Assembly of the Izh-Planet 5 box: detailed instructions, diagram and recommendations

Izh-Planet 5 boxes are often assembled when repairing or replacing parts. This node is not very reliable. This is due to the poor quality of the components, poor assembly, poor requirements for the precision of bearing manufacturing, crankcase and other mechanisms. You can find your pluses. First, it's a cheap production. Secondly, it has to be repaired by our own hands. Consider what the detail is and how to build the Izh-Planet 5 box, and also find out useful recommendations.

Common issues

Most often, the motorcycle in question is missing or badly switched to the second gear. This may be due to the negligent inclusion of velocities. For example, when dialing large revolutions in the first gear without neutral, when engaged with a gear of the second speed, a shock occurs, which contributes to intensive wear of the unit. Therefore, it is not recommended to strongly "untwist" the first speed. If all the same problems with the second position continue, there are several options for their resolution.

In some cases, the easiest way, without complete disassembly and subsequent assembly of the Izh-Planet 5 box, will help. It is necessary to put the motorcycle on the right side, then remove the kick-starter and the shift foot together with the shaft. Then, the crankcase cover and the clutch basket together with the disks are dismantled.

When the gears of the box are formed, the teeth engagement deteriorates. In turn, this leads to slippage, jerks and failure of the second gear. Another reason may be the wear of the input shaft bearings. Since from vibration it leaves a little to the left, it is necessary with the help of the kyanka to displace it with light blows into place. To fix the element in the desired position will allow the installation of suitable washers for the diameter. Then the bearing stopper and other dismantled parts are assembled in the reverse order.

Other malfunctions

It happens that the disassembly / assembly of the Izh-Planet 5 box may be necessary in the event of a fourth speed failure. This is often associated with the failure of the bearings on the secondary 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 similar to repairing the second gear. If it does not help, a complete disassembly of the unit will be required.

At jamming of the switch of speeds from the raised range on the lowered mode - the spring system of the mechanism, switching has failed. It must be replaced. The strained work of the assembly after the assembly of the IZ-Planet 5 gearbox indicates that the shims are not correctly installed. To avoid this, it is necessary in the process to mark and fix the previous placement of these elements.

Disassembly and assembly of the Izh-Planet 5 box

First, it will be necessary to perform a complete dismantling of the clutch, the starting device and the motor transmission, and also drain the oil. After these manipulations are carried out, it is possible to proceed with the removal of the control gear. In the area of the right side of the engine, remove the eight fastening screws. Removed the driver's footsteps, the lever of the foot brake, the crankcase cover on the right side. The clutch cable is disengaged, the ball and the pusher of the input shaft are delivered. After this, the chain is disconnected. Legend on 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 holding the star with your hands and pulling yourself. If the element does not give way, pay attention to the washer of the worm shaft, which could be skewed. In the hole between the crankcase and the lid, you should put a pair of tweezers or a knife, and then fix the part. When the case is dismantled, a pair of washers may fall out. The second element is slightly thicker and is mounted on the copying shaft. They need to be signed and removed to the rest of the spare parts.

Main Stage

As noted in the Izh-Planet 5 box assembly scheme, further disassembly operations are performed on the inside of the roof of the assembly, since the secondary shaft and sector could remain in it. If it is necessary to remove them, you need to unbend the petals of the washer-stopper, unscrew the nut, remove the star and the washer. Very carefully holding the gear, in order to avoid the jump of the shaft, the cover is moved to a clean and level surface with a gear wheel upwards.

It should be noted 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 can fall out, so be careful. If the specified element has developed a decent resource, there is a risk that when removing the secondary shaft, the outer ring can pop out of the landing nest and remain on the rollers. Then it is necessary to do the pressing of the stuffing box. To do this, the mounting rings are taken from the cover hole, after which the outer ring of the bearing is removed.

The final stage

Then the second and third speed gears are removed from the primary shaft, after which the primary shaft is dismantled. To do this, it must be carefully dislodged with a stopper and a light hammer. The upper and lower forks are removed.

Then the intermediate shaft assembly is taken. With a screwdriver or other suitable tool, bend the lock with the neutral indicator, carefully pull out the worm (cushion) roller. On its rear part there are adjusting washers, which could stick to the crankcase. They need to be collected and stored with the rest of the removed parts. Then the copy shaft turns. Check the edges of the figured jacks in which the guide forks move. They should not be chipped or dented. Unscrew a pair of screws securing the switching mechanism, which is also removed. Now it is possible to replace unsuitable parts and carry out the scheme of assembling the gearbox "Izh-Planet 5". Below in the figure are indicated: the locking cap (1), the bolt (2), the crankshaft sprocket (3), the double-row chain (4), the clutch drum (5), the primary shaft (6).

Repairs

After the unit is gutted, it is possible to begin to be determined with the parts to be replaced. As a rule, you have to buy a set of shims, a set of gaskets and sealant. This is the case if there are no more serious failures. Once you have determined the elements to be replaced, you will need to adjust the worm shaft axis, and after final assembly - the clearance along the axis of the primary, intermediate and secondary shaft.

The adjusting washers are put on the far step of the copying roller, they should be lubricated with a special compound. The support washer is mounted on the near edge, the shaft is put in its place. Rotate it in such a way that the neutral sensor aligns with its protrusion into the deepest groove. Then, using a ruler (while without the cover of the gearbox), the clearance between the washer and the feeler gauge is measured in the crankcase plane. It should be no more than 0.2 mm. Depending on the indicator, the regulators are placed or retracted. If it is impossible to accurately set the gap, it is best to make it smaller.

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

For the correct assembly, first you need to install the primary shaft, then the gear of the first gear by turning down. Then a return spring with a change-over shaft is mounted, it is first necessary to put on the spring mechanism and place the unit in the seat. After this, a worm shaft with adjusting washers is placed. To facilitate installation, lubricate the "Lithol" mobile mechanisms.

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

Important

Perform these operations, follow the label in the middle of the sector. It must coincide with a similar risk on the shaft. At the last stage, the crankcase cover is installed. If the work is properly done, it will fit into its place without problems.

It is necessary to look, that all stocks and shafts coincide with native landing nests. They should rotate freely without creaking and jamming. When screwing the screws, apply an average force, as in the crankcase of soft metal it is easy to break the thread. All fasteners are tightened evenly, to avoid skewing.

Completion

The above is a detailed assembly of the box "Izh-Planet 5". After tightening the latches, check the driving sprocket again for correct rotation. At the end, a ratchet with a spring is installed, the clutch drum sleeve and it, and the chain drive is connected to the driving star, the transmission oil is poured into the box.