Java motorcycle without battery. Drawing, description

PERSONAL TRANSPORT: GROUND, WATER, AIR
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Java motorcycle without battery. Personal transport

Personal transport: land, water, air

Directory / Personal transport: land, water, air

To convert a motorcycle into a batteryless one, I purchased: an alternator 43.3701 (from Minsk or Voskhod motorcycles), two KET-1 thyristor switches, a BKS-261.3764 unit, an inductive sensor, as well as lamps and a 12 V sound signal. also make a 12-volt generator from two G427 generators from old motorcycle models: use one of them as the base together with the lighting section (it is wound with a thick wire), and from the other - only the lighting section. To do this, on the first generator it is necessary to remove three sections wound with a thinner wire (without touching the ignition winding, which is covered with a metal plate), and replace them with a lighting winding taken from another generator. Then connect both sections in series. If during the subsequent check of the generator on the motorcycle it turns out that the voltage generated by the generator has not increased, but decreased, then it is necessary to change the connection of one of the sections to the opposite.

From steel of any brand, you need to turn the adapter flange, install it in the crankcase bore and attach it with M6x30 mm screws. When marking the holes on the flange, use the generator stator as a template. To put the rotor on the crankshaft trunnion, you need to use a drill of the appropriate diameter and a file to make a new recess for the key (pin). I do not recommend making a recess for the pin at another point, since in this case the optimal location of the generator inside the crankcase will be violated. Since the new alternator is small, the right crankcase cover requires little or no rework. It is only necessary to remove a part of the partition, as shown in the figure, and glue an additional aluminum partition 5-6 mm thick (check its dimensions locally). It is also required to glue a partition into the crankcase, which ensures the tightness of the generator compartment. It is best to use epoxy glue, adding small aluminum filings to it.

Now you can do the generator itself. The most time-consuming operation is fixing an inductive sensor for the second cylinder on it. Please note that the coincidence of the ignition timing in the right and left cylinders depends on the accuracy of this operation. There is no place for mounting the second sensor on the generator, so you will have to rearrange the terminals of some windings to other places. To pre-mark the position of the sensor, the generator must be installed on the engine. Using the indicator, find the top dead center (TDC) of one of the pistons and orient the generator so that the slot of the magnet on the rotor is exactly against the protrusion of the sensor core, and then tighten the generator fastening screws. Next, check the crankshaft and find the TDC for the other piston. By attaching the sensor to the generator, you can mark its location. Unfortunately, already existing holes from the terminal screws will be found at the sensor mounting points, so two small steel plates 3 mm thick will have to be riveted from the inside of the generator, in which holes should be drilled and M4 threads cut for the sensor mounting screws. Since the holes are drilled in place, care must be taken not to damage the ignition winding with a drill.

Due to the fact that it is almost impossible to immediately ensure the exact position of the sensor, it is best to secure each plate with only one rivet. Thanks to this fastening, by loosening the screws, you can move the sensor in the desired direction during the final adjustment. The generator prepared in this way can be installed on a motorcycle. To clarify at what position of the rotor relative to the sensor a spark jumps, which is important for the subsequent adjustment of the ignition timing, it is good to use a stroboscope. At speeds below average and a correctly adjusted gap between the rotor and the sensor (0,3 ... 0,6 mm), the distance "a" (see figure) is 1 mm. With a further increase in speed, this distance increases by about 0,6 mm, which ensures an automatic increase in the ignition timing.

The standard relay-regulator should be dismantled, and two KET-1 switches should be installed in this place. At the same time, it is important to ensure reliable electrical contact of the KET-1 bodies with the "mass" of the motorcycle. The BKS block containing the voltage stabilizer is fixed with clamps under the tank between the ignition coils and the air filter. It is desirable to close the side of the BCS block, where the compound with which the circuit elements are filled, with a flat duralumin cover.

Modified circuit diagram of the motorcycle "Java-634/8" (click to enlarge): EL1-EL4 - turn signal lamps (12 V, 15 W); EL5 - high-low beam lamp (12 V, 40/35 W); EL6, EL10 - marker lights (12 V, 4 W); EL7 - high beam indicator (12 V, 2 W); EL8 - speedometer illumination lamp (12 V, 2 W); EL9 - stop lamp (12 V, 20 W); SA1 - anti-theft switch; S1 - turn signal switch; S2 - switch high-dipped beam and sound signal; X1-X3 - connectors of the same type, VD1 - VD4 - KD202 diodes; C1 - electrolytic capacitor 4 ... 10 microfarads (at 25 V); A1 - block BKS-261.3734 (at 12 V); AS1 - ignition lock; L1, L2 - ignition coils; K1 - turn signal relay; SA2 - brake light switch; A2-1, A2-2 - electronic switches, thyristor (KET-1), G1 - generator 43.3701 or G427 (generator terminals; O - main windings, 12 V; 3 - ignition windings; D1 - sensor of the first cylinder; D2 - sensor second cylinder) HL1 - light signal; HA1 - sound signal

Java motorcycle without battery
The position of the rotor relative to the sensor, corresponding to the moment of sparking

Java motorcycle without battery
Generator rotor (view from the mounting hole): 1 - keyway groove; 2 - recess for the pin.

Adapter flange (click to enlarge)

Java motorcycle without battery
Refinement of the crankcase (a) and its cover (b): 1 - partition; 2 - plate

Schematic diagram (a) and printed circuit board topology (b) turn signal relay (click to enlarge)

Due to the fact that the ignition and lighting windings on the new generator are separated, a significant alteration of the motorcycle electrical circuit is required. As can be seen in the modified wiring diagram, all consumers are constantly connected to the generator, and the wire connected to the "mass" of the motorcycle and to terminal 30 of the ignition switch is switched. Thanks to this, nothing changes outwardly: when you insert the key all the way, the ignition turns on, turning the key to position "1" turns on the dimensions, and to position "2" - the headlight. For the above reason, it is necessary to modify the rear light - remove it and remake the side light lamp mount so that both of its terminals are isolated from the housing, as shown in the electrical diagram.

Both switches are powered by the same winding, its power is enough for the normal operation of the motorcycle. The SA1 toggle switch, installed under the saddle of the motorcycle, blocks the start of the engine. The switches are included in the motorcycle circuit through connectors X2, X3. Connector X1 of the same type is connected to the BCS unit (A1). If one of the KET-1 switches fails, it is enough to rearrange the corresponding connector, disconnecting it from the faulty switch and connecting it to the BCS, and you can continue moving. The main role of the BCS unit on a motorcycle is to stabilize the voltage in the on-board network. For this, the "0" winding of the generator, to which all consumers are connected (except for the ignition system), is connected to terminal 02 of the BCS unit. Ignition coils L1 and L2 have not been replaced.

When changing a lamp in a headlight, to connect it, it is necessary to replace the narrow plugs with wide ones or cut off the lamp contacts with a needle file so that their width matches the width of the plug.

After installing a new generator, difficulties arise with connecting an audio signal. In order to be able to use a car signal that operates only on direct current, it is necessary to assemble a rectifier on semiconductor diodes VD1 -VD4 and capacitor C1.

The capacitance C1 must be large enough - 4 ... 10 microfarads for a voltage of at least 25 V. If you could not find a capacitor of a suitable capacity, you can make it up from several connected in parallel. The rectifier is located on a triangular plate made of insulating material (for example, textolite), which is fixed under the gas tank in a triangular space formed by the frame pipes. If the capacitor bank does not fit there, it can be placed in any other suitable place.

The K1 direction indicator relay can be used from a Voskhod or Minsk motorcycle with 12-volt electrical equipment or an electronic relay can be made. The advantage of the latter is high stability of operation with significant voltage fluctuations in the on-board network when the engine is idling.

A pulse generator is made on the DD1 chip, the frequency of which is adjusted by the resistor R2. Through the current amplifier on transistors VT 1 and VT2, the pulses are fed to the control electrode of the triac VS2. Diode VD1 - AC rectifier; VS1, R6, C2 - parametric stabilizer for powering the DD1 chip; SA1 - turn signal switch; EL1 and EL2 - turn signal lamps.

Relay K1 is housed in a housing from a polarized relay RP4. Triac VS2 is mounted on an aluminum corner, which is fixed to the board with two rivets. A circuit assembled from serviceable parts does not require adjustment.

Author: S. Savinovsky

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