Dnepr MT9 Istruzioni operative

MOTORCYCLES "DNEPR"

MT9

and

MTIO

REPAIR

MANUAL

V/0 AVTOEXPORT •

USSR

•

MOSCOW

CONTENTS

Pag

''

I.

Preparing the Mota·C)cie for Repairs

I

I.

Checking the Motorcycie for Technical

Co

nditi

on

Ill. N\ounting and Dismanllmg Operations

JV.

Engine Reconditioning

·~

L<0

v.

Repairing the Gear

Box

7'

• j

V

I.

Repairing the J\la

in

Drive

~2

VII. Repairing the Whe

el

r.s

r-

VIII. Repairing lhe r ront

fo,··k

:

·

~

I

X.

1\epairing the ,Frame

~

F

'

X.

Rep

ai

ring the Rear Suspension

!ILi

XI.

REpairing the Ha-ndlebar and Control Cables .n

XII. Repairing

!li

e rue! Supply

Syst

em I

JG

XIII.

Repairing the Intake and Exhaust Systems l•

ll

X

IV

. Repairing the Sideca,, 1

02

XV.

ElectricaI System

De

v1ces

l!'l

I. PREPARING

THE

MOTORCYCLE

FOR

REPAIRS

Regardless

of the

type

of

repairs

to be

carried

out,

one

must

do

·

the

following:

wash

the

motorcycle;

check it for

technical

condition;

draw

up an inspection report.

Prior

to

washing

the

motorcycle,

take

out

the

iouls; remove

the

seat

cus

hion

and

back,

take

off the cov

er

as

the3e should be

washed

separately

.

Fig

. !. Motorcycle "Dnepr"' MT9

When

washing,

take

care

to keep

water

out

of

the

ele

ctrical

de-

vices,

carburettors,

air

filter,

air

passages

and

petrol

tank.

The

techni

ca

l condit

io

n of

the

motorcycle

should

be checked

by

inspection

as

well

as

by

testing

the

appropriate

units

or

asse

mblies

du-Fing

riding.

r 3

.. .

Before

doing

this, it is

necessary

to

adjust:

spark

plug

gaps;

contact

breaker

gaps;

clearances

in the

va

lve

gear

drive;

carburettors

fo

r idling,

average

speed

and

for the

synchronous

operation

of

the

cylind

ers;

brakes

contro

ls;

c

lut

ch

release

drive;

tyre

pressure.

Fig. 2.

Motorcycle

"Dn

epr"

MTIO

At

the

same

time, check

the

amo

unt

of oil

in

the

crankcase

and

in

the

gear

box and

main

drive

cas

in

gs

.

Adju

st

the

clea

ranc

es in accor

danc

e with lhe Ope

ratin

g

In

s

tru

c-

tions.

II.

CHECKING THE MOTORCYCLE FOR TECHNICAL

CONDITION

The

technical

co

ndition

of the motorcycle, of its

units

and

assem-

blies

deteriorates

in

the

process of co

ntinuou

s service. As

th

e compo-

nents

become

worn,

the

eng

ine power diminishes, fuel

an

d oil con-

s

umption

incr

eases

,

operation

of

some

of

the

units

becomes

noisy

and

failures

occur

mor

e fre

qu

ently due to

fatigue

and

corrosion.

The

wear

of com

ponent

s leads to

increas

ed

clearances

in the

joi

nts, and

ca

uses

the

dynamic,

economical

and

operating

ch

arac

teri

stic

s

of

the

motorcycle

to

deteriorate.

Therefore,

periodic checks of the

motorc

ycle for tec

hnical

condi-

tion a

nd

elimination

of detected

faults

in due

tim

e are

mo

st impor-

tant

to

prolong

its

service

life. In

order

to

determine

whether

the

motorcycle

and

its

units

are

in good

conditio

n, it is

necessary

to

:

1.

Check

tha

t

ihe

motorcycle

is complete with all

necessa

ry

units;

parts

and

accessor

ies.

2.

Check

the

general

condition

of

the

motorcycle,

including:

free

rolling

path;

ma

ximum speed;

braking

di

stance;

trial

petrol

consumptio

n.

3. Check

the

engi

ne co

ndition

:

oil

consumption;

compression in the

cylinders;

make

sure

that:

no

extra

neous noises

are

produced

during

operation;

no loca l

heating

is ob

served;

there

are

no oil lea

kage

s;

check the

engine

operation

under

l

oad

at

various

rotational

speeds.

4.

Check

the

clutch

mechanism

condition,

including:

disengagement

of disks

during

declutching;

smoo

thn

ess

of

engagement;

absence

of

s

lipping

;

absence

of

extraneous

noise

with

the clutch released.

5.

Check

the

gear

box co

ndition

:

return

of

the

st

ar

ting

mechanism

pedal;

easy

and

faultless

gea

rs

hiftin

g;

mak

e

sure

that:

the

gears

do

not

di

se

ngag

e by

themselves;

there

are no o

il

l

eakages;

no local

overheati

ng

is observed;

no

extra

neous

noises

are

heard.

6.

Check the

propeller

sh

aft

and

the

main

drive

for:

the

absence

of

increased

cl

eara

nces in

th

e

joint

s

of

elas

tic

coup

l-

ing, in the uni

versa

l

joint

,

geari

ng

a

nd

at

the

wheel

hub

junction;

absence

of oil l

eakage;

absence

of local

overheating

and inc

rea

sed

run-out

of

the

pro-

peller shaft;

check

ihe

el

astic

coupling

for good

condit

ion.

7.

Check the

wheels

for:

wear

of the

tyres

and

possible

damag

e;

wear

of

ih

e shoes

and

of

intern

al

surfaces

of

the

brake

drum

s;

wear

of the

bearing

s;

radial

a

nd

axial

run-out

of

the

rim

and

tyre;

make

sure

that

th

e spokes

are

all

available

and

uniformly

ten-

sione

d;

check the condition of

the

toothed

coupling

with

the

wheel hub.

8.

Check

th

e front fork for:

clearances

in

the

stee

ring

column,

lower

end

piec

es

of

the

fork,

.as well

as

at

the

bridg

e

and

traverse

joints;

1

I

\

smoothness

of

operation

during

riding,

the

condition

of

the

cas-

ings

and

fender;

tightening

of

fastenings

;

absence

of h

eavy

shocks

during

ope

ration;

co

ndition

of

the

springs;

abse

nce

of d

amp

ing

f

luid

leakage

.

9.

Check

th

e

motorcycle

frame

for:

tightening

of

fastenings;

abse

nc

e of cr

acks

at

weld

sea

ms;

ab

se

nce of exte

rn

al s

ign

s of

damage;

proper

cond

ition of fenders.

10.

Check

the con

dition

of the hy

drauli

c shock

abso

rbers,

including:

s

moothne

ss

of their

operation

during

riding;

co

ndition

of

the

casings

and

silent-blocks;

absence

of

heavy

s

hock

s

during

operation;

absence

of da

mping

fluid l

eakage;

clea

ranc

es in the

joints.

11.

Check

th

e

condition

of

the

petrol

tank

by

making

sure

that

:

petrol

does

not

leak

through

weld

seams

and

joint

s;

the

petrol

cock

and

hos

es

are

in

good

c

ondition;

the

petrol

tank

is

free

of

dents

and

other

injuri

es.

12

.

Check

th

e

exhaust

system

for:

tight

co

nn

ections;

absence

of

dents

and

other

signs

of

damage

on

th

e

lubes

and

silencers

.

13.

Check

the

condition

of

the

contro

ls,

including

:

condition

of

the

handl

e

bar

and

of

the

levers

and

other

mecha-

nisms

dispo

sed

on it;

co

ndition

of

cables

and

cable

sh

eaths;

foot

brake

pedal

and

brake

controls;

braking

effect,

when

using

the

both

brakes.

14.

Check

the

condition

of

lhe

sidecar,

including:

condition

of

the

shock

absorber;

absence

of

clearances

in

lhe

sidecar

-to-motor

cycle

attachment

hinges;

condition

of

the

wheel

fender, body,

sidecar

frame,

seat

cushion

and

back, cover.

15.

Ch

eck

the

condition

of

the

el

ectric

devices:

operation

of

the

ignition

lock;

operation

of

the

light

switch;

condition

of the

lighting

devices

;

operation

of

the

ignition

system;

operation

of

the

horn;

co

ndition

of

the

pilot

lamps;

condition

of the

wiring;

condit

ion of

the

speedome

t

er;

operation

of

the

emergency

oil

pressure

transmitter,

stop

light,

neutral

position

indicator

and

turn

indicator

switch.

6

.

~

' .

. ..

METHODS FOR

CHECKING

THE

MOTORCYCLE'S PARAMETERS

The

free rolling

path

of

the

motorcycle

is

measured

by

riding

a

fully

loaded

motorcycle on a

st

r

aight-line

section

of

the

hard-surface

road, in

dr

y

weather,

at

a

wind

speed

not

exceedin

g·

3

m/s.

The

mo-

torcycle is acce

lerat

ed up to 50

km/hr,

following

which

the

clutch

is

withdrawn,

the

gea

r

sh

ift

lever

is

set

to

the

ne

utral

position

and

th

e

motorcycle

is

allowed

to

move

until

it

comes

to a full

stop.

Measure-

ments

arc

made

by

riding

the

motorcycle

in

both

di r

ect

ions.

Th

e

l

engt

h of the

rolling

path

is

measured

from

the

point

of

clutch

with-

drawa

l to the ful l

stop

of

the

motorcyc

le.

The free

rolling

path

is

determined

as

the

arithmet

ic

mean

of

two

rides

in

both

directions

and,

·with

the

motorc

ycle in

good

repairs,

must

be

not

le

ss

than

250 m.

The

maximum

speed

is

determined

by

riding

on a

measured

(1

km

lo

ng)

stretc

h of

the

road

,

the

time

being

mea

s

ur

ed

with

a

stop-

watch.

The

maximum

speed

is

determi

n

ed

as

the

arit

hm

et

ic

mean

of

the

speeds

deve

l

oped

during

two

rid

es

in

the

opposite

directions

and

must

be

not

less

than

100

km/hr

for

the

MT9

motorcycle,

and

105 km/

hr

for

the

MTIO

model.

The

acceleration

must

be

sufficient

to a

llow

the

motorcycle

to

develop

th

e

maximum

steady

speed

before

reaching

the

measured

s

tretch

of

the

road,

the

road

cond

iti

ons

being

the

sa

me

as

when

measuring

a free

rolling

pat

h.

If

the

maximum

speed is

below

th

e

specified

figure

,

with

the

l

ength

of

the

free

rolling

path

being

nor-

mal,

this

means

that

the

engine

power

.is

insuffici

e

nt

and

the

engine

h

as

to be

repaired.

The

trial

petrol

consumption

mu

st

be de

termin

ed by

riding

the

se

rvi

ceab

le

motor

cycle

under

full

load

in

two

opposite

directions,

on

a m

easu

red (

10

km

long)

s

tr

etch of

the

dry,

hard-surface

road

hav-

ing

no

steep

upgrades

and

descents,

with

the

motorcycle

running

in

a

high

gea

r

at

75

km

/

hr

speed.

The

petrol

consumption

must

not

exceed

7.2 1

per

100

km

(to

be

mea

s

ur

ed

by

adding

petrol

into

the

tank

from a

measuring

vessel).

Simultaneously

with

measuring

petrol

consumption,

oil

consumption

is checked, which

must

not

excee

d 0.15 I per 100

l<m.

The

engine

condition

to

be

diagnosed

by

extraneous

noises

pro-

duced

during

the

engi

ne

operation,

as

we

ll

as

the

compression

in

the

cylinders

are

checked

emp

irically

by a

skilled

mechanic

of a

se

rvice

station

or

maintenance

shop

(Table

1).

Local

heating

and

general

overheating

can

be

detected

to

the

touch.

The

clutch

me

c

hani

sm

is

checked

for

condit

ion in

the

follow-

ing

manner:

when

the

e

ngine

is

inop

e

rativ

e,

release

the

clutch

and

turn

the

kick lever, in

this

case

the

engine

crankshaft

must

not

turn;

when

the

engine

is

running,

with

the

first

speed

gear

engaged

and

the

clutch

released,

the

motorcycle

must

not

move.

When

gradu-

:ally

engaging

the

clutch

release

l

eve

r,

the

motorc

ycle

must

start

moving

smoothly,

without

jerks.

With

the

gear

and

clutch

engaged,

7

..

JJ

I

a

sudden

ope

nin

g of

the

throttles

must

cause

the

motorcycle

to ra-

pidly

increa

se

its

sp

eed

w

ithout

any

noticeable

clutch

slip.

Th

e

gear

box,

propeller

shaft

and

main

drive

shou

ld be checked for

good

con-

clition by

testing

the

operation

of

these

mec

hani

sms

with

the

motor-

cycle

at

r

est

and

on

the go.

The

backla

sh in the

main

drive

gearing

must

be

wit

hin

0.1

and

0.3 mm,

the

permissible

run-out

of

th

e

propeller

s

haft

not

exceed-

ing

1.5

mm.

The

wheels

are

checked for condition by succ

essive

ly

in

specting

each

of

them

(by r

ais

in g, r

otating

th

e

whee

l

and

rocking

it

from

side

to

side)

. The

whee

ls must

rotat

e freely,

wit

h

out

play,

snaps

and

se

izur

es.

The

permissible

(lateral

and radial)

run-

out

of the

rim

s

hould

be

1.

5

mm.

The

spokes

are

checked

for

uni

form

tens

ioni

ng

by

li

stening to the sou.

nd

produc

ed when

tapping

the

spokes.

Th

e

front

fo

rk

, hy

draulic

shock

absorb

ers, s

teering

contro

ls

and

br

akes

are

checked for

condition

by

inspecting

them w

ith

th

e

motor-

cycle

at

rest or by t

est

ing their

operation

on the go. The

fork

must

be free

to

rotate

in the steerin g

column,

without

pla

ys

and

sto

pping

in ce

rt

ain

positions

.

When

inspecting

and

checking lhe

motorc

ycle

units,

m

ake

sure

that

the

<lnti

ru

st

co<1ting and p<linting of

the

component

p

ar

ts are in

good

co

nditi

on.

The

cau

ses

of

faults

and

troubl

es

hootin

g

procedure

s

are

gi

ve

n in

Table

2.

On

completing

the inspection

and

checking,

draw

up a

technical

co

ndition

r

eport,

on

th

e

basis

of

which

th

e

motorc

ycle _

ma

y be

sub-

jected

to

adjust

ment,

partial

or

total

di

sm

an

tling

and

r

eq

uir

ed re-

pairs.

III. MOUNTING AND DISMANTLING OPERATIONS

If, as·

lhe

result

of

checking

for

technical

condition,

it

is found

necessary

to

pe

rform

a

partial

or

total

dis

mantling

of

some

of

th

e

units,

asse

mblies

or

the

entire

motorc

yc

le for

th

e

purpose

of

repair-

ing

or

re

placing

the

component

parts,

the

dism

a

ntling

should

be

carried

out

to

the

ex

tent

not

greater

than

required.

Subj

e

ct

ed to

partial

dism

a

ntling

ma

y

be

the

assemblies

that

are

removed

or

not

removed

from

the

motorcycle.

Prio1

to

dismant

l

ing,

clean

and

wash

the

e

ntire

assembly

to

remove

oil,

dirt

and

du

st

that

may

foul

the

friction

parts

of

the

jointed

membe

rs

during

dismantling

.

After

disassembling,

clean

off

dirt

,

carbon

deposits

and

remnants

of

bak

elite

lacquer

from

th

e

co

mponent

part

s,

wash

and

examine

them

for

good

condi.tion,

mak

e

appropriate

mea

s

urements

to

determine

the

degree

of

wear.

The

maintenance

shop

or

service

station

must

have

at

its

disposal

a com-

plete

set

of

tools

necessar

y for

dismantling

or

assembling

th

e

motor

-

cycle

units.

In

case

the

unil

s or

assemblies

have

to

be

dismantled

without

re

moving

them

from

the

motorcycle

or

when

their

removal

is requ-ired,

it

is

advisable

to

detach

the

sidecar

to

ensure

a

better

access

and

thus

facilitate

the

re

pair

operations.

8

l ...

~

• •

~

Table

1

Checking the Motorcycle Engine lor Technical Condition by Noises and Knocks

Point

s

(junction

of

com-En

gine

!her-

Engine

operating

Poin

ts (l

ocatio

n

s)

Cone!usions

regarding

pone

nt

s)

of

possible

kn

ocks mal condi· conditions

to

be

Iistened

to

~aturc

ol knocks

further

usage

tions

Piston

pin -

conn

ect

-~

Warmed

U

nd

er load,

Cylinder

loca-

Clear

shrill

me

tal-

I

Must

not

he

opera

ted.

ing

-rod

small

e

nd

up followed by a lion lie knock

Cl

e

an

the

combu

stion

s

udd

en incr

ease

chamb

er

to

r

emove

car-

in ro

tati

ona

l bon de

posits;

if

neccs-

speed

sary,

replace

the

piston

pin en

sur

ing

that

i

ts

co-

louring

corresponds

to

that

of

con

n

ect

ing

rod

sma

ll end

Same

Pi

ston

pin -

piston

Sa

me

Same

Knocks

no

t

so

boss

clea r

but

be

come

more

distinct

as

the

engine

warms

to

a

higher

tc

n1p

c

rature

Pi

ston -

cylinder

Cold

Idling

Cylinder

Joca -

Dry

metallic

knock

May be

operated

in

lion

\\"hich

becomes

mo- case the !mock

disap-

re

apparent

as

the

peMs

as

the

engi

ne

rota

tiona I

spe

ed

warms

up.

When

r

epai

r-

changes;

the

knock

ing

, repl

ace

the

piston

be

comes

l

ess

audible

as

the e

ngine

war

ms

up

<0

I

Simi

la r

kno

ck

due

Must

not

be

operate

d.

· to

the

pin being

Replace

the

piston

and

I

se

ized in

the

con

-

p:

n

necting-rod

sma

ll

end

i ,

' "

0

Points

(junction

of com-

ponents)

of

poss

ibl

e

kno

cks

Engine

ther-

mal

cond

i-

tions

Connecting-rod

big

I Any

end-

crankp

in

(of the

cranksha

ft)

Crankshaft

bearings

-

~

Warmed-

crankshaft

up

Va!Yc lilfli

ng-

pi

ni

on I Snrnc

Va l

ves-

val

ve

seats

I Warmed

up

Clutch disks Any

flywheel-

cr

an

ksha

ft

S

ame

Engine

operating

Points

(locations)

Nature

ol

knocks

conditions to be listened to

During

idling

and

especially

when the motor-

cycle runs after

coasting,

at

s

li

ghtly closed

throttles (thrott-

led down sl

ig-ht-

ly)

Under loa d

and

when the thrott-

les arc suddenly

opened

Idling

During

id

li

n

g-

and coast

in

g

Central portion I ,\tedium pitch thud

of

the engine

crankc:1sc

Crankcase,

at

I

Lo

w pitch thud

points where bea-

rings

ar

c located

Location

of

pi- Frequent metallic

nions

ru111bling

knock (of

varying

tone)

Cylinder heads Frcqucnl clear so-

und w

hi

ch

increases

with increasing- ro-

. tationaI speed re-

gard

less oi

th

e load

Continued

Conclusions

regarding

further

usag-e

Must not

be

operated.

Engine needs

to

be

repaired

Same

lv\ay be operated.

\Vhen rep2iring the en-/

gine, repla

ce

the pinions

..

May

be

operated. Ad-

l/

ju

st

the clea rance. When

repairing the

eng

ine.

lap the \'aJI·es

C

lu

tch released Zone of

cl

utch

location

on

engine

Clear

knock metallic I Nlay

be

operated.

Idling, clutch

not released Rear

po

rtion

of

the e

ng

ine

Strong

metallic

thud, which disap-

pears when the

clutch is released

\Vhen repairi

ng

the

c

n-

gine, examine the clutch

Must

not

be

operated.

ReiiJove the clutch

and

fly11'heel,

check the key

joint, fit the flywheel

in

place and secure reliab-

ly

Dnepr MT9 Istruzioni operative

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