Ural-Daihatsu

[Stuart]

Topic split from Bike Building Fourum similarly named to preserve that thread.

Mark, did you make any drawings of that clutch mounting plate that fits the engine by any chance?

[mark_in_manchester]

No - I made a cardboard template (which I still have, I think) and gave it to a bloke at my (previous) works who got it sent out and laser cut for me straight from that. It saved a huge amount of chain-drilling and filing, and was pretty cheap - 15 quid comes to mind. I make everything in cardboard first - the guy who got it cut for me thought this was very funny, as he's a 3d (solidworks) modeller.

If anyone really want to make one, contact me and I'll try to think of a way to turn it into a drawing. It might fit onto A3 and I could reduce it on a photocopier.

cheers

Mark

[Stuart]

I only ask because 10 minutes after posting that I had a Daihatsu engine turn up on my drive I've no lifting gear or bench so it's doubtful I can do the work but just you mentioning the Laser Cutting business gives me hope. Either way it's bike bound. It's a non turbo version btw.

[mark_in_manchester]

Great - well, you don't need to get it off the floor to make that plate. I would have made it in aluminium but I couldn't find a nice thick bit at the time. What bike might you use? Ural/Dnepr is most popular, but not as cheap as they used to be...my mate built a Kubota / Guzzi V50 which is very nice, and V50s are very much undervalued I think. I'll have a look for my template.

You know you really ought to buy a bench and vice!

Those engines are now hard to find - where did you find yours? Be SUPER careful about water - they split the heads between the valve seats and pressurise the water system, if they overheat. I have a couple of knackered heads. Since things are now so scarse, if I ever need to I guess I'll have to spend big money getting one welded / skimmed / new seats etc etc.

If you do decide to go Russian, stay in touch as I have a lot of stuff, though I'm not so close to you. I might also have the bits to turn your non-turbo into a turbo if you so desired, though I'm not sure how much of this stuff is surplus and how much I was going to hold onto as spares. I have loads of photos which Johnny Flatau sent me years back, which you might find useful too. Might be easier to post them to you on a stick.

cheers

Mark

[Stuart]

My engine has just come over from the Netherlands - Teun (Zeus sidecar outfit) has trailored it over). It was to be used as a generator on a boat but the guy tried to do it without changing something in the diff so he gave up on it. I'm hoping it's ok but we know this end that some work maybe required?
I don't have a bike lift bench but do have a table & vice
I'd like to see the engine in a big, cheap old Jap bike but shaft rotation on different machines is something I know little about.

[mark_in_manchester]

Shaft rotation...I don't have one to hand in bits, but on looking at russian gearbox pictures I think Daihatsu engine rotates anti-clockwise, looking at flywheel from rear. Ural and Dnepr gearboxes both have output shafts which rotate clockwise when viewed from the rear. I happen to know this is opposite to BMW (but I don't know anything about Jap shaft-drive bikes) - it does mean that if you find yourself with 5 reverse gears, it is certain that you can swap for either BMW or Ural / Dnepr FD bevel box, and get yourself out of trouble - so long as you can sort the shaft out. With USSR options this is not so tough, as only one proper UJ is involved on the shaft - at the 'engine end' a large and very-approximately engineered rubber donut is used which would facilitate all sorts of inter-species coupling...

Rather than worrying about shaft rotation, I'd be more concerened about choosing something where gear ratios are available and swappable - both in the gearbox, and in the bevel box. The most low-geared Russian option has a 20:26 4th gear and 1:4.6 FD ratio, giving an overall reduction of nearly 6:1. My bike will pull a 1:1 top gear pair in the gearbox and a 3.2:1 FD ratio (from about 30mph to about 90 ) - so nearly half the reduction of a standard ural 650 sidecar bike (which OK, is rather undergeared).

The unavailablity of gears would result in something with pointless 1 and 2 gears, and a 45 mph top speed. I was lucky these bits were available and that lots of people had gone before me.

cheers

Mark

[Stuart]

Ok, finally got the picture upload working here.

[coachgeo]

Looks to me you could face the engine either north or south according to which way your final drive spins and cut off the opposite side shaft........ weld the differential and be done. Would work best of course in a large bike or trike....... Looks like it begs for a two in front one in rear trike setup

[Stuart]

What ever it goes into it won't have 3 wheels

[Stuart]

Exhaust manifold seems to have a water jacket. Serial number is not quite laid out as the manual suggests. It's pretty clean with label saying belt changed at 98k km.

[mark_in_manchester]

The exhaust manifold is a home-brew - perhaps for the boat application you mentioned. The standard one is a rather odd casting on the non-turbo engine - see Johnny Flatau's bike for an example. But perhaps you could use yours for making tea! Don't worry about the pneumatic actuators on the injector pump - you can remove them, and it will still tick over fine on a cold morning. The only one I retained changes fuel mix depending on turbo plenum pressure, which of course you don't have. Also don't worry about heater plug controller - a non-latching switch (so you don't forget and leave them on) which you push and hold, count to five, then kick (you are going to kick, right? ) will be fine.

What else - fuel solenoid is obvious and just in front of injector pump - apply 12v to switch on. You probably don't need a fan so themostat sender is prob redundant (on top of thermostat housing). The little connector on the side of same is for your temp gauge. Write when you start to worry about how to plumb the cooling system and which bits to blank off, and I'll take some pictures. Mine is fine with an (old) Mini radiator and no fan. Oh, and your alternator looks like it's already been changed for a nice small one, so oil send and return to the vac pump which sits on the back of the standard item (to run brake servo assist) must already have been dealt with...? Oil pressure sender is somewhere on LHS towards the back of the block.

Edit to add - also noticed plastic cover for inj. pump belt is missing. You'll need something to stop it eating your right trouser leg at the knee, if you go long-ways!

Exciting stuff...takes me back (and gives me a kick up the a*** to get mine out and going again - thanks!).

M.

[Stuart]

Cheers for that Mark. I'm gonna print it off & start a folder for reference material like this

[Stuart]

Just a few random shots going up of my Daihatsu engine. It's like new under the flywheel

[Stuart]

FYI: flywheel, clutch plate & push plate combined weigh in at 12.5 KG.

[mark_in_manchester]

Hey Stuart - how are you getting on?

You may have seen my cooling concerns elsewhere in this bit of the forum. I've not made any progress yet looking deeper into this - too much family stuff going on.

I picked up my spare Charade engine - you may remember it was also from a boat - last night. A very nice guy from Devon sold it to me and met me at B'ham on his way elsewhere. It's a turbo engine - turbo is missing, but I have a spare. There's even more complication regarding pneumatic actuators than on my last one around the injector pump, and also an extra 'thing which looks like a throttle cable arm' mounted low on the side of the pump, which was not present on my last one (throttle is on top). When I take some pics it will be interesting to compare with yours. But...1/2 term and kids intervene. First I have to store it somewhere - life with no garage can be tiresome.

cheers
Mark

[Stuart]

I can certainly post a few shots of the engines areas you are interested in seeing. I've not looked at that side of things yet - I've started making the wooden template for the BMW gearbox just now.
Starter motor positioning is something I'd like to make different from other bikes I've seen. If I can get a more modern, smaller motor to fit then I will use that.

[mark_in_manchester]

Well, head problems with my existing engine have grown to it blowing rusty water all over my left leg all the time, from the expansion bottle - so mystery spare engine has to go in, before I attempt head-off etc etc. I answered my own question upthread about mystery attachment low-down on injector pump, on this (later) engine compared to my original. Here: http://www.youtube.com/watch?v=oj8ElcsSNkA a Hungarian guy commented on elsewhere on this site, shows a bike with the same engine. Despite not understanding Hungarian, the knob connected to that mystery attachment is very helpfully labelled with a 'choke' symbol (!) - so there we go. Existing engine seems to do without this very well, even with my kickstart-only installation, but we'll see about this one - if it even runs!

This site is vital in maintaining my collapsing motivation levels. I really should come here more often.

cheers
Mark

[Stuart]

Still messing with project but finding the time is hard.

[mark_in_manchester]

Well, if you run out of motivation entirely, I may yet be in the market for another spare engine!

Another diesel-tech man has been bolstering my confidence regarding cracked heads by saying 'they all do that - just change the gasket'. So, we'll see. This guy rides a pre-war New Imperial in tweeds, and seems altogether enthuse-able about weird stuff - so I hope to enlist his advice when the existing engine comes apart.

[Stuart]

I'm mating to the K75 box so a bit different from the Ural. I'm still mocking up the clutch housing with wood & plastic. When that's done I will begin trying to fit a starter into it.

[mark_in_manchester]

My spare engine is (finally, tonight) a runner!! I'm splurging this all over the boards - I'm a dog with two d*cks...

[Stuart]

The Grom rebuild project & repairing the Ruggerfield have gotten in the way of my Daihatsu build but it's a long term thing anyway .