Cossack Voskhod 175 rebuild

[moggie]

Made alot of progress on the bike this week.

I ordered new tyres & tubes over new year from Wheelhousetyres.co.uk. ordered on the friday. Arrived on monday. They are Mitas H-05 3.25x16. came with tubes and rimtape all for £87.

Gutted to lose the old USSR tyres, but they were just a tad cracked and old.

Heres a bit of the cracking

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3925.jpg

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3926.jpg

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3930.jpg

& a weird patched bit where the patch has fallen off

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3928.jpg

For posterity

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3922.jpg

The bike has had so few miles ridden on it the molding stud nipple things arent even worn down on the rear wheel
https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3929.jpg

Fitting the new ones was pretty easy. I sanded down and prepped the wheels themselves and mounted the tyres on. Then left then deflated and masked over the sidewalls with tape. That way I could just paint them and inflate the tyre without the risk of damaging the paint when mounting the tyres on.

Even though both tyres are 3.25x16 the Ruskies must have had a different way of measuring their widths because the new tyres are a bit thinner. Maybe 3.50 would have been more similar, but its too late now. The tread isnt as cool, but its better than the Dunlop alternative.

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3945.jpg

I don't know if this is unusual?, but the spokes have straight heads on them rather than a 90 degree angle. The hubs are specially designed for this, plus the spoke heads are hidden away from the elements.

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3946.jpg

Halfway through painting

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3955.jpg
____________________
MT-03 | CX500B | Yamaha RS125 | Voskhod 2

[moggie]

By this point we've got almost everything ready for the rebuild, so we started off with the frame on a homemade trolley and put theengine back in:

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3956.jpg

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3957.jpg

If you remember the engine had been lose in the frame and was missing a rear mount. This was the missing one. Im guessing they left it of because they couldn't be arsed to removed the engine cover and to get to the opening for putting the bolt back in

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3959.jpg

The kickstart rubber was missing so its got a new one now
https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3960.jpg

Putting the sidestand back on isnt that easy. The cylindrical bit welded to the frame has got a spring and piston pressed inside it, so the only way to get the stand back in place is to press it back in with a clamp.

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3961.jpg

With the rack and mudgaurd on its starting to look like a bike again
https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3963.jpg

Used new bearings in the headstock. some of the old ones had split in two.

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3967.jpg

Forks, fork covers and sideboxes back on

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3970.jpg

The batteries we had we going to be too big, so we are using this 12v 2.4ah backup battery instead. fits nicely. It'll get some padding to secure it in place later.

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3971.jpg

The engine only has four wires. There'll be a lot more wiring on this thing than a Voskhod has ever had by the time its finished. The rectifier mounted on the frame is another piece of Yamaha RS125 being put to use.

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3972.jpg
____________________
MT-03 | CX500B | Yamaha RS125 | Voskhod 2

[moggie]

The tail light was missing from the bike, so thats yet another piece taken from the RS125. It has the right look, but wouldnt fit straight on because the bulb holder stuck out too far to fit with the curve of the mudgaurd. So I turned the lens around 180 degrees and fettled the back panel bit to allow this. Then since the reflector dish would no longer work for the numberplate light its got an outdoor led stuck to the bottom.

Fits nicely like this. Once mounted its level unlike in this photo:

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3975.jpg

the led underneath:
https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3979.jpg

The indicators were a straight fit. Just needed an extra hole with a grommet in to make the wiring fit neatly.

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3985.jpg

The speedo was missing its bulb + holder, so I cut up a piece from the broken Yamaha dash light holder and used that
https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3987.jpg

and made a new speedo seal out of some old motorbike inner tube
https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3989.jpg

The headlight had a big three pinned 6v 35w/35w bulb in it. I couldnt find a new one of these at all, not even a 6v one let alone a 12v. However a H4 fits the opening nicely, so with a rubber seal in there too its a solid fit and alot cheaper to replace.

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3988.jpg

Now to look at the brakes!!!

Heres a demonstration as to why the brakes on these things are so pitiful. on the left is the FRONT drum from the Voskhod, Centre is the REAR from a Yamaha RS125 and the left is a REAR from a CX500. All bikes from roughly the same era.

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3993.jpg

It gets worse when you look at the widths side by side

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_3994.jpg

So with that in mind, here is a sneak peak at the plan b option for when the brakes arent enough and considering the horn in the lampbowl is purely cosmetic...

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_4004.jpg
____________________
MT-03 | CX500B | Yamaha RS125 | Voskhod 2

[pepperami]

Can you not get the brake shoes re-lined with a different/better material to improve braking?
____________________
I am the sum total of my own existence, what went before makes me who I am now!

[moggie]

[blurredman]

Any updates on this wonderful (ahem ) machine?
____________________
CBT: 12/06/10, Theory: 22/09/10, Module 1: 09/11/10, Module 2: 19/01/11
Past: 1991 Honda CG125BR-J, 1992 (1980) Honda XL125S, 1996 Kawasaki GPZ500S.
Current: 1973 MZ ES250/2 - 17k. , 1979 Suzuki TS185ER - 9k, 1981 Honda CX500B - 91k, 1987 MZ ETZ250 (295cc) - 38k, 1989 MZ ETZ251 - 49k

[moggie]

Here's the various bits I acquired for making new cables. The should be all fine, but it remains to be seen if the front brake cable will be good enough - might remake this one in thicker cable in the future

https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_4000.jpg

All the little end nipples are soldered onto the ends of the cables like this:
https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_4001.jpg

Giving you something like this:
https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_4002.jpg

and the finished cables:
https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_4003.jpg

Heres the headlight back in place:
https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_4009.jpg

and what the front end looks like with the indicators and rebuilt lamp:
https://i223.photobucket.com/albums/dd216/jascook/Voskhod/IMG_4007.jpg

We are actually way further ahead than this now, but I've not got the photos uploaded. The biggest problem currently is that once the front end wass all put back together we discovered one of the forks has got a hairline fracture to the welding at the axle end - so its leaking fork oil quite badly. We'll need to take it all apart again and reweld this up. Just haven't mustered the will to do this yet as Ive been distracted with other stuff.

Oh and the vespa ignition we ave used is crap! it only switches off properly in the OFF position about half the time. So that's another thing which will need re-doing.
____________________
MT-03 | CX500B | Yamaha RS125 | Voskhod 2

[paddlesat16]

Tis looking good

Regards
____________________
I once saw a bloke shagging a donkey.... in Saudi arabia. Theory Test Passed 26/10/09 Mod 1 Passed 26/4/10, Mod 2 Passed 7/6/10 Current Bikes Suzuki GSX1400 K5, Aprillia Pegaso 650, Suzuki DR350T.

[pepperami]

Still watching
____________________
I am the sum total of my own existence, what went before makes me who I am now!

[VTRkemshell10...]

sweet thread - watching with interest
____________________
Past Rides: Sym Jet Euro X, Gilera DNA, Aprillia RS125 (Spains No1 Replica), 1991 Honda NSF, 2006 Honda CG125, 1992 Honda CB400 Super Four, 2000 VFR800 FY-I
Current Rides: 2001 VTR1000 FIRESTORM

[Werny]

A genuinely interesting rebuild project, really enjoying this thread!

Thanks for sharing

[map]

Quick question.
With only a km/h speed dial do you expect any issues with MOT?
Or is there an age exception on things like this?
____________________
...and the whirlwind is in the thorn trees, it's hard for thee to kick against the pricks...
Gibbs, what did Duckie look like when he was younger?

[et1]

Nice good quality work. Nice

[trevor saxe-coburg-gotha]

[blurredman]

[Kickstart]

[alexlawriewoo...]

Really cool, watching with great interest!
____________________
Yamaha RXS100 [returned to mate], 1982 Honda CM125 [stolen], 1982 Suzuki GS850G

[27cows]

Dear God, I can't believe there's still one of these knocking about I had a 125 Cossack some time in the late 80s and can attest that it did indeed have the worst brakes ever devised. Made those on a Honda Camino seem decent.

Those indicators look suspiciously like RXS100 ones (83-86 model - the nice chrome ones before they stuck the horrible matt black ones on).
____________________
The RXS100: vehicle of choice for Chuck Norris

[dialup_2001]

...So there I am in my mates scrapyard and an old guy pushes in this old fucking wreck of a shit soviet era!!!
https://i413.photobucket.com/albums/pp211/dialup_2001/Canterbury-20110409-00353.jpg

He takes his £31 and walks out. I fall in love and take it home!!!!

[alexlawriewoo...]

I kind of fancy a downgrade, looking at these things.

Good buy.
____________________
Yamaha RXS100 [returned to mate], 1982 Honda CM125 [stolen], 1982 Suzuki GS850G

[f1fan111]

[pepperami]

I appluad you lot taking on these Soviet bikes, 10 out of 10 and much .

I`m struggling with a Jawa , so how you lot manage to sort out these bikes out is a mystery?
However my Jawa has been put on the back burner at the moment while I sort out this Superdream I`ve picked up.
____________________
I am the sum total of my own existence, what went before makes me who I am now!

[blurredman]

[pepperami]

Is it my pc or have some of the pictures disappeared?
____________________
I am the sum total of my own existence, what went before makes me who I am now!

[roadracejoe]