Yanmar dnepr project thread

[kapis]

Hi, wanted to update you on my bike progress - the process is wery slow due to lack of free time so here are some pictures of the bike

first half of frame welded

Testing how it will fit

overall look of the bike

heh, please don't mock me about an open injector port and open oil filter caps - I know that debris can get insode, bau no worries, the engine has no guts in it, there is only crankshaft in the cases

[Sphere]

Well, it's a start at least. But why don't you plug the holes with some newspaper, or toiletpaper? Better safe than sorry.

[kapis]

Better safe than sorry.

That's true but I will be washing/cleaning the cases anyway prior to assembly

[kapis]

So this is the update to build thread As I said earlier - the progress is slow

So here goes the pictures :

Shaft made to accept the clutch basket

Modified Dnepr clutch basket

Making of the adaptor for transmission

Making of the adaptor for transmission

Adaptor ready

From the other angle

Making of an engine to frame adaptor :)

Any comment and suggestions - welcome
Thanks.

[kapis]

hmm, sorry for the pic quality - taken by phone, anyways - wanted to ask, what do you think about electric blower to cool this engine? I need this because the engine with flywheel is too long and don't fit in the bike's frame, and I don't want to strech the frame because I want to keep it compatible with the original engine so I can pass the MOT with original one and put the diesel in afterwards

[Sphere]

Looking great Must be cold to work on it duiring the winter? At least you will be rewarded in the spring when you can ride your new diesel bike

[kapis]

Yea, it's cold here, about -15celsius but it's not so bad - I have wood burning stove so I can get Temperature in the shop to about +15 celsius ant thats is enough for working

P.S. here's a vid of last winter when I tried to make a used oil heater http://www.youtube.com/watch?v=SISZrLE29iE but sadly I had to cool it down and clean every 3 or 4 hours as it clogged up due to my poor design of air holes

[Sphere]

Nice video Unfortunately Holland is too densely populated to pull off stuff like that, your neighbours would start complaining instantly.

About your flywheel question: I have read in many threads that you should not do away with forced air cooling. I also think Mouse learned the hard way, but I would have to look up his thread to be sure. Just make sure your cooling solution is adequate, does not fail, or if it fails you are notified at once, so you can shut off the engine.

[arnaud]

Was it difficult to grind the crankshaft down to fit the dnepr flywheel?
You used a tapered shaft or re-worked a straight shaft?
I guess this straight-on assembly is needed to fit the gearbox in the frame.?
If you experience problems with this, you can try an ural gearbox, this one is slighlty shorter

But try to keep te dnep[r gearbox, they shift very good! (and ural gearboxes do not..)

[kapis]

Nice video Unfortunately Holland is too densely populated to pull off stuff like that, your neighbours would start complaining instantly.

Hi Sphere, it's not so bad, when it's made well and warmed up it doesn't smoke at all

[kapis]

Was it difficult to grind the crankshaft down to fit the dnepr flywheel?
You used a tapered shaft or re-worked a straight shaft?
I guess this straight-on assembly is needed to fit the gearbox in the frame.?
If you experience problems with this, you can try an ural gearbox, this one is slighlty shorter

But try to keep te dnep[r gearbox, they shift very good! (and ural gearboxes do not..)

Thanks for the Ural gearbox tip - I didn't know that they are shorter

regarding the shaft, It is straight one I just shortened it and made a groove for 8x8mm wedge (I hope that it will hold) . The Dnepr flywheel was designed for tapered shaft so I had to fill that hole with metal and grind a new hole for straight shaft.

[pietenpol2002]

I believe your proposal for converting from flywheel driven cooling to DC fan cooling is quite reasonable. The inlet for the forced air from the flywheel is quite small and could easily accommodate a duct facing forward. The ducting could incorporate an inline 12V fan that could be either temperature controlled or triggered by a switch when the engine drops to an idle. Cooling would otherwise be provided by the forward facing intake duct that would force air across the engine when at speed. The intermittent feature of the fan would also reduce the load on the battery (but might still need an upgraded alternator/generator/dynamo).

If using a 12V fan for cooling, the flywheel shroud would no longer be needed and the fins on the flywheel could be removed on the lathe, freeing up both space and power. The absence of shroud and fins would then allow you to move the engine forward a good deal. The reduced size of the flywheel could then be covered by an aluminum frying pan, shallow stainless bowl, or the like.

As these engines rely a good deal on oil cooling via the aluminum case, I would seriously consider adding an oil cooler.

And then the disclaimer - I am not an engineer nor have I tried what I've proposed. But I'd love to see someone try it!!

[Sphere]

Also, if you are going the fan route, use some industrial metal ball-bearing type fan, not a flimsy plastic computer fan.

[kapis]

But I'd love to see someone try it!!

Heh, looks like I would be the the one to try it out

Also, if you are going the fan route, use some industrial metal ball-bearing type fan, not a flimsy plastic computer fan.

I was thinking of an motorcycle fan, when the cooling fan on my Yamaha TDM comes on - it blows like hell and is pretty small

[kapis]

Hi all,

today received long waited nozzle witch I bought at ebay ( http://tinyurl.com/4vyc556 ), wnt to garage and .......... IT WON"T FIT

photo for comparison:

comparison

[Sphere]

Start a dispute with Ebay right away, otherwise you will lose your money. Saying you will leave negative feedback nearly doesn't make as much of an impression as PayPal disputes/claims.

[kapis]

just emailed the seller - lets see what he will reply.

[pietenpol2002]

When one compares your pic to the Yanmar manual it's clear that your injector is closest to the original. I first wondered whether the injector that came with the engine was in fact the correct one. Especially since the engine was not running when you received it. But the Yanmar manual seems to dismiss that possibility.

See figures 8 & 9, 22 & 23 and 35 & 36. And while the title suggests it's for the L40/L48, it covers the range up to and including the L90 and L100.
http://dawinfo.com/L-AE-Series-Parts/L4 ... mplete.pdf

[kapis]

the new nozzle doesn't even fit the engine head

[thundercougarfalconbird]

it looks as though the ebay injector is for a 186fa engine and not the 186f, the fa is 418 cc and the f is 406 cc.

i have a picture of both, these are both chinese clone injectors not yanmar. i hope this info will help out.

http://img228.imageshack.us/img228/566/injector4.jpg

[Sphere]

What is the difference between F and FA? 10cc? Or other differences as well, i.e. rpm etc?

[thundercougarfalconbird]

im not sure if yanmar has a 406 and 418, or if it is just the clones, i guess it depends who is manufacturing the clone as im sure there are several different factories in china making copies, the other change they may make is with or without ballanceshaft. these engines appear to look the same but when you take them apart there is no interchange on parts, this is true with the honda clones and im very sure the same applies to the yanmar clones

[kapis]

Hi falconbird, thanks for the pic, listen, maybe you know at what pressure these 418cc injectors "pop" and is the spray angle the same as 406cc angle??

If yes, then i think I could manufacture some kind of a thick copper gasket to put between the head and a nozzle to make the tip length match the 406cc injector.

[pietenpol2002]

In the link below they show a "sleeve" associated with the injector in question. Would that be anything close to what your speaking of? Or solve the mystery?

http://www.emergencypower.com/generator ... tem-parts/

[kapis]

Hi, just visited a friend who owns a lathe ....

Now we have made a new "sleeve" from brass with copper gaskets from both ends to accommodate the NEW nozzle, sorry about the pics - remembered to photograph only after the "sleeve" had been made and pressed into the head.

link to pics: http://fotki.lv/lv/kapis/comments-32770465/

[Sphere]

Interested to learn if your engine runs now. The best part about building a bike is overcoming a problem, and enjoying a beer afterwards, at least that's my take on it

[thundercougarfalconbird]

im not sure about the spray angle or the pressure on the single cylinders, i cant test those injectors i dont have a fitting as the injector has a female thread and all the adaptors i have are made for a male fitting on the injector. i have tested the injectors in my punsun 22hp and they are between 2400 and 2500 pounds. i hve to make and adapter to test the singles.

[kapis]

Hi,
wanted to notify you that the engine partially runs . Yesterday I put it together and it fired up!
here are some vids:

first start: http://www.youtube.com/watch?v=bNPOxrvH3wE
second try: http://www.youtube.com/watch?v=Gbtng8Cl0Vg

Engine prior to assembly, with the right "tool" besides it

So maybe somebody can tell whats with the smoke?

[sbrumby]

White smoke 100% injection timeing too far retarded.

[pietenpol2002]

Is it an optical illusion, or are you running that without a flywheel?