inner drum (4), nuts (5, 6).

A crankcase cover is placed on the prepared rag or paper. You can pull it out by taking the asterisk with your hands and pulling it towards you. If the element does not lend itself, pay attention to the worm shaft support washer, which could be warped. Insert tweezers or a knife into the hole between the crankcase and the cover, and then correct the part. When dismantling the housing, a couple of washers may fall out. The second element is slightly thicker and is mounted on a copy shaft. They must be signed and removed with the rest of the spare parts.

Main Stage

As noted on the assembly diagram of the Izh-Planet 5 box, further disassembly operations are carried out above the inside of the roof of the assembly, since the secondary shaft and sector could remain in it. If necessary, remove them to unbendpetals of the washer-stopper, unscrew the nut, remove the star and washer. While holding the gear very carefully to prevent the shaft from popping out, the cover is moved to a clean and flat surface with the gear up.

It is worth noting that the bearing of this part of the assembly does not have a retaining ring. Therefore, when removing the shaft with the bearing, the rollers may fall out, so be careful. If the specified element has developed a decent resource, there is a risk that when dismantling the secondary shaft, the outer ring may pop out of the seat and remain on the rollers. Next, you need to do the pressing out of the gland. To do this, the adjusting rings are removed from the hole in the cover, after which the outer ring of the bearing is removed.

Final stage

Next, the gear of the second and third speeds is removed from the input shaft, after which the input shaft is dismantled. To do this, you need to carefully knock it out with a stopper and a light hammer. The top and bottom forks are removed.

Next, the intermediate shaft assembly is taken out. Using a screwdriver or other suitable tool, bend the lock with the neutral indicator, carefully pull out the worm (copy) roller. On its far side there are shims that could stick to the crankcase. They need to be assembled and stored with the rest of the removed parts. Next is the turn of the copier shaft. Check the edges of the shaped sockets in which the guide forks move. They should not have chips or dents. Loosen a couple screwsswitching mechanism, which is also removed. Now it is possible to replace unusable parts and assemble the Izh-Planet 5 gearbox according to the scheme. The figure below shows: lock cap (1), bolt (2), crankshaft sprocket (3), double row chain (4), clutch drum (5), input shaft (6).

Repair

Once the unit is gutted, you can begin to determine the parts to be replaced. As a rule, you have to buy a set of shims, a set of gaskets and sealant. This is in the event that there are no more serious breakdowns. After you have decided on the elements to be replaced, you will need to adjust the axis of the worm shaft, and after final assembly, the clearance along the axis of the primary, intermediate and secondary shaft.

Adjusting washers are put on the far ledge of the copy roller, they should be lubricated with a special compound. A support washer is mounted on the near edge, the shaft is put in its place. Turn it in such a way that the neutral sensor with its protrusion fits into the deepest groove. Then, using a ruler (so far without the gearbox cover) on the plane of the crankcase, the gap between the washer and the probe is measured. It should be no more than 0.2 mm. Depending on the indicator, regulators are added or removed. If it is impossible to accurately set the gap, it is better to make it smaller.

Assembly of the box on the motorcycle "Izh-Planet 5"

For proper assembly, you must first installinput shaft, then the first gear gear groove down. Then the return spring with the range switching shaft is mounted, first you should put on the spring mechanism and place the block in the seat. After that, a worm shaft with shims is placed. To facilitate installation, lubricate the moving mechanisms with Lithol.

When mounting the assembly, care must be taken not to damage the neutral speed sensor. In order for the shaft to snap into place, use a screwdriver to slightly bend this indicator. When mounting, remember the small washer that eliminates the play. A similar part is installed on the copy shaft. After that, the gearshift compartment is mounted.

Important

When performing the indicated operations, follow the mark in the middle part of the sector. It must match the same mark on the shaft. At the last stage, the crankcase cover is installed. With proper work, she will sit in her place without problems.

It is necessary to ensure that all rods and shafts match with native seats. They should rotate freely without squeaks and jams. When tightening the screws, use medium force, as the threads can easily be stripped in a soft metal crankcase. All fasteners are tightened evenly to avoid distortion.

Finishing

Above is a detailed assembly of the Izh-Planet 5 box. After tightening the clamps, you need to check the drive sprocket again for correct rotation. At the end, a ratchet with a spring, a drum sleeve are installedclutch and he himself, and also the chain drive is connected to the leading star, transmission oil is poured into the box.