MINSK Repair Manual

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Minsk Repair

Manual

Digby Greenhalgh

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Summary of Contents for MINSK Minsk

Page 1 Minsk Repair Manual By Digby Greenhalgh ...
Page 2: Table Of Contents
Understanding the Generator Understanding the Electric Box Understanding the Air/petrol System Understanding the Cylinder and Piston Understanding the Transmission System HOW TO GET YOUR MINSK RUNNING Starters Checking the Sparkplug Solving Electrical System Problems Checking the Air/Petrol System How Good is your Carburettor?
Page 3 REPAIRING NON IGNITION PARTS Adjusting the Clutch Improving the Clutch Mechanism Repairing a Flat Inner Tube Removing the Front or Back Wheel Adjusting the Chain Tightening the Brakes Changing the Clutch Oil Repairing the Lights and/or Horn Checking and Adjusting the Spokes Checking the Tyres Repairing the Head-Lamp Replacing the Cables...
Page 4 Welding Parts Back On Spotting Problems with the Cam Disk RECOGNISING STRANGE NOISES WHEN YOU GET STUCK IN WATER MINSK TOOL KIT HOW TO MAINTAIN YOUR MINSK HOW TO START YOUR MINSK USEFUL ADDRESSES MINK LANGUAGE...
Page 5: Hail The Minsk
15 dogs, three huge pigs, one cow, one buffalo, seven people, three other Minsks or 20 bicycles. The Minsk is a beast that will get you where you want to go. No wonder the Vietnamese call it the “con tr©u gi ” (old buffalo).
Page 7: Understanding The Minsk
Minsk the initial movement of the magnet is caused when you kick-start the bike. Once the bike has started, the force to spin the magnet comes from the movement of the piston.
Page 8 There are two types of generators made for use in the Minsk. In version #1 a large solid magnet attached to the shaft inside the engine spins inside a set of six coils which are on the inside of a fixed circular casing.
Page 9: Understanding The Electric Box
These thick wire coils are much more robust and burn out once in a blue moon but create too much electricity. So Cuong also installs a transformer to bring the charge back down to 12 volts – the standard for the Minsk. Understanding the Electric Box...
Page 10: Understanding The Air/Petrol System
Minsk Repair Manual A – Electricity that comes from the transducer coil in the generator which boosts the charge to the sparkplug. 3 – Electricity coming from the thin-wired coil(s) in the generator which power the sparkplug. 02 – Electricity coming from the four large-wired coils in the generator which powers the lights and horn.
Page 11 Combine this with a spark and you get what you need to haul your Minsk up a muddy track. The two jets have different purposes and are of different length. The shorter one called the idle jet has the job of making the air/petrol spray when the engine is idling (when you have yet to turn the throttle) and is always open.
Page 12: Understanding The Cylinder And Piston
The Minsk might be a little bike and it might be a dirty bike, but no one has ever said that it lacks the power to get you up and over any obstacle thrown up by the back roads of Vietnam.
Page 13 (which spins the clutch via a small chain called the clutch chain). If you look at your Minsk from above you clutch and drive generator, engine will notice that the axis of the generator...
Page 14 An interesting feature on the Minsk is that the first gear is very large meaning that it is a slow but very powerful gear, strong enough to get you over most obstacles.
Page 15: How To Get Your Minsk Running
If your Minsk does not start or it suddenly stops running then you either have a problem with the electrical system or with the air/petrol system. Luckily you very rarely have problems, especially if you start out with a Minsk serviced by Cuong.
Page 16: Solving Electrical System Problems
Minsk Repair Manual carefully pry it open with you pair of pliers. Solving Electrical System Problems If there is no spark at the sparkplug then either there is no electricity in the bike or the sparkplug is dead. To determine which is the case, remove the spark-plug cap from the sparkplug wire and touch the end of the exposed wire to the engine.
Page 17 Minsk Repair Manual Otherwise, first make sure there is no problem with the sparkplug wire. Ensure that both ends of the sparkplug wire coming from the transformer to the sparkplug goes to sparkplug transformer sparkplug wire (screwed into the sparkplug cap) cap are screwed in nice and tight. Then ensure that this thick wire is not old and weak.
Page 18 Minsk Repair Manual sandpaper as a last resort. If there is no spark from the ‘3’ wire then you have to turn your attention to the generator. Use your screwdriver to remove the generator casing first. If you have a generator version #1 then touch the ‘*’ nut (see diagram below) and the magnet at the same time with your screwdriver and kick-start the bike.
Page 19: Checking The Air/Petrol System
Minsk Repair Manual Checking the Air/Petrol System If there is a good spark to the sparkplug but the engine is still not starting then the problem is with the air/petrol system. Essentially there is too much petrol, too little petrol or water is getting into the engine and fouling the sparkplug. The problems causing these involve the air filter, the carburettor, the petrol and the seals between them.
Page 20 Minsk Repair Manual are very hard to replace. You also want the stopping pin to be able to move up and down freely. Sometimes it can get jammed. Of critical importance if you have the square petrol carburettor is the tiny plastic washer on the stopping enters pin.
Page 21: Solving Air/Petrol System Problems
Minsk Repair Manual Finally, if your kick stand is weak causing your bike to lean over to its left at an acute angle then the mechanics of the float in the carburettor can be inhibited. The float can get jammed before it closes off the petrol which means that it will always flood.
Page 22: Cleaning The Carburettor
Minsk Repair Manual the petrol mix which might do the trick. If it doesn’t work then return it to its original position. Prolonged rain or a high stream crossings will dampen the paper in the air-filter and limit the amount of air passing through to the carburettor. This will cause a petrol-rich mixture to get to the sparkplug which will flood it and cause it to die when the accelerator is opened too much.
Page 23 Minsk Repair Manual Cleaning the carburettor is not as difficult as it sounds as most of the parts in it have non-uniform shapes which can’t be put back together the wrong way. All you need is a #13 spanner, a flat screwdriver, a thin strand of electrical wire, a clean rag and a pair of pliers.
Page 24 Minsk Repair Manual sound. Dirty petrol often gathers around this washer seal on the stopping pin causing the carburettor to overflow – therefore make sure it is clean. Check that the overflow hole on the bottom cup of the carburettor is not blocked as then any excess petrol will not be able to get out, which will make the bike harder to start.
Page 25: Adjusting The Carburettor
Minsk Repair Manual When you replace the top lid, the spring and the gate mechanism back to the main body of the carburettor you will have to slowly slide it back into place making sure that the long pin fits into the hole at the bottom. If it does not slide in sweetly then the pin is not in position.
Page 26 Minsk Repair Manual Don’t pump the petrol by pushing the petrol button on the side of the rectangle carburettor. Then remove and open the carburettor and note where the level is with respect to the two jets. Bend the brass connection point either a little up or down to let more or less petrol in.
Page 27 Minsk Repair Manual For both carburettors, turning this screw clockwise limits the amount of air in the petrol mix, and turning it anticlockwise increases the air in the mix. As with the idle screw, the engine’s pitch is affected by turning this screw – clockwise makes the engine run lower, anticlockwise makes it run higher.
Page 28: Summary Of Ignition Problems
Minsk Repair Manual Summary of Ignition Problems If your Minsk breaks down or does not start straight away, then one or some of a finite number of problems are at work. As the list below shows, there are only 33 possible faults which cause ignition problems. If you become familiar with this list then you can always get your Minsk going if you persevere.
Page 29: Recognising Ignition Problems
Minsk Repair Manual Recognising Ignition Problems Experienced mechanics are able to home straight to a problem because they recognise the symptoms caused by faulty or improperly adjusted parts. The following list summarises these symptoms and will help you to repair your bike quicker. Always remember though that the best approach is to start from the beginning and then to slowly isolate the problem in a methodical fashion.
Page 30: Repairing Non Ignition Parts
Minsk Repair Manual Repairing Non Ignition Parts Adjusting the Clutch When the clutch pads wear down, they get thinner, which causes the clutch lever to become looser and the gear changing clunkier. This is normal and you can compensate the effect by adjusting the clutch screw. This adjustment can not go on forever, and eventually as the clutch pads wear right down, they will begin to slip when you accelerate.
Page 31: Improving The Clutch Mechanism
Improving the Clutch Mechanism When the cable pulls the lever arm up, the large screw thread pushes a rod into the clutch plates. You can make this action much easier on the Minsk by cleaning, greasing and protecting the thread/lever mechanism. To do this, remove the generator cover to reveal the drive sprocket, the generator and the clutch lever mechanism.
Page 32: Repairing A Flat Inner Tube
Minsk Repair Manual Repairing a Flat Inner Tube There are so many mechanics in Vietnam that flat tyres are normally not a problem once you have paid VND50,000 for the service of getting them fixed. However, once you are off deep in the mountains then it is very possible that there will be no one to help you.
Page 33 Minsk Repair Manual forget its position. Clean the area around the hole with soap and water if you have it, let it dry, then rough up the inner-tube with sandpaper before applying the glue (not too much) to both the patch and the area around the hole. It is important to keep oil and dirt away from the patch and the glue so keep your hands clean.
Page 34 Minsk Repair Manual When the tyre is back on, pump it up, making sure all the circumference of the inside of the tyre is equally spaced from the rim. There are concentric lines moulded on the tyre around the inside circumference to aid this.
Page 35: Removing The Front Or Back Wheel
Minsk Repair Manual Removing the Front or Back Wheel You might want to remove the entire wheel in order to install a new inner tube. First prop the bike up on a large rock as described above. Removing the front wheel is easy. First loosen the small lock nut which tightens the brace thereby fixing the axle shaft in position –...
Page 36: Adjusting The Chain
Minsk Repair Manual this metal tube will now allow you to move the wheel away from the chain housing and then away from the bike. You might need to tilt the bike at an angle to make this easier. As you move the wheel away, the lid holding the brake pads will fall off but it will still be connected to the back brake rod.
Page 37: Tightening The Brakes
Minsk Repair Manual Once the wheel is free to move, you force it backwards, thereby tightening the chain, by turning the #13 nuts on the threads found on both sides of the back wheel just behind the nuts mentioned above. Of the pair of #13 nuts on either side, it is the ones furthest to the rear which you must screw clockwise to push the back wheel backwards.
Page 38 Minsk Repair Manual Screwing this thread anti-clockwise effectively makes the brake pads further away from the brake lever on the handle bars meaning the whole action will be tighter. You will need a pair of pliers for this, but first loosen the lock nut by turning it anti-clockwise.
Page 39: Changing The Clutch Oil
Most people neglect to change their oil regularly allowing grime, water and dirt to foul their Minsk’s insides prematurely. To replace the oil, first remove the stubby bolt on the top of the clutch cover above the kick-start pedal.
Page 40 Minsk Repair Manual (1) Just the Horn Dies Remove one of the wires from the horn, touch it to the frame, start the bike and hit the horn button. If it sparks then you know the horn is broken. If not then the wires are most likely to be loose.
Page 41: Checking And Adjusting The Spokes
Minsk Repair Manual Then take off the seat and note the three wires going into the back light casing which run along the top of the back wheel’s mud guard. Two enter it via a plastic connection clip and one via a screw. Ensure that the screw is tight and the connection clip secure.
Page 42: Checking The Tyres
Minsk Repair Manual Alternatively, tap them with a spanner and listen for a clear sounding noise. If they are loose then this tapping will produce a dull thudding sound much different from the harmonic ring when they are tight Normally a visual check while spinning the wheel will tell you if the rim is warped but if you want to be more accurate about where exactly the warp is then do the following.
Page 43: Replacing The Cables
Minsk Repair Manual If the beam from the front light is eschew then simply remove the three tension clips between the glass and the head-lamp cover and twist the glass until the writing on it is horizontal and the right way up. There is a small arrow on the glass which must be at the top.
Page 44: Dealing With Cracked Hand Levers
Vietnamese even go so far as to weld a lever onto this lock nut so that they can open or close the clutch with their foot rather than their left hand. Dealing with Cracked hand Levers If you drop your Minsk then the levers can snap. Luckily brake clutch...
Page 45: Spotting Gear Box Problems
Minsk Repair Manual easier. If you are having trouble undoing a screw then hit the handle end of the screwdriver with a hammer or rock a few times while the other end is in the head of the stiff screw. This is usually enough to jar any rust or grime from the screw’s thread thereby allowing it to turn.
Page 46: Checking The Suspension
Cuong can install front suspension from the Bonus motorbike which is much stronger than the Minsk version. Not a bad idea if you are cashed up. There are three types of back suspension ranging from the stiff, black pig- carrying Chinese set to the longer, silver medium Chinese or Russian set to the weak set which comes with a new bike.
Page 47: Adjusting The Handle Bars
Minsk Repair Manual Adjusting the Handle Bars Two bolts and two nuts keep the handle bars from moving around. The two #12 bolts that you can see on top of the two braces around the middle of the handle bars allow the height of the handle bars to be changed. Just loosen them, move the handle bars higher or lower and then retighten the two bolts.
Page 48: Tightening The Frame Bearings
Minsk Repair Manual Tightening the Frame Bearings The entire back of the bike where the chain and wheel are can move independently from the engine block and main frame because of a set of tough rubber plugs at the point where the back wheel’s brace frame connects to the main frame. These rubber plugs allow the whole back system –...
Page 49: Spotting Problems With The Cam Disk
Minsk Repair Manual going into the electric box under the seat. This action will break the electrical loop which would otherwise facilitate huge surges of electricity going through some of the bike’s more sensitive electrical bits and blowing them up. Spotting Problems with the Cam Disk Any problem with parts under the piston is a big problem as the whole engine needs to be taken apart.
Page 50: Recognising Strange Noises
Sometimes a weak part will begin to rattle against other parts on the bike. Being able to recognise these sounds and do something about it will help you no end in your pursuit of trouble free Minsk adventure. Near the Exhaust Pipe...
Page 51: When You Get Stuck In Water
Water will not kill your Minsk, it will only quiet it down a while. Basically you are going to have to get the water out of the air box and filter, the carburettor, the exhaust pipe, the generator, the wires and the engine.
Page 52: Minsk Tool Kit
Minsk Tool Kit Always carry a full tool and repair kit. Store it in the removable side panel on the left-hand side of the Minsk. Problems do occur, so the better prepared you are, the easier time you will have should things go wrong. I highly recommend that you take with you all the equipment listed below.
Page 53 Minsk Repair Manual way down the front suspension forks and the lock nut on the back wheel. It can also be used to adjust the spring on some back suspension sets. 10. Tyre repair kit – glue and patches. Before you head out squeeze some of the glue out of the tube as they are prone to breaking open.
Page 54: How To Maintain Your Minsk
Minsk Repair Manual How to Maintain Your Minsk Make sure all the bolts and nuts are tight. Make sure the chain is not too loose. Oil it occasionally. Watch that there is smoke always coming out from the exhaust pipe. Some shops do not give you enough oil mixed in with the petrol. 4%=1 Pepsi bottle (200ml) per 5 litres.
Page 55: How To Start Your Minsk
How to Start Your Minsk This section might seem a little redundant for most drivers. However, there is an easy way and a difficult way to start your Minsk so you may as well know the right way. 1. Check that the engine start/stop switch on the right hand side of the handle bars is up i.e.
Page 56: Useful Addresses
Minsk Repair Manual Useful Addresses Minsk Club The club knows all about the Minsk and can tell you everything you need to know about biking in Vietnam. WebPage: www.minskclubvietnam.com Email: minskclub@hotmail.com Mechanics in Hanoi Mr. Cuong (the most famous in the whole Hanoi region) can fix everything.
Page 57: Mink Language
Minsk Repair Manual Mink Language MINSK PARTS Accelerator cable D©y ga Kh«ng khÝ Air filter Läc giã Battery ¾c quy Bearings Bolt Bu l«ng Brake Phanh Brake cable D©y phanh Brake lever Tay phanh Brake light §Ìn phanh Brake pad M¸ phanh Bulb Bãng ®Ìn Cam disk Trôc quay, biªn...
Page 58 Minsk Repair Manual Gear pedal CÇn sè Generator bé ®iÖn Generator coil quËn næ Headlight §Ìn pha Horn Cßi Indicator lights §Ìn xi nhan Inner tube X¨m Khoa Kick stand Ch©n trèng Kick-starter CÇn khëi ®éng Lock æ khoa Mud guard Cao su ch¾n bïn Number plate BiÓn sè...
Page 59 Minsk Repair Manual MINSK TOOLS Air pump Exhaust pipe Chßng v¨n cæ x¶ removing tool Gaffer (electrical) Gi¾c ®iÖn tape Inner-tube repair Bé v¸ Pliers K×m Sand paper GiÊy gi¸p Screwdriver T« vÝt Spanner Spanner Má lÕt (adjustable) Spanner number.. Cl sè ..