Table Of Contents - Dnepr MT9 Repair Manual

Table of Contents

Table Of Contents2
Preparing The Motorcycle For Repairs3
Vehicle View3
Checking The Motorcycle For Technical Condition4
Methods For Checking The Vehicle's Parameters7
Mounting And Dismantling Operations8
Checking The Engine For Technical Condition By Noises And Knocks9
Troubleshooting Of The Motorcycle Units11
Engine Troubles11
Power Transmission Troubles17
Running Gear Troubles19
Control Mechanism Troubles24
Electrical Equipment Troubles27
Removal And Installation Of The Engine Together With Gear Box29
Removal And Installation Of The Gear Box30
Disconnection And Attachment Of The Sidecar30
Intake And Exhaust Systems Removal And Installation31
Fuel Supply System Removal And Installation32
Wheels Removal And Re-Fitting32
Main Drive Removal And Installation33
Removal And Installation Of The Handlebar Together With Control Cables34
Front Fork Removal And Installation34
Rear Suspension Removal And Installation35
Electrical System Parts Removal And Installation35
Engine Reconditioning38
Dismantling And Assembling The Engine38
Removal And Installation Of The Cylinder Head38
Removal And Installation Of The Cylinder39
Removal And Installation Of The Piston And Piston Rings39
Removal And Installation Of The Tappets41
Cover Of Timing Pinions Removal And Installation41
Centrifuge Removal And Installation42
Camshaft Removal And Installation42
Clutch Removal And Installation44
Flywheel Removal And Installation45
Clutch Disks Removal And Installation - Diagram46
Connecting Rod Removal And Installation48
Crankshaft Removal And Installation48
Nominal Sizes, Tolerances And Interferences In The Engine And Clutch51
Repairing The Engine Units And Component Parts56
Repairing The Crank And Connecting-Rod Assembly56
Maximum Permissible Values Of Wear And Clearances In The Engine56
Crankshaft Repair57
Cylinder Repair57
Piston Rings Repair58
Piston Repair58
Piston Pin Repair59
Valve Timing Gear Repair59
Cylinder Head59
Removal Of The Valve Springs - Diagram60
Checking The Valve Seat For Play62
Pressing Out The Valve Seat63
Characteristics Of Valve Springs63
Valve Rocker With Pin64
Push Rods64
Tappets64
Valve Timing Drive Pinions65
Camshaft65
Repairing The Lubrication System65
Oil Pump65
Repairing The Engine Crankcase And Covers66
Oil Lines66
Repairing The Clutch Mechanism66
Repaired Engine Adjustment And Running-In67
Running-In Conditions69
Ill69
Gear Box Cross-Section70
Repairing The Gear Box71
Gear Box Dismantling And Assembling71
Clutch Release Mechanism Removal And Installation71
Removal And Installation Of The Speedometer Drive72
Gear Box Disassembling Into Basic Units And Reassembling73
Removal Of The Cover73
Shafts And Gears Removal And Installation73
Installation Of The Cover75
Final Steps In Assembling The Gear Box75
Repairing The Gear Box Units And Component Parts76
Repairing The Clutch Release Mechanism76
Repairing The Speedometer Drive76
Repairing The J\La In Drive ~276
Repairing The Gearshift Mechanism And Other Component Parts77
Repairing The Cover And Component Parts Secured On It79
Repairing The Casing79
Repairing The Gear Box Shafts79
Primary Shaft79
Secondary Shaft80
Starting Mechanism Shaft81
Repairing The Main Drive82
Main Drive Dismantling And Assembling82
Propeller Shaft And Universal Joint Removal And Installation82
Universal Joint Dismantling And Assembling83
Dismantling And Assembling The Main Drive84
Sizes, Tolerances And Interferences In Main Drive And Propeller Shaft86
Main Drive Units And Component Parts Repair87
Propeller Shaft And Universal Joint Repair87
Main Drive Repair87
Wheel Dismantling And Assembling88
Tyre Removal And Re-Fitting88
Repairing The Wheel R.s88
Wheel Hub Dismantling And Assembling90
Wheel Assemblies And Components Repair91
Tyre And Inner Tube Repair91
Wheel Hub Repair91
Replacing The Rim And Spokes91
Front Fork Repair93
Front Fork Dismantling And Assembling93
Fork Leg Dismantling And Assembling93
Front Fork Component Parts Repair94
Front Fork Shock Absorber Dismantling And Assembling94
Sizes, Tolerances, Interferences In Front Fork Basic Mating Members95
Repairing The Frame96
Rear Suspension Repair96
Dismantling And Assembling The Rear Suspension96
Shock Absorber Dismantling And Assembling96
Shock Absorber Sectional View98
Handlebar And Control Cables Repair99
Throttle Control Grip Dismantling And Assembling99
Rear Suspension Lever Removal And Installation99
Xi. R.epair.ing The Handlebar. And Control Cables99
Fuel Supply System Repair100
Repairing The Clutch And Brake Cables And Levers100
Carburetor Dismantling And Assembling100
Intake And Exhaust Systems Repair101
Repairing The Fuel Supply System Units101
Petrol Tank/Petrol Cock And Hoses Repair101
Carburetor Repair101
Sidecar Dismantling And Assembling102
Sidecar Body Repair102
Repairing The Sideca,, 1102
Electrical System Devices103
Sidecar Frame Repair103
Storage Battery Specifications103
Checking The Storage Battery For Condition103
Determining Degree Of Discharge From Specific Gravity Of Electrolyte104
Generator Specifications105
Generator Winding Data105
Checking The Generator For Proper Operation106
Checking The Generator In The Motor Duty106
Determining Rotative Speed Of Generator107
Checking The Generator On Motorcycle107
Generator Dismantling And Assembling107
Repairing The Generator108
Current-And-Voltage Regulator109
Winding Data109
Current-And-Voltage Regulator Check110
Current-And-Voltage Regulator Adjustment111
Ignition System Devices113
Breaker And Ignition Advance Automatic Device Specifications113
Diagram Of The Electrical Equipment And Colour Coding Of Wires114
Automatic Device Characteristics115
Two-Tap Ignition Coil Specificatins115
Spark Plug115
Distributor-And-Contact Breaker Unit Specifications119
Ignition Coil Specifications119
Repairing The Headlamp119
Electrical Equipment Circuit Diagram120
Lighting And Signalling Equipment121
Horn Data122
Wires122