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Cossack Voskhod 175 rebuild

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moggie
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Joined: 27 Oct 2012
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PostPosted: 20:31 - 27 Oct 2012    Post subject: Cossack Voskhod 175 rebuild Reply with quote

Been lurking for ages, thought I'd join to keep a record of this project.

Its a 1978 (built in 1975) Voskhod -II 2-stroke 175cc single with twin exhaust ports.

The bikes claim to fame is it came with the worst brakes ever fitted to a motorcycle Mr. Green

It was last on the road in 1982, but the engine runs fine. Plan is to respray the orange and do other parts in either cream or satin black. There are a few panels missing and the headlight/tailights but I have stuff to replace them with.

Its basically a Soviet equivalent of a BSA bantam. i.e. another copy of a DKW RT125. This thing is built like a tank, the steel is very good, almost no signs of rust, very thick and weighs a ton.

Already made some progress on it but for now here she is:

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_1619.jpg

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_1620.jpg

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_1629.jpg

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_1624.jpg

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_1625.jpg

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_1626.jpg

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_1630.jpg
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moggie
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PostPosted: 21:48 - 27 Oct 2012    Post subject: Reply with quote

Started stripping it apart:
https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3450.jpg

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3451.jpg

This thing is made out of girders, properly overengineered in places:
https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3452.jpg

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3454.jpg

I love the tyres, front and back are the same size. They are stamped 'made in the ussr'. I want to keep them, but they are very cracked, not sure if they would pass an MOT...?
https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3455.jpg

Its missing one of the 4 exhaust clamps and it leaks badly form each of the joins even when they are tightened fully. Ill need to find some new gaskets that fit and maybe use some exhaust gum.
https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3458.jpg
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nowhere.elysium
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PostPosted: 22:45 - 27 Oct 2012    Post subject: Reply with quote

I am quite spectacularly envious.

I wouldn't hang on to the tyres; if there's any visible cracking in the sidewall, it's enough of a sign to change them. Not to mention the fact that the Russians are hardly renowned for their world-class tyres.

I'm also quite liking the screw-fit exhaust clamps - it's a wonderfully quirky touch.

Have you checked things like parts availability yet?
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Valentino Mossy
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PostPosted: 22:50 - 27 Oct 2012    Post subject: Reply with quote

Looks very solid for its age Thumbs Up
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69chris
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PostPosted: 22:57 - 27 Oct 2012    Post subject: Reply with quote

nowhere.elysium wrote:
I am quite spectacularly envious.

me too, i love 'interesting' stuff like this Cool


I'm also quite liking the screw-fit exhaust clamps - it's a wonderfully quirky touch.


my old 350 morini had the same, had to lock wire them tight or they would slowly undo, usually waiting till you were smack in the middle of town to fall off completey Laughing

is that a de-compressor fitted to the cylinder head in the last pic ???


Last edited by 69chris on 22:58 - 27 Oct 2012; edited 1 time in total
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moggie
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PostPosted: 23:19 - 27 Oct 2012    Post subject: Reply with quote

69chris wrote:


is that a de-compressor fitted to the cylinder head in the last pic ???


Yes it is. At the moment its the only way to stop the engine (apart from stalling it on purpose) but I've got a new ignition for it. The ignition goes on the side of the headlamp.

I think the decompressor has the same thread as the spark plug, so i could be made into a twinspark Very Happy
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Kawksam
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PostPosted: 00:51 - 28 Oct 2012    Post subject: Reply with quote

I love it really nice bike going to be a hoot to drive
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Shaft
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PostPosted: 01:57 - 28 Oct 2012    Post subject: Reply with quote

moggie wrote:


Yes it is. At the moment its the only way to stop the engine (apart from stalling it on purpose) but I've got a new ignition for it. The ignition goes on the side of the headlamp.

I think the decompressor has the same thread as the spark plug, so i could be made into a twinspark Very Happy


Twin spark, twin port single you say?

There's got to be some serious potential for tuning here, n'est-ce pas?
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moggie
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PostPosted: 15:21 - 28 Oct 2012    Post subject: Reply with quote

Shaft wrote:

Twin spark, twin port single you say?

There's got to be some serious potential for tuning here, n'est-ce pas?


haha, maybe. I've only ridden it about 100yards though with no brakes and a solid clutch, so the plan is to get rebuilt and running to see how it performs before any tinkering.

The carb is also in poor nick. Its leaking and has no needle, so have that to fix first as well. Suprisingly it ran just fine without a needle Laughing

I'll post a video of it running at some point.

Some innards.
https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3459.jpg

The bare Frame - weighs a ton!
https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3463.jpg

Then recieving a degreasing. Gave the frame and the engine a jetwashing after this:
https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3465.jpg

Heres the tank sanded and getting some primer:
https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3449.jpg

And painted - using Rustoleum, its slightly deeper orange than the original, but nice and 70's Smile
https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3462.jpg

More bits sanded down. The original paint is pretty solid, no need to do anymore than sanded it back and paint over it.
https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3467.jpg

and painted hanging on the line:
https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3480.jpg

Mudgaurds being painted:
https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3481.jpg
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pepperami
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PostPosted: 15:41 - 28 Oct 2012    Post subject: Reply with quote

Much I am liking this! Different yes! two-stroke yes! Thumbs Up

Tell me as much as you can about where you get parts & spares please.
I have a couple of old Jawas that are going to be made into one bike (I hope), so the more Eastern Bloc sites we know about the better Thumbs Up

Lots of detail please
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moggie
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PostPosted: 16:40 - 28 Oct 2012    Post subject: Reply with quote

pepperami wrote:
Much I am liking this! Different yes! two-stroke yes! Thumbs Up

Tell me as much as you can about where you get parts & spares please.
I have a couple of old Jawas that are going to be made into one bike (I hope), so the more Eastern Bloc sites we know about the better Thumbs Up

Lots of detail please


So far theres been zero spares & parts in the sense of proper Eastern Bloc ones.

I have the headlight from a Yamaha RS125 , which with a bit of fettling fits really well. Ignition from an old vespa. Tailight from the same Yamaha and indicators, although I'm not sure if I'll put indicators on it yet. I know its not original soviet stuff, but without taking a trip to Russia its the best option.

My brother is going to build a new wiring loom (half his project too, but hes not got a bike license) and we are going to use 12v for all lighting and leave the engines electrics just to power itself. We've done the exact same thing on a couple of other 6v bikes and its the way to go for an easier life. (6v lights are shite!)

I've now got the V5 for it which was easier said than done. It didnt come with a V5 when i bought it, so I sent off the V62 with the frame number and everything correctly filled in. Weeks later the DVLA finally get back to me requesting that I tell them the frame number. Confused So I ring them up and manage to garner from them that they might have the engine number down by mistake as the frame number ( because of 40 year old hastily filled in registration docs I guess). Anyway I send them emails of labelled photos and hard copies explaining that the frame number I gave them is definately correct and they need to change that on the doc for the engine number they mistakenly have......another 3 weeks later!, I get the v5......with the wrong number still on there. DVLA - Useless tards. Middle Finger
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moggie
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PostPosted: 20:35 - 28 Oct 2012    Post subject: Reply with quote

Anyone want to hear what a Soviet 175 2-stroke with a blowing exhaust sounds like?

https://youtu.be/TsPx56eHA2E
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Irn-Bru
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PostPosted: 20:44 - 28 Oct 2012    Post subject: Reply with quote

Looks cool Thumbs Up As for the brakes, cable operated drums? Oh god why Laughing Interesting bike for sure Thumbs Up Thumbs Up
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Kickstart
The Oracle



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PostPosted: 20:48 - 28 Oct 2012    Post subject: Reply with quote

69chris wrote:

my old 350 morini had the same


Vincent also used a similar setup.

Irn-Bru wrote:
Looks cool Thumbs Up As for the brakes, cable operated drums? Oh god why Laughing


Honda tried using cable operated disks. One of their worse ideas.

All the best

Keith
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blurredman
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PostPosted: 21:46 - 28 Oct 2012    Post subject: Reply with quote

Irn-Bru wrote:
cable operated drums?


You are for real right? Most drums are cable operated on bikes.. Laughing Laughing
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Nisp
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PostPosted: 22:26 - 28 Oct 2012    Post subject: Reply with quote

Quote:
Honda tried using cable operated disks. One of their worse ideas.


I can conform this,

what I used to do was to warn cars I was there by locking up the back wheel wen they might pull out, it made the most awful noise but was more effective the the brake!

BTW the horn wasn't grate ether
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Nisp
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PostPosted: 22:27 - 28 Oct 2012    Post subject: Reply with quote

Nisp wrote:
Quote:
Honda tried using cable operated disks. One of their worse ideas.


I can conform this,

what I used to do was to warn cars I was there by locking up the back wheel wen they might pull out, it made the most awful noise but was more effective the the brake!

BTW the horn wasn't grate ether


edit: also Avon do a classic tire range, classic tread but with modern rubber
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_mjs_
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PostPosted: 00:48 - 29 Oct 2012    Post subject: Reply with quote

In Soviet Union, bike rides you.
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Efes123
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PostPosted: 10:11 - 29 Oct 2012    Post subject: Reply with quote

Seriously envious, but I don't envy you trying to find parts. Looking forward to more updates.
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moggie
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PostPosted: 14:31 - 29 Oct 2012    Post subject: Reply with quote

Efes123 wrote:
Seriously envious, but I don't envy you trying to find parts. Looking forward to more updates.


Fingers crossed, but at the moment it doesn't look like we'll need to find any parts. We can mostly make whatever we need or find something else that fits. It's not going to be a faithful concourse condition rebuild, just a sensible one. For instance I'd love to get everything rechromed, but it would be silly money and not reflected in its final value. So most chromed parts are going to be either Rustoleum cream or Satin black.

For the tyres it looks as if there's only two options. Either Matis tyres for £35 or so each or rather pricey Dunlops for £70 ish each. Matis it is then Thumbs Up

This is the Yamaha headlight trim, it's almost a perfect fit, but it just needed the lip cutting down to fit snuggly on the Voskhod lamp. It would have been easier to cut the Voskhod lamp, but decided to keep that unmolested on the extremely thin chance of ever finding a genuine headlight. with the lip gone the clips that hold the glass/reflector in place no longer worked, so we just gluegunned the glass in place. (added bonus is its now its watertight)

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3464.jpg

Here's the lamp painted, we've since fucked up the finish on this by trying to polish it so will need to repaint it.

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3475.jpg

The rear shocks seem to be fine. These along with the wheels and rack have all been badly painted in silver metal paint at some point. They've done this because the original chrome has disintegrated. The Ruskies where masters of making steel, but frankly total shit at chroming. The plan with these is to do them two tone, either orange or cream on the top sleeve and black below.

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3473.jpg

Some more random photos. I guess it would have been nice to save these stickers, but I destroyed them when trying to peel them off. Truth be told I didn't like them anyway, i think keeping a high res record of them is good enough. Its the sort of thing I would have peeled off if I'd bought it new myself anyway.
https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3470.jpg

Back of the storage boxes being cleaned:

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3471.jpg

Inside one of the storage boxes. Not sure what the little shelf thing is for, probably the missing toolkit. The bakelite switch is the for the rear brake light. The bike only has that, theres is no front brake light switch. It will pass and MOT with only one brake light switch because of its age (can't remember the year it has to be older than off the top of my head, but I did check)

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3472.jpg
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pepperami
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PostPosted: 20:16 - 30 Oct 2012    Post subject: Reply with quote

MOAR NOW!!
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Efes123
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PostPosted: 21:20 - 30 Oct 2012    Post subject: Reply with quote

pepperami wrote:
MOAR NOW!!


How's those two wrecks you bought getting on?
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moggie
Borekit Bruiser



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PostPosted: 14:44 - 31 Oct 2012    Post subject: Reply with quote

The rack was painted in the same shitty silver as the wheels and the shocks. Should be grateful that it was done to be honest because there is maybe about 15% of the original chrome left on it, the rest has just flaked off. The rack is solid though, no rust. a little bent, but it's straightened now.

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3776.jpg

That big rectangular opening at the front is for the airbox intake, we are planning on using some of that area to mount the new 12v battery(s). Gotten some 12v dry cell alarm batteries leftover from them being replaced at my brothers work. Ill get a photo of them up now I think about it. The best batteries for small bike 12v conversions are the ones they sell for alarm backups/model airplanes etc.. cos they are smaller/more powerful and sealed so you can mount them in whichever weird place you can find to fit it.

It took quite alot of wire wheeling on the grinder, then I went over the remaining chrome with a flap disc to cut into it.

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3777.jpg




Testing the cream, then i remembered I was supposed to be painting the underneath in black first.
https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3778.jpg

Underside in hammerite, purely for protection, none of this will be visible:

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3779.jpg

And the finished rack. The cream is Rustoleum Combi-color aerosol can. It's only £4.50 on the Rustoleum website, produces a really nice finish straight from the can. Takes hours to dry though, unlike Hammerite or the orange Rustoleum which are dry in about 30 mins.
https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3854.jpg

This is the frame after jetwashing. Gave it a light going over in some places with the flap disc.
https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3845.jpg

At some point a previous owner has had the engine out, but put it back in without one of the rear engine mounts. Because of this the engine has been vibrating too much and started to crack the front mounts just in front of the welds. This photo shows it, but the other side was bigger, I forgot to get a photo of that though before we welded it.

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3843.jpg

This is the other side after welding and grinding back down with the flapdisc. Just used an Aldi arc welder to do it. That's another bonus of the Russian steel Laughing its so thick you can use an arc welder.
https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3842.jpg

The frame is now painted, I'll get the pics of that up later. After that this thread will be right up to date with the progress, so we'll have to get some more done!. Been distracted from it the last few days with cleaning CX500 carbs.
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pepperami
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PostPosted: 15:41 - 31 Oct 2012    Post subject: Reply with quote

Efes123 wrote:
pepperami wrote:
MOAR NOW!!


How's those two wrecks you bought getting on?



Laughing Laughing Thread Hi-jack Laughing Laughing .

One is living in the garden covered in grease & oil until I get the time to strip it.
The other is living in the garage having it`s electrics prodded and poked Shocked .
A new second hand ignition switch turned up today and the numbers match my diagram Thumbs Up .
The headlamp that came also, is to small Sad so a bit of "Heath Robinson" will be required unless I can find another that fits?
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