Dnepr MT10-36 Operating Instructions Manual Download Page 1

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Summary of Contents for MT10-36

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Page 2: ...ons on the Use of Storage Batteries 4 Tool Kit 5 Spare Pads Kit _ Due to the constant 9evelopm nt of the motorcycle design some minor modifications not indicated in this manual can be expected in the...

Page 3: ...r A 1 1 1 A V 1 is 4c s LI r LA f3 F 5 7 z 7 j 6 c J 1 J 8 L5 c d r 41 v z_ A G 1J Os i 5 MOTORCYCLE Dnepr MTI0 36 OPERATING INSTRUCTIONS VfOAVTOEXPORT e USSR 0 MOSCOW...

Page 4: ...a Motorcycle for Use Operating Instructions Driving Procedure Design Operation and Adjustment of Motorcycle B11sic Units Troubleshooting Technical Servicing Storage Bearings Used in Motorcycle Rubber...

Page 5: ...orcycle specifications its de sign and principle of operation of its basic units and mechanisms The manual iists the necessary data on troubleshooting The terms and scope of the motorcycle maintenance...

Page 6: ...period of motorcycle parking This will lead to discharge of the storage batteries and failure of the ignition coil To lubricate the mot orcycle units a nd assemblies use should be made only of oils an...

Page 7: ...the room can be well ventilated Remember that the engine exhaust gases are t oxic since they contai n carbon monoxide SPECIFICATIONS General Data Wheelbase mm not more than 1500 Road clearance mm not...

Page 8: ...s of friction ma terial on either side Double declutching drive manual drive actuated by lever on the handle bar and foot operated drive interlocked with gearshift mechanism four speed with reverse sp...

Page 9: ...ankcase Gear box case Main drive casing Front fork blade Suspension shock absorber Priming Capacities I PP330 62 i 6 ff5 rfi t itet A IV 8 C38 CTI102 f8127 BK854 TI25A TI201 PC427 MM126 TIJJ 20E TIJJ...

Page 10: ...brake lever 7 turn indicator switch 8 throttle control grip 9 rear wheel brake pedal 10 reverse lever 1 kick starter lever 12 gearshift lever 13 horn button 14 dimmer switch 15 clutch release lever 1...

Page 11: ...of the throttles of a new engine that has not been subjected to running in is restricted by the stops Do not apply force to overcome the re sistance of the stops as this may cause rupture of the cabl...

Page 12: ...of power _ J supply Fig 4 Switch commutation diagram lamp In this position the ignition key may be tak en out not disturbing the above mentioned switching night parking light 3 The key is inserted as...

Page 13: ...ring column To ins alil the device put the spring on the lock insert rod introduce the insert in the lock hou sing and fix ihe housing cover with a rivet The lock is closed by turning tlhe key clockwi...

Page 14: ...ation protected against precipitation in order to keep water out of the petwl tank When preparing tlhe motorcycle for a ride check the oil level in the engine crankcase gear box casing and main drive...

Page 15: ...n Starting Mechanism and then with a sudden jenk start up the engine If the quadr ant fails to be engaged a hard resistance is felt roll the motorcycle forward and backwar d Do not try to overcome the...

Page 16: ...r t Following that the speed should be regulated by operating the throttles of the carburettors Since the gear box has provision for clutch operating device so me other methods of gearshifting may be...

Page 17: ...down the rear wheel brake pe dal and the front brake lever Using two brakes at the same time ensures a better stabil ity of the motorcycle Braking may be also effected by using only the foot brake In...

Page 18: ...overcoming the stretches of thick sticky dirt follow the same procedune as when crossing the quicksand If much dirt piles up under the fenders thus hindering t he rotation of the wheels stop the moto...

Page 19: ...engine reduce he engine speed to a mi nimum and without switch ing off the ignition fully close the choke of the air corrector The engine must stop wiJ hout knocks and back impacts Following that swi...

Page 20: ...cult to repair da mage The air choke of the air filter must be closed during washing Avoid driving the motorcycle into water for washing pur poses or stopping the engine while overcoming the ford if t...

Page 21: ...to 3 min T he recommended operating speed for the mo torcycle that has been subjected to running in shonld be equal to 60 70 km h when moving over an improved road During the running in period do not...

Page 22: ...ne crankcase 4 tappet 5 outlet tube of breather 6 special nut 7 high voltage wire to the cylinder pl ug 8 cylinder gasket 9 crankshaft Wi th connecting rods 10 sump II sump gasket 12 drain pipe 13 oil...

Page 23: ...driving timing pinion 5 gasket of driving timing pinion 6 centrifuge washer 7 sea ling ring 8 gasket of centrifuge washer 9 centrifuge body 10 centrifuge cover I I centrifuge sealing ring 12 contact b...

Page 24: ...22...

Page 25: ...of old cotter pins is inadmissible Piston Piston R ings and Piston Pins Engine piston 15 Fig 5 consists of a spherical head skirt and bosses The piston is provided with four grooves in which the pisto...

Page 26: ...illing the crank chamber beco me compressed and force the oil outwards through the packi ng gland s and crankcase and cover joints To avoid this the crankcase is provided with a fopced air supptly To...

Page 27: ...achable joints and through packing glands but also premature contamination of oil and excessive wear of engine components After every 10000 km run clean the combustion chambers to re mov e carbon depo...

Page 28: ...nkcase after first removing the rubber plug In this position the both valves will be completely closed whereas their rockers must freely swing on their pins Then using a flat feeler gauge check the cl...

Page 29: ..._ Fig 9 lnstallalion of camshaft I genera lor gear 2 ca mshaft driven pi nion 3 camshaft 1 driving timing pinion 5 oil pump d ivc gear I marks...

Page 30: ...he above appliance rotate the valve in either direction in such a manner that the turn in one direction is about twice as long as the turn in the opposite direction i e ensure that the valve is gradua...

Page 31: ...ition adv ance angle after every 1000 km run of the motorcycle Check and if necessary adjust the gap between the spark dis chargers in the ignition coil This gap must be equal to 8 to 9 mm The springs...

Page 32: ...el 14 gauze filter 15 drain hole plug 16 redu cing valve 17 oil supply passage of reducing valve 18 drain pipe 19 main oil llne 20 hole for draining oil from centrifuge 21 slot in tappet for supplying...

Page 33: ...centrifuge body 9 screen 0 timing pinion gasket II driving timing pinion 12 front bearing body 3 front crankshaft ball bearing 14 crankshaft plug 15 crankshaft 16 screw A from oil pump 6 which are mou...

Page 34: ...of the engine Overheating of the cylinders and their heads power drop and knocks in the engine are an indic ation of insufficient lubrication The operation of the lubricating system is monitored by m...

Page 35: ...ody 2 knob 3 slide valve 4 slide valve scaling gasket 5 settler 6 filter bowl 7 filter spring 8 filter gauze 9 settler sealing gasket 10 sealing gasket of petrol cock body 1I threaded bushing 12 petro...

Page 36: ...pring 9 fuel filter 10 main jet 1 plug 12 gasket 3 gasket 14 plug 15 idling jet 16 air filter body J7 air filter gauze 18 air fuel ratio adjusting screw for adjustment at slow speed 19 atomizing hole...

Page 37: ...t possible steady speed on completing the adjustment lock screws 18 and 1 by means of check nuts Taking hold of the cable raise the throttle of the carburettor being adjusted if this will cause an inc...

Page 38: ...grooves By bringing the retainer into each of the grooves it is possible to ob tain six dif ferent positions of the car burettor a djustment The lower the position of the needle the weaker the mixttur...

Page 39: ...ndi tion In case a fuel leakage is detected tighten up the fasteners or replace the sealing gaskelts If fuel leaks through the draining device of the carburettors thi S is an indication of poor tightn...

Page 40: ...lso check the fuel s upply to the carburettors and the operation of tthe carburettor throttle control drive When operating the motorcycle check the presence of oil in the oil bath of the air filter 11...

Page 41: ...di sk 8 interm ediate disk 9 and bea ring disk 11 all of the disks being fitted on the il Wheel pins At the centre of the pressure disk is a square hole into which en ters the dutch release ro d The...

Page 42: ...es of the starting shaft is a toothed quad rant The quadrant is pressed to rubber Pecoil buffer 5 Fig 17 by a torsion spring The spring is wound up by giving bushing 1 Fig 15 fitted in the front wall...

Page 43: ...r of the secondary shaft are also moved forward As a result the sliding gear comes into mesh Fig 15 Lay out of shafts I starting shaft bushing 2 scaling rubber ring 3 starting shaft spring 4 spring st...

Page 44: ...ry shaft 7 gearshift fork 8 gland 9 sh1fter shaft 10 crank cam II crankpin 12 gearshift mechanism pawl 13 gearshift disk pin Putting the motorcycle in reverse when any of the other gears is engaged is...

Page 45: ...cha nism shalt 8 primary shaft The outer lever rocking on its pin actuates the clutch release rod through the slide block bearing and end piece Servicing the Gear Box Servicing of the gear box consist...

Page 46: ...depress the gearshift pedal abruptly but avoiding an impact The speed gear engaged gradu ally let the gearshift pedal return to the middle posi tion To ensure a smooth return movement of the pedal tr...

Page 47: ...ired by means of a djusting bolt 6 Fi1 g 20 With the proper adjus tment there must be a small clearance between the end of the adjusting bolt and the intermediate rod The presence of the clearance can...

Page 48: ...iece 14 sealing rubber ring 5 th rust ball bearing 16 slide block 17 outer clutch release lever 18 pin 19 clutch hand drive cable 20 clutch cable adjusting screw The motorcycle must not be operated un...

Page 49: ...standstill and the engine is not operating or the clutch is disengaged with the engine operating Therefore it is advisable to set the neutral or a gea r Cilose to neutral fi rst or second before the m...

Page 50: ...nut securing the crank cam take off the crank cam from the splines of the shifter shaft and extract the shifter shaft 13 Remove the reverse lever handle and take the pin an d lever out of the case As...

Page 51: ...the casing has an oil drain hole closed with a plug At the top there is a filling hole into which a dipstick with a breather is screwed Avoid dismantling the main drive unless it is necessary to do so...

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Page 53: ...e bolt unscrew the nut using a soft drift knock out the wedge bolt remove the universa joint from the shank of the driving bevel gear 2 Take off the four lock rings of the universal joint bearings Pla...

Page 54: ...and extract the axle remove the dust protecting washer insert and tighten up the axle with out the washer slacken the bearing adjustment check nut ho lding up the wheel with one hand screw in the nut...

Page 55: ...f the sidecar wheel the sidecar wheel instead of a spare wheel and the spare wheel instead of the rear wheel in the clockwise direction Do not allow long time over 30 days standing of the motorcycle o...

Page 56: ...ective cloth Such a patch does not need to be coated with rubber cement but it must be refreshed with petrol The faulty slide valve must be replaced If the air leaks between the valve and tub e tigtht...

Page 57: ...d and after removing the front wheel from the brake disk take down the wheel after first disconnecting the front brake cable Screw out shock a1 bsorber wing nut 1 Fig 25 Unscrew nuts 4 and 2 take down...

Page 58: ...7 casing 8 gland 9 upper bush of fork blade tube 10 fork blade tube II lower bush of fork blade tu be ll locking ring of fork blade 13 fork shock absorber 14 special washer 15 wa sher 16 bo t 17 left...

Page 59: ...g 12 right hand bracket of headlamp 13 left hand bracket of headlamp 4 gland 15 ball bearing protective washer 16 friction washer of handlebar shock absorber 7 friction washer of handlebar shock absor...

Page 60: ...e bearings pres sed into the frame head use grease Lithol 24 Insert the fork into the frame head and secure with nut 7 Fig 25 then install traver se 3 Fig 24 on the cones of tubes 10 Screw the ends of...

Page 61: ...5 rebound valve nut 16 rebound valve adjusting shim 7 rebound valve spring 18 rebound valve washer 19 rebound valve retainer 20 rebound valve disk 21 rebound valve throttle disk 22 valve retainer 23 b...

Page 62: ...e shock absorber The fluid should b poured i hen the working cylinder together with the compressiOn valve IS mserted mto the shock absorber body Fill the woTking cylinder with fluid up to the brim the...

Page 63: ...shoes Initially the compensation of wear is perfonmed lby tightening the rope sheath which is done by turning out adjusting union 11 Fur ther on when the adjustment by means of the union becomes impos...

Page 64: ...10 2 7 g Fig 27 Front brake 1 brake shoe 2 rod with lurks 3 cam 4 disl 5 tappet 6 spring 7 driving lever 8 driven lever 9 return spring 10 pin II adjustinll union I w sh r not sh9wn conv qtionallr A...

Page 65: ...d up the return spring If the above assembling requirements are observed and necessary conditions for the reliable operation of the brake at the expence of simultaneous pressing of both shoes to the w...

Page 66: ...to the drum and cam with equalizer Longitudinal gwoves on the taper surface are provided for fixing the taper position The tap pets acted upon by springs 9 which tighten the 1 brake shoes enter these...

Page 67: ...rt of the dnaw rod must not be sunk in the nut if neces sary release the check nut of the forked end piece and set the requi Fig 29 Rear wheel brake drive I footstep 2 pedal 3 pedal hinge with lubrica...

Page 68: ...posi tion of turn indicator of high and lower beam and turn indicator switch turn indiaator interrupter oil emergency pressure transmit ter stop light switch dip and turn i ndi cator switch The elect...

Page 69: ...n terrupter PC 427 18 block of fuses ITPIIB 19 current and voltage regulator PP330 20 storage battery to earth PP330 relay to earth wire 21 storage battery wire 22 storage batte ry 3MT6 23 dashboard 2...

Page 70: ...ge the storage battery When using and servicing the storage battery follow the instruc tions for using the storage battery Generator Specifications for the 1 424 Generator Rated voltage V Rated power...

Page 71: ...ar is provided with a clam ping screw The rectifier unit must never be disassembled Mounted on the extension of rotor 3 shaft under protective ca sing 10 is axial fa n 9 which is intended to cool the...

Page 72: ...the bear mgs duri ng periodic servicing The fa ctory filled grease of the bearmgs is intended to last throughout the entire peri od of generator usage The sHp rings of the f424 genera tor do not form...

Page 73: ...punch the cover metal into the splines of the screws When assembling the generator foll ow the order reverse to that of dismantling The locks on the covers of the generator and stator must be arranged...

Page 74: ...tion coil and distributor and contact breaker installed on the engine I ignition coil 5204 2 dis ributor and contact breaker DM302 01 Ignition Coil The 5204 igniti on coil Fig 34 has two taps for high...

Page 75: ...wo flats at the end and a threaded hole The clearance between the contacts is adjusted to 0 4 0 6 mm by screw 12 after first releasing lock screw 1 The adjusting screw has an eccentric head which ente...

Page 76: ...e plate and the holes of the weights should be lubri cated with grease U I1ATHM 201 Operation of the Ignition System When the ignition is switched on the circuit of the ignition coil primary winding b...

Page 77: ...from the ground now check the lower beam The upper boundary of the light spot projected onto the screen must be not less than 10 em below the headlamp centre with the lower beam filament switched on...

Page 78: ...l w ilh coniact 3 board 1 base 5 orange diffuser 6 colourless diffuser 7 reflector 8 protective hood D gnsket 10 bulb A12 21 II bulb A12 8 5 5 2 7 3 5 Fig 39 Sidecar rear lamp l ill2J95 I panel with c...

Page 79: ...to 10 5 mm The switching off is effected by means of a return spring of the switch rapid o pening of the contacts is ensured by the switch auxi liary spring The switch is not liable to repair under op...

Page 80: ...ntact clean the con tacts with a needle file and wash them with petrol Every 5000 km run check the following the spark gap of the plugs the gap should be equal to 0 5 0 6 mm if required clean the p lu...

Page 81: ...ded on the left hand side of the inner wall of the trunk are brackets used for fastening the air pump The sidecar body is secured to the front tube of the frame by means of two clamps with rubber pads...

Page 82: ...e spring and hydraulic shock absorber The absorber is installed on the frame bow and the carrying le ver of fhe wheel using rubber hinged bushes Fig 42 Collet hinge for attachment of sidecar jaw 2 nut...

Page 83: ...uring the sidecar attach ment bracket By moving the bracket in or out of the rear tube of the frame achieve the r equired toe in which is checked by means of two straight bars to be applied to the whe...

Page 84: ...sh clean and wash replace petrol Set according to instruc tions adjust carburettors adjust the mixture wash cleaner adjust needles lower the needles adjust the mixture eliminate inleakage adjust the n...

Page 85: ...ou led facings of driven disks worn out rinse with petrol and dry replace worn out parts tv aladjustment of clutch re Adjust drive lease drive Gear Box Gearshift pedal is bent and Straighten the pedal...

Page 86: ...he full extent and tur ned to the right battery charge control lamp indicator lamp of gearshift mechanism neu tral position and oil pres sure warning lamp will not light up with the engine inoperative...

Page 87: ...the motorcycle includes daily mainten ance each time before leaving the garage or after each ride technical servicing No after every 2500 km run technical servicing No 2 after every 5000 km run techn...

Page 88: ...and signalling equipment Check tyre pressure Tyre gauge When checking the motorcycle for technical condition pay special atten tion to the fastening of the handlebar to securing of the front fork in...

Page 89: ...recommended for use in summer M 12f No 8 in win ter M8f No 9 or all weather oil M IOf TY38 l 267 69 Change oil after every 5000 km run Refer to Technical Servicing TS No 2 Refer to TS No 2 Technical S...

Page 90: ...ricant Lithol 24 GOST 21150 75 Technical Servicing No 3 Carry out all the jobs of Technical Servicing No 2 Take off the spring and hydraulic ab sorbers of rear suspension and of si decar wheel dismant...

Page 91: ...d consume completely the petrol from the car burettor float chamber s unscrew the plugs and pour 25 30 cm3 of AC 8 oil into each cy linder Turn the crankshaft through 10 15 revolutions by dep fes sing...

Page 92: ...adial ball bearing 207 Single row radial ball bearing 209 Single row radial ball bearing Bearing descriJ tion a nd point of ins ta llation Camshaft rear ball bearing On the cam shaft Camshaft front ba...

Page 93: ...er bearing of crank gear In the en gine crankcase Bearing of gear box primary shaft Secondary shaft bear ing In front cover of gear box casinJ and in casing u c u 0 0 O E 1 1 2 Single row tapered Whee...

Page 94: ...m Continued Bearing description and point of Installation Ball bearing with ra ces In steering co lumn of frame and on steering column bar of front fork 1 Universal joint bear 4 ing At universal joint...

Page 95: ...imary shaft 1 45 31 7 204157 Secondary shaft 1 48 35 5 8 t205113 B Main drive casing 1 44 205033 Universal joint fork 1 49 3 33 10 5006350 Wheel hub 4 38 24 8 MT804130 Gearbox crankshaft 1 30 15 5 7 7...

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Dnepr MT10-36, Operating Instructions Manual

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