Yanmar dnepr project thread

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kapis
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Yanmar dnepr project thread

Post by kapis » Mon Nov 08, 2010 7:33 am

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 :)
DSC00018.JPG
first half of frame welded
DSC00021.JPG
Testing how it will fit
DSC00022.JPG
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 ;)
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Re: Yanmar dnepr project thread

Post by Sphere » Mon Nov 08, 2010 1:54 pm

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

Post by kapis » Mon Nov 08, 2010 2:33 pm

Better safe than sorry.
That's true :) but I will be washing/cleaning the cases anyway prior to assembly :)
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Re: Yanmar dnepr project thread

Post by kapis » Mon Dec 20, 2010 8:12 am

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

So here goes the pictures :
DSC00062.JPG
Shaft made to accept the clutch basket
DSC00064.JPG
Modified Dnepr clutch basket
DSC00067.JPG
Making of the adaptor for transmission
DSC00069.JPG
Making of the adaptor for transmission
DSC00082.JPG
Adaptor ready
DSC00081.JPG
From the other angle
DSC00086.JPG
Making of an engine to frame adaptor :)
Any comment and suggestions - welcome :)
Thanks.

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Re: Yanmar dnepr project thread

Post by kapis » Mon Dec 20, 2010 8:18 am

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 :)
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Re: Yanmar dnepr project thread

Post by Sphere » Mon Dec 20, 2010 8:20 am

Looking great 8) 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 :D
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Re: Yanmar dnepr project thread

Post by kapis » Mon Dec 20, 2010 8:32 am

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 :)
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Re: Yanmar dnepr project thread

Post by Sphere » Mon Dec 20, 2010 10:47 am

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.
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Re: Yanmar dnepr project thread

Post by arnaud » Mon Dec 20, 2010 11:21 am

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 :wink:

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

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Re: Yanmar dnepr project thread

Post by kapis » Mon Dec 20, 2010 11:52 am

Sphere wrote: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 :)
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Re: Yanmar dnepr project thread

Post by kapis » Mon Dec 20, 2010 12:06 pm

arnaud wrote: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 :wink:

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.
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Re: Yanmar dnepr project thread

Post by pietenpol2002 » Wed Dec 22, 2010 4:35 pm

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!!
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Re: Yanmar dnepr project thread

Post by Sphere » Wed Dec 22, 2010 4:46 pm

Also, if you are going the fan route, use some industrial metal ball-bearing type fan, not a flimsy plastic computer fan.
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Re: Yanmar dnepr project thread

Post by kapis » Thu Dec 23, 2010 7:24 am

pietenpol2002 wrote: But I'd love to see someone try it!!
Heh, looks like I would be the the one to try it out :D ;)
Sphere wrote: 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
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Re: Yanmar dnepr project thread

Post by kapis » Wed Jan 12, 2011 6:33 pm

Hi all,

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

photo for comparison:
nozzle_comparisson.jpg
comparison
:cry:
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Re: Yanmar dnepr project thread

Post by Sphere » Wed Jan 12, 2011 6:44 pm

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.
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Re: Yanmar dnepr project thread

Post by kapis » Wed Jan 12, 2011 7:22 pm

just emailed the seller - lets see what he will reply.
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Re: Yanmar dnepr project thread

Post by pietenpol2002 » Thu Jan 13, 2011 1:11 am

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
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Re: Yanmar dnepr project thread

Post by kapis » Thu Jan 13, 2011 7:01 am

the new nozzle doesn't even fit the engine head :(
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Re: Yanmar dnepr project thread

Post by thundercougarfalconbird » Thu Jan 13, 2011 4:16 pm

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
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Re: Yanmar dnepr project thread

Post by Sphere » Thu Jan 13, 2011 4:34 pm

What is the difference between F and FA? 10cc? Or other differences as well, i.e. rpm etc?
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Re: Yanmar dnepr project thread

Post by thundercougarfalconbird » Thu Jan 13, 2011 4:40 pm

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
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Re: Yanmar dnepr project thread

Post by kapis » Fri Jan 14, 2011 7:07 am

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.
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Re: Yanmar dnepr project thread

Post by pietenpol2002 » Fri Jan 14, 2011 11:33 am

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/
Ron
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Re: Yanmar dnepr project thread

Post by kapis » Fri Jan 14, 2011 12:59 pm

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

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/
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Re: Yanmar dnepr project thread

Post by Sphere » Fri Jan 14, 2011 1:34 pm

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 :D
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Re: Yanmar dnepr project thread

Post by thundercougarfalconbird » Fri Jan 14, 2011 7:38 pm

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.
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Re: Yanmar dnepr project thread

Post by kapis » Sat Jan 15, 2011 10:21 am

Hi,
wanted to notify you that the engine partially runs :D . 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 :D :D :D
DSC00114.JPG

So maybe somebody can tell whats with the smoke?
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Re: Yanmar dnepr project thread

Post by sbrumby » Sat Jan 15, 2011 5:50 pm

White smoke 100% injection timeing too far retarded.
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Re: Yanmar dnepr project thread

Post by pietenpol2002 » Sun Jan 16, 2011 3:32 am

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