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URAL Motorcycles Deco Classic 1998 Owner's Manual

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URAL® MOTORCYCLES 1998 Models
IMZ-8.103-10 - Deco Classic, Italia
IMZ-8.103-40 - Tourist
IMZ-8.107 - Sportsman
IMZ-8.123 - Solo
IMZ-8.503 - Utility

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  • Page 1 Use the table of contents to the left to navigate that manual. URAL® MOTORCYCLES 1998 Models IMZ-8.103-10 - Deco Classic, Italia IMZ-8.103-40 - Tourist IMZ-8.107 - Sportsman IMZ-8.123 - Solo IMZ-8.503 - Utility...
  • Page 2 Introduction Welcome to the URAL Motorcycling Family! Your new URAL motorcycle conforms to all applicable US Federal Motor Vehicle Safety Standards and US Environmental Protection Agency regulations effective on the date of manufacture. This manual covers the Solo motorcycle, IMZ-8.123, the motorcycle with sidecar accessory, IMZ-8.103-40 (Tourist) and IMZ-8.103-10 (Deco Classic and Italia Classic "Cruiser"s) and the motorcycle with a driven sidecar wheel, IMZ-8.107 (Sportsman).
  • Page 3 you just like to putt around on a rig that draws an instant crowd wherever you park, welcome aboard! The classic boxer twin has a German heritage. So effective, simple and powerful is this design that Porsche, Volkswagen, and even Harley (during the war with the XA model) made this design their choice.
  • Page 4 the schedule generally referred to throughout the manual. Finally, all new owners will receive a complementary membership in the URAL Motorcycle Owner's of America (UMOA) which is an owner's club that we have formed to facilitate communication, adventure and motorcycling experience for the new URAL owners across America.

  • Page 5: Important Notice

    Important Notice! Statements in this manual preceded by the following words are of special importance: WARNING: Means there is the possibility of personal injury to yourself or others. CAUTION: Means there is the possibility of damage to the vehicle. NOTE: Other information of particular importance has been placed in italic type.
  • Page 6 Table of Figures Figure 1 Figure 16 Figure 27 Figure 4 Figure 17 Figure 29 Figure 5 Figure 18 Figure 30 Figure 6 Figure 19 Figure 31 Figure 7 Figure 20 Figure 32 Figure 10 Figure 21 Figure 35 Figure 12 Figure 22 Figure 36 Figure 13...

  • Page 7: Specifications

    Chapter 1 Specifications *Note: -10 Models are Deco Classics & Italias TOURIST/SPORTSMAN GENERAL SOLO UTILITY/* -10 Models 108 km/h / 65mph Maximum speed of motorcycle 122km/h / 77mph *119 km/h 74 mph Reference fuel consumption at 12.5 km/l / 29 mpg 16.7 km/l / 39 mpg 85% of maximum speed *14 km/l / 32.5 mpg...
  • Page 8 Cylinder bore 78 mm / 3.07 in Piston stroke 68 mm / 2.68 in Compression ratio Rated horsepower Rated rotational speed 5600 RPM Rated torque, Nm 45 Nm / 33.2 ft.-lbs. Ignition system Contactless with electronic ignition timing Lubrication system Dual system of forced lubrication and by splashing SAE 20W/50 (see section "Maintenance of Lubricant...

  • Page 9: Gear Ratios

    Clutch Dry double-disk clutch 4 speed box with reverse gear (no reverse for solo Gearbox model) and gear shifting foot pedal GEAR RATIOS TOURIST/SPORTSMAN SOLO* -10 Mdls I gear II gear 2.28 2.28 III gear IV gear N/A on Solo Reverse gear 4.2 on -10 mdls Speedometer drive ratio...

  • Page 10: Running Gear

    RUNNING Rugged (Tourist & Cruiser Models GEAR Sportsman) Frame Tubular welded Swing arm with Sidecar: Same Rear wheel hydraulic Solo: Lower spring suspension spring shock absorbers rate Leading link for the Front fork sidecar Telescopic spring model Cushioned body (on Sidecar rubber cushions) and wheel on long-lever...
  • Page 11 FREE TRAVEL/ADJUSTMENTS Hand brake control lever 5 - 8 0.2 - 0.3 Clutch control lever 5 - 8 0.2 - 0.3 ¼ of full stroke Foot brake drive pedal of pedal, 25 - 1.0 - 1.2 Toe-in throughout motorcycle center distance (exception: 10 mm 3/8 inch Sportsman 0°...

  • Page 12: Torque Specifications

    Chapter 1 (Specifications) Torque Specifications Metric (in repair US Equivalent Location on Bike manual) 29 to 33 Nm 22 ft/lb to 25 ft/lb cylinder heads 22 to 25 kgf-m 175 ft/lb to 185 ft/lb fly wheel tightening screws 3.8 to 4.2 kgf-m 30 ft/lb to 40 ft/lb cylinder 2.1 to 3.0 kgf-m top...
  • Page 13 CHAPTER ONE (Specifications) Conversions To convert from mm to in, divide by 25.4 (there are 25.4 mm per inch). To convert from liters to gallons, divide by 3.785 (there are 3.78 liters per gallon). To convert from liters to quarts, multiply by 1.056 (there are 1.056 quarts per liter).
  • Page 14 Chapter 2 Motorcycle Control & Instrumentation Figure 1. Controls and Instrumentations 1 - Speedometer 12 - Gear shift (foot) pedal 2 - Turn indicator pilot lamp 13 - Turn indicator switch 3 - Trip odometer reset knob 14 - Horn push-button 4 - Neutral and reverse gear 15 - "High-low"...
  • Page 15 21 - Master battery switch 10 - Reverse gear lever (n/a on (under seat) except electric start Solo) models 11 - Kick start lever CONTROLS Clutch control lever (Fig.1, #15) . When the clutch lever is squeezed, the engine is disengaged from the gearbox. When the lever is released, the engine is engaged to the gearbox.
  • Page 16 position. Now you can shift into first gear. If desired, neutral may be selected by shifting into reverse and back to forward again, when the first gear is engaged, and then moving the reverse gear lever forward into neutral. The rear brake pedal (Fig.1, #9) applies the rear wheel and sidecar wheel brakes simultaneously.
  • Page 17 and ignition on (down). Low and high beam light switch (Fig.1, #17), turn indicator switch (Fig.1, #12) and horn push-button (Fig.1, #13) are combined in one unit on the left-hand handle bar control housing. Master battery switch (Fig.1, #20) is under the seat except on electric start models where it has been eliminated.
  • Page 18 Chapter 2 (Motorcycle Control & Instrumentation) SIDE STAND (SOLO MODEL ONLY) WARNING: Be sure the side stand is fully retracted before riding the motorcycle. If the side stand is not fully retracted during vehicle operation, it could contact the road surface with possible loss of vehicle control.

  • Page 19: Pre-Trip Preliminaries

    Chapter 3 Engine Operation and Maintenance Pre-Trip Preliminaries Before each trip, attend to all the requirements of the everyday maintenance as outlined in this manual. When priming the motorcycle with fuel and oil, take all the precautions to keep everything neat and clean. Gasoline level in the tank fully primed should be 10 - 15 mm /½...

  • Page 20: Chapter 3 (Engine Operation And Maintenance)

    Chapter 3 (Engine Operation and Maintenance) Starting the Engine WARNING: Before starting the engine, make sure that the gear shift mechanism is in the neutral position (between I and II gears) to prevent accidental movement which could cause possible damage to motorcycle and personal injury. (With electric starter, clutch may be pulled in instead of shifting into neutral.
  • Page 21 Note:Do not open the throttle while kicking the engine over since it may flood the spark plugs. To start an engine that is flooded, first open the throttle fully, hold it there and give the engine up to 10 swift kicks It should start. If it still doesn't fire, take the spark plugs out to see if they are wet with gasoline.
  • Page 22 and have greatly reduced power. WARNING: Sustained operation on only one cylinder for even just a few minutes could overheat the cylinder and cause irreversible damage to either the valves or piston. Thus it is critical to immediately shut the engine down if it appears to be running on only one cylinder.

  • Page 23: Operating Precautions

    Chapter 3 (Engine Operation and Maintenance) Operating Precautions WARNING: Make sure that sidecar windshield is in the full back position so it doesn't interfere with the right handlebar. To move the motorcycle from rest, shift to the I gear only. Avoid releasing the clutch suddenly, because the engine is liable to stall or the motorcycle will start with a jerk.
  • Page 24 to slow the motorcycle. Avoid continuous use of brakes to avoid overheating of the brakes and reduced efficiency. To stop an overheated engine, reduce the engine speed to the minimum and completely shut the air control shutter (choke) without switching off the ignition. This will make the engine stall without any knocks or backfire.

  • Page 25: Running-In The New Motorcycle

    Chapter 3 (Engine Operation and Maintenance) Running-in the New Motorcycle The running-in period for the motorcycle is the first 2,500 km. When running-in, keep the speeds within the limits stated in the following table. Since the URAL engine is an old fashioned design it is critical to observe this running-in procedure.
  • Page 26 Chapter 3 (Engine Operation and Maintenance) Speeds Not to Exceed for Running-In Tourist (-40 ) & Gear Solo & Cruiser ( -10 ) Sportsman 0 - 2,500 After 0 - 2,500 After Run-In Run-In Pay special attention to lubrication of the engine. It is required maintenance that after the initial 500 km, the oil be drained out of the engine crankcase, flush it and fill fresh oil and oil treatment up to the correct level.
  • Page 27 offender to civil punishment and fines. This air/oil cooled engine must always run on both cylinders as evenly as possible. Whenever one cylinder is not firing, stop the engine and determine the cause and correct it before proceeding.
  • Page 28 Chapter 4 Brief Description of Design & Maintenance Engine The motorcycle is equipped with a twin-cylinder four-stroke carburetor-type air-cooled engine. Opposed arrangement of cylinders in the horizontal plane is the outstanding feature of the motorcycle design which ensures proper cooling and balancing of the crank gear.
  • Page 29 The engine is provided with forced ventilation of the crankcase. Breather (Fig. 4, #15) located in central opening of the timing gear cover is used for ventilation. Figure 4. Engine (longitudinal section) 1 - Flywheel 12 - Camshaft gear 23 - Packing ring 2 - Crankcase 13 - Timing gear cover 24 - Oil filter plug...
  • Page 30 18 - Front ball bearing 7 - Crankshaft cheek 29 - Seal housing 8 - Front journal of 19 - Ball bearing 30 - Ball bearing crankshaft 31 - Flywheel 9 - Generator gasket 20 - Timing pinion fastening bolt 10 - Camshaft bearing 21 - Oil trap 32 - Crank pin...
  • Page 31 22 - Duct for oil out of 36 - Cylinder fastening 8 - Cylinder cylinder head 9 - Piston 23 - Gasket 37 - Carburetor 24 - Oil drain tube of 10 - Cylinder head 38 - Spark plug tip cylinder 11 - Valve 25 - Compression rings...
  • Page 32 Chapter 4 (Brief Description of Design and Maintenance) Valve Timing Gear The valve timing gear (Fig. 6) controls the feed of combustion mixture into the cylinders and waste gas exhausted into the atmosphere. The intake and the exhaust valves are not interchangeable.
  • Page 33 rings. Figure 6. Engine Valve Timing Gear 1 - Push rod 13 - Lower retainer 2 - Push rod housing 14 - Outer valve spring 3 - Hose 15 - Inner valve spring 4 - Breather pipe 16 - Upper retainer 5 - Camshaft gear 17 - Valve block 6 - Breather tenon...

  • Page 34: Lubrication System

    Chapter 4 (Brief Description of Design and Maintenance) Lubrication System The motorcycle engine features a dual lubrication system, some parts are force-lubricated by pressure built up by the oil pump, while others by splashing (Fig. 7). A full-flow paper oil filter is provided in the lubrication system to prolong the engine life.
  • Page 35 15 - Holes in crank pin for 1 - Duct for oil flow to rear lubrication of connecting rod bearing big end bearing 2 - Connecting bar and oil pump 16 - Oil supply duct to drive gear left-hand cylinder 3 - Duct in rear bearing housing 17 - Inner cavity of crank pin for oil flow...
  • Page 36 13 - Holes in connecting rod B - Gas escape out of engine small end for lubrication of crankcase piston pin 14 - Holes in piston bosses for C - Oil drain out of crankcase of piston pin sump lubrication Chapter 4 (Brief Description of Design and Maintenance) Lubrication System...
  • Page 37 Important! The bypass valve has been accurately adjusted to pressure the oil mains, therefore, do not attempt to dismantle the valve. While screwing in the filter plug, be careful so as not to damage the rubber gasket. During motorcycle service, keep oil level in the engine crankcase close to the top groove of the oil dipstick.

  • Page 38: Ignition System

    Chapter 4 (Brief Description of Design and Maintenance) Ignition System The ignition system incorporates the power supplies, ignition coil, moving coil pickup, electronic commutator, two spark plugs, a set of low and high voltage wires and the ignition switch. A contactless ignition system with electronic ignition timing is employed.
  • Page 39 Periodically, check all wires to be sure they aren't crimped or have loose connections. Ignition Timing. When checking the ignition setting at the time of service, please have the URAL idling (800 rpm) and use a stroboscope (timing light). This way a more precise adjustment can be achieved than when using marks on the rotor and pickup base as guidance.
  • Page 40 run on both cylinders as evenly as possible. Whenever one cylinder is not firing, stop the engine and determine the cause and correct it before proceeding.
  • Page 41 Chapter 5 Tuning Mikuni Carburetors VM & TM 1 - Throttle cable rubber 2 - Cable adjuster 3 - Cable adjuster locknut 4 - Mixing chamber top 5 - Mixing chamber top gasket 6 - Throttle valve spring 7 - Spring seat plate 8 - Needle positioning clip 9 - Needle...
  • Page 42 spring 32 - Idle adjusting screw 33 - Needle valve washer 34 - Needle valve 35 - Main jet ring 35a - Washer 36 - Main jet 37 - Vent tube anchor plate 38 - Float bowl screw 39 - Guide screw 40 - Needle jet setter 41 - Needle jet setter 0-ring...
  • Page 43 However, in order to be effective, it must first break the fuel into tiny particles (in the form of vapor) and then mix the fuel with air in a proper ratio so it can burn without leaving excess fuel or air. 2.
  • Page 44 Low-speed fuel system (Fig. 2 and Fig. 3) Since the engine is operated with the throttle valve almost closed at idling or in the low speed range, the velocity of air flowing through the needle jet (2) is slow. Consequently, a vacuum strong enough to draw fuel from the needle jet in the main fuel system is not created.
  • Page 45 C - Float System (Fig. The float system serves to maintain a constant level of fuel in the bowl. Fuel flows through the needle valve (14) and enters the float chamber (15). As the fuel enters the float chamber, the float (16) moves upward to its pre-determined level because of buoyancy.
  • Page 46 Enrichment System (Fig. In place of the choke the enrichment system is employed for Mikuni carburetors. Fuel and air for starting the engine are metered by entirely independent jets. the fuel metered by the starter jet (17) is mixed with air and is broken into tiny particles in the emulsion tube (18).
  • Page 47 8 - ENGINE TROUBLE SHOOTING When the carburetor setting is not correct or out of tune various irregularities in engine performance are noticeable. These irregularities can be traced to two basic causes: When air-fuel mixture is too rich: a) The engine noise is dull and intermittent. b) Engine performance grows worse when the enrichment valve is opened.
  • Page 49 Chapter 5 (Mikuni Carburetors) Carburetor Troubleshooting Chart PROBLEM POSSIBLE CAUSE CORRECTIONS HARD STARTING Incorrect use of choke Correct use of choke Set mixture adjustment Incorrect air-fuel mixture screw in accordance adjustment with Owner's Manual or shop manual instructions. Clogged fuel filter. Clean filter.
  • Page 50 Low cylinder Repair, replace or compression. adjust as necessary Adjust idle rpm in POOR IDLE OR Idle speed adjustment(s) accordance with STALLING set too low. specifications in Owner's Manual or shop manual. Idle speed adjustments Equalize throttle stop are unequal Equalize setting.
  • Page 51 Idle speed adjustments are unequal (twin Equalize throttle stop carburetor models and settings. multi-carburetor models using individual throttle stop adjustments.) Clean and inspect Throttle valve sticking. throttle valve and return spring. Replace if necessary. Throttle linkage sticking. Clean and inspect throttle linkage and return spring.
  • Page 52 Fuel jets "O" rings leaking (models using Replace "O" rings "O" rings) Float stuck Remove float bowl, check float operation and correct or replace. Float damaged or Replace float. leaking. Incorrect float level. Set float height in accordance with shop manual specifications.

  • Page 53: Power Transmission

    Chapter 6 Power Transmission The power transmission of the motorcycle is comprised of the clutch, gearbox, propeller shaft and the final drive. Clutch The clutch (Fig. 13) relays torque from the engine to the gearbox, disengage the engine from the gearbox during shifting of the gears and during braking to a stop.
  • Page 54 7 - Adjusting 2 - Rod seal 12- Thrust plate 17 - Seal screw 8 - Clutch release 13 - Intermediate 18 - Driven plate 3 - Rod tip lever driving plate 4 - Thrust ball 9 - Lever axle 14 - Driven plate 19 - Spring bearing...
  • Page 55 Chapter 6 (Power Transmission) Gearbox with Reverse Gear The principal parts of the gearbox are the split box with covers, clutch shaft and main shaft with gears and shift sleeves, the gear shift mechanism, the kick starter and the reverse gear engagement mechanism.
  • Page 56 23 - Kick lever 28 - Driven 1 - Gear IV of clutch shaft 12 - Gear IV of main shaft gear to speedometer 2 - Clutch shaft bearing 13 - Main shaft sleeve 24 - Kick starter shaft 3 - Clutch shaft seal 14 - Gearbox case 25 - Intermediate gear 4 - Clutch shaft...
  • Page 57 1 - Return spring 2 - Kick starter shaft bushing 3 - Kick starter gear 4 - Kick starter shaft 5 - Pawl spring 6 - Spring 7 - Pawl 8 - Pawl axle 9 - Pawl release 10 - Kick starter buffer 11 -...
  • Page 58 1 - Pedal 2 - Pawl with tenon 3 - Return spring 4 - Ratchet 5 - Pawl crank with spring 6 - Lock ring 7 - Quadrant shaft spring 8 - Quadrant spring 9 - Reverse gear engagement lever 10 - Reverse gear engagement quadrant...
  • Page 59 Chapter 6 (Power Transmission) Adjustment of Gear Shift Mechanism All gearboxes are thoroughly adjusted at URAL America's warehouse prior to shipment to the dealer. The URAL gearbox, once properly adjusted, should last a lifetime with no further adjustments necessary, as the adjusting screws have been "loctited"...
  • Page 60 1. Put your URAL motorcycle on the central stand, make sure it's in neutral. 2. Position the locknuts on both adjusting screws so approximately 3 grooves of the screws show up over both locknuts' top. 3. Screw the adjusting screws into the case until the locknuts touch the case.
  • Page 61 stops immediately after the "click" is felt. After adjustments, tighten the locknuts on both adjusting screws and put the plastic cap back over the nut as described in number 5.

  • Page 62: Gearbox (Solo Motorcycle)

    Chapter 6 (Power Transmission) Gearbox (Solo Motorcycle) The gearbox is of the four speed design equipped with constant meshed gears and gear-shift sliding sleeves. The principal parts included in the gearbox (Fig. 18) are the split box with covers, the clutch shaft and main shaft with gears and shift sleeves, the gear shift mechanism and the kick starter.
  • Page 63 3 - Clutch shaft ball 23 - Right hand cover of gear 13 - Clutch crankcase bearing case 4 - Clutch shaft seal 14 - Main shaft sleeve 24 - Hand gear change lever 25 - Speedometer driven 5 - Clutch shaft sleeve 15 - Gar shaft sleeve gear 16 - Gear III and IV shift...
  • Page 64 1 - Gear shift pedal 2 - Pawl with tenon 3 - Return spring 4 - Ratchel 5 - Pawl crank with 6 - Lock ring 7 - Quadrant shaft spring 8 - Gear shaft quandrant 9 - Hand gear change lever 10 - Quadrant lock 11 - Gear change...
  • Page 65 * The gearbox may incorporate parts normally used in the reverse gear gearbox. Every 500 km check oil level in the gearbox and fill to required level. Every 10,000 km change oil in the gearbox. Remove the filler and the drain plugs and drain oil. Replace the drain plug and fill the gearbox with 400 cm³/0.4 qt, minimum, of the oil used for the engine;...

  • Page 66: Final Drive

    Chapter 6 (Power Transmission) Final Drive The final drive is devised as a pair of helical bevel gears housed in a casing which serves at the same time as a plate for the brake shoes, as an oil tank and a support for the right-hand end of the rear wheel axle.
  • Page 67 Chapter 6 (Power Transmission) PROPELLER SHAFT DRIVE The propeller shaft drive (Fig. 22) incorporates the flexible joint, the propeller shaft and the universal joint. The flexible joint is essentially a coupling sleeve fitted with plates and pins. Propeller shaft (Item 23) is aligned by means of the ball end of the main shaft which enters the socket in the front end of the propeller shaft.
  • Page 68 15 - Double-row ball 27 - Flexible joint driven 3 - Gasket bearing disk 4 - Crankcase bushing 16 - Adjusting washer 28 - Packing ring 17 - Universal joint fork 5 - Needle bearing roller 29 - Needle bearing seal 6 - Casing seal 18 - Protective washer...
  • Page 69 Chapter 7 Running Gear The running gear of the motorcycle is comprised of the motorcycle and the sidecar frames, front fork, rear wheel and the sidecar wheel suspension, wheels and the seat. Figure 23. Motorcycle and Sidecar Frames 1 - Rear suspension swinging 10 - Collet clamp 20 - Lever - sidecar wheel 2 - Rear mud shield...
  • Page 70 6 - Strap 15 - Sidecar frame legs 25 - Tie rod nut 7 - Motorcyclel frame 16 - Sidecar wheel brake rod 26 - Sidecar fender 17 - Rear collet clamp 27 - Rubber member of 8 - Sidecar adjusting strut bracket body suspension 9 - Sidecar frame legs 19 - Lever...

  • Page 71: Motorcycle And Sidecar Frames

    Chapter 7 (Running Gear) Motorcycle and Sidecar Frames The frame is the principal bearing element of the motorcycle to which all the units and assemblies of the motorcycle are attached. The motorcycle is furnished with a twin closed frame of welded construction.

  • Page 72: Spring Loaded Hydraulic Shock Absorber

    Chapter 7 (Running Gear) Spring Loaded Hydraulic Shock Absorber The suspension spring and the hydraulic shock absorber (Fig. 24) perform different functions. The supporting spring (Fig. 24, #4) serves as an elastic element of the suspension, while its oscillations are damped by the double-acting hydraulic absorber enclosed in body (Fig.
  • Page 73 8 - Working cylinder 19 - Rebound valve throttle 30 - Seal washer plate 9 - Rod 20 - Intake valve plate 31 - Rubber seal of rod 10 - Check ring 21 - Bypass valve spring 32 - Felt seal of rod 11 - Moving cam 22 - Bypass valve retainer 33 - Pressure washer...

  • Page 74: Adjustment Of Sidecar Installation

    Chapter 7 (Running Gear) Adjustment of Sidecar Installation (Single Wheel & Dual Wheel Drive) Note: Sportsman (driven sidecar wheel model) should be set-up with no toe-in and 1° or less lean out. The sidecar should be installed in a definite position relative to the motorcycle.
  • Page 75 wheels. Tighten up the bolt fastening the bracket, adjust the length of the legs and secure them with bolts. Check the lean-out of the motorcycle using a level gauge or protractor with a plump bob and a ruler. Adjust the two inclined legs by screwing the forks in or out Check the lean-out angle while the motorcycle is running on the road.

  • Page 76: Front Fork

    Chapter 7 (Running Gear) Front Fork The telescopic front fork used on the Solo, Cruiser, and Utility models is equipped with inside springs and the double-acting hydraulic shock absorber. The front fork (Fig. 26) is made up of stem (Fig. 26, #8), the steering column with bridge (Fig.

  • Page 77: Steering Head Bearings

    Chapter 7 (Running Gear) Steering Head Bearings The steering head bearings must be adjusted periodically to avoid excessive play which might cause steering instability. When properly adjusted the front fork should turn with just a hint of bearing drag, but not free play or obvious resistance to turning. WARNING: Improper adjustment of the steering head (e.g.
  • Page 78 34 - Damper rod 35 - Damper tube nut 36 - Rubber seal 37 - Moving washer 38 - Bottom angular ball bearing 39 - Fixed washer of steering damper 40 - Head tube of frame A - Cavity under piston B - Cavity above piston To adjust the bearings: 1.
  • Page 79 check once again that bearing clearance is now acceptable. Figure 27. Lever-Type Front Fork 1 - Protective washer 9 - Bearing nut 17 - Fork leg left tube 10 - Upper radial-thrust ball 18 - Spring-hydraulic shock 2 - Seal bearing absorber 3 - Fork crosspiece...

  • Page 80: Wheels And Tires

    Chapter 8 Wheels and Tires The URAL motorcycle is equipped with easily demountable interchangeable wheels with the cast (aluminum) brake drum on short spokes of the same size. Inner splines provided at the right-hand side of the hub receive the splined end of the final drive hub in case the wheel is used as a drive wheel.
  • Page 81 Figure 29. Motorcycle Wheel 1 - Tire 2 - Tire flap 3 - Spokes 4 - Brake drum 5 - Roller bearings 6 - Thrust washer 7 - Right-hand distance bushing 8 - Intermediate bushing 9 - Left-hand distance bushing 10 - Seal 11 - Seal nut 12 - Locknut...
  • Page 82 Adjustment of wheel bearings. After 5,000 km be sure to check the condition and adjustment of the bearings. In adjusting adhere to the following sequence: Remove the wheel from the motorcycle. Fit the rear wheel axle (less the protective hood), tighten it by nut with the aid of a bushing, 100 mm long, with 21 mm bore and 25 - 30 mm O.
  • Page 83 has two studs that fit the two holes in the round nut holding the luggage rack down.

  • Page 84: Running Gear Maintenance

    Chapter 8 (Wheels and Tires) Running Gear Maintenance During the pre-trip inspection, check air pressure in the tires (chapter 1). Check assembly units and parts for safe fastening, be sure to tighten the fasteners and eliminate play as soon as they get loose or demonstrate excessive play.
  • Page 85 Chapter 9 Control Levers and Cables Handle Bar and Controls The handle bar is mounted on the front fork through two brackets secured on the cross-piece of the front fork. The handle bar is adjustable in the brackets. The throttle control twist grip is linked to the carburetor throttles by flexible control cables.

  • Page 86: Wheel Brake

    shoes are interchangeable with the motorcycle brake shoes. The rear wheel brake is mounted in the final drive case. Figure 30. Fron Wheel Brake 1 - Top brake lever 9 - Brake lever spring 2 - Inspection hole plug 10 - Adjusting screw 3 - Brake shoe 11 - Tie rod 4 - Adjusting bolt locknut...

  • Page 88: Chapter 9 (Control Levers And Cables)

    Chapter 9 (Control Levers and Cables) Brake Adjustment Note: The front brake lower lever is set at a distance of 85 mm/3.3 in from its vertical axis to the adjusting screw bracket center. Angle of deviation of the rear brake lever backward from the vertical axis of the final drive equal to 33±5°...
  • Page 89 result in brake malfunction and personal injury. If you ride under adverse conditions, steep hills, heavy traffic, etc., more frequent inspection, 1,000 km or less, will be necessary. We do not recommend using the rear brake only.

  • Page 90: Control Cable Adjustment

    Chapter 9 (Control Levers and Cables) Control Cable Adjustment The control cables are adjusted by screw adjustments at the cable ends. With the control levers released: for the clutch a play at the clutch lever end should be equal to 5 - 8 mm/0.2 - 0.3 in for the brakes - a 0.3 - 0.7 mm/0.012 - 0.028 in.

  • Page 91: Control Cable Maintenance

    Chapter 9 Control Levers and Cables Control Cable Maintenance The daily preventative maintenance involves checking the functioning, condition and fastening of the tie rods, cables and braking action. Refer to the Maintenance Summary Schedule in chapter 11 for lubricating and schedule. After every 5,000 km, check the condition of the brakes, clean the brake shoes and the active surface of the brake drums, lubricate the hinge pins and the cams of the brake linings, the joints, the...
  • Page 92 Chapter 9 (Control Levers & Cables) Speedometer The speedometer scale is illuminated with two lamps. The speedometer is driven by the main shaft of the gearbox via a flexible shaft. After every 10,000 km add five or six drips of oil into the union butt end to lubricate the speedometer axle.
  • Page 93 Chapter 10 Electrical Equipment The electrical equipment of the motorcycle (Fig. 32) includes power supplies, auxiliary instruments and electric wiring. Electric power supplies are storage battery and an AC generator with a built-in rectifier. A single wire system is employed for wiring the electric circuit, i.e. a single wire runs from the electric power supplies to the electric loads (from the positive poles of the storage battery and the generator), and the frame and other metal parts of the motorcycle...
  • Page 94 portion of the horn body. Headlight. A 7" diameter DOT approved sealed beam headlight is used on the US URAL. Adjust it so that the high-beam is horizontal when the motorcycle is in its normal loaded condition. Figure 32. Electric Circuit Diagram...
  • Page 95 1 - Sidecar side 13 - Neutral gear 24 - Battery bulb ON indicator bulb 14 - High/low 2 - Sidecar front 25 - Master beam headlight lamp Battery Switch* bulb 3 - Traffic 15 - Speedometer 26 - Generator indicator bulb 27 - Generator 4 - Sidecar rear...
  • Page 96 parking. The switch is located under the seat except on the electric start models where it has been removed.

  • Page 97: Electrical Equipment Maintenance

    Chapter 10 (Electrical Equipment) Electrical Equipment Maintenance During the daily preventive inspection, check the functioning and the condition of the electrical equipment. After every 4,500 - 5,000 km, inspect the spark plugs. The gap is readjusted by bending the end of the side electrode. Also check the condition of the spark plug wires.
  • Page 98 1 - Sidecar side 13 - Neutral gear 24 - Battery bulb ON indicator bulb 14 - High/low 2 - Sidecar front 25 - Master beam headlight lamp Battery Switch* bulb 3 - Traffic 15 - Speedometer 26 - Generator indicator bulb 27 - Generator 4 - Sidecar rear...
  • Page 99 8 - "Day/night" switch with 20 - Foot brake emergency 31 - Ignition lock signal switch "ignition out" switch 32 - Light and 9 - Hand brake 21 - Motorcycle turn indicator signal switch rear lamp switch, horn button 10 - Turn 22 - Braking 33 - Interrupter indicator...

  • Page 100: Maintenance Of Motorcycle

    Chapter 11 Maintenance of Motorcycle Maintenance should be performed after the specified total kilometers run irrespective of the technical condition of the motorcycle. Different service duties and technical condition of the motorcycle may necessitate a change in the intervals. The Lubrication Chart indicating lubrication points of the motorcycle is given in Fig.

  • Page 101: Maintenance Schedule Summary

    Chapter 11 (Maintenance of Motorcycle) Maintenance Schedule Summary The following schedule is broken into two columns to indicate the type of usage and operating environment to which the machine will be subject. The "Normal Duty" category includes operation in dusty, hot climates, while pulling loads on hilly terrain for significant periods of time in the maintenance cycle, operation primarily with the sidecar accessory attached or for owners who want to take extra care to keep their machines in "tip top"...
  • Page 102 Light: Every 4,500 - 5,000, replace at 10,000 km Figure 35. Lubrication diagram...

  • Page 103: Lubrication Chart

    Chapter 11 (Maintenance of Motorcycle) Lubrication Chart (see next page for oil details) Part To Be Item Lubricant After Break-In Lubricated Lever pin and interrupter felt Industrial oil or Every 5,000 km Pins and weight holes, spindle oil Every 5,000 km automatic unit cam bushing Engine crankcase...
  • Page 104 Pins and cams of brake Grease Every 5,000 km shoes Wheel hub Grease Every 10,000 km Front fork dampers Spindle Change every 10,000 km (lubrication points) oil/WD-40 Carburetor throttle control Grease Every 5,000 km twist grip Speedometer drive Industrial oil or flexible shaft and Every 10,000 km spindle oil...

  • Page 105: Required Lubrication

    URAL motorcycles by Hilton Oil Co. This product, URAL Oil Treatment, has proven in tests to lower the engine's operating temperatures and reduce the friction and wear in the engine, gearbox and final drive.

  • Page 106: List Of Recommended Lubricants

    Chapter 11 (Maintenance of Motorcycle) List of Recommended Lubricants Total Detergent Volume Lubrication URAL Oil Amount Area Treatment Amount Lubrication Fluids 20w/50 Engine Castrol 55.6 12 oz. 2.0 L (67.6 oz.) Crankcase: 20w/50 Gearbox: Castrol 19.5 12 oz. 0.9 L (31.5 oz.) Final Drive: 80/90 wt.

  • Page 107: Care Of Motorcycle Paint

    Chapter 11 (Maintenance of Motorcycle) Care of Motorcycle Paint When washing the motorcycle, use a weak stream of cold or slightly heated water. Do not remove dust and mud by rubbing the surface with a dry cloth as sand particles will degrade the surface and the paint will rapidly lose its brilliance.

  • Page 108: Preservation And Storage

    Chapter 11 (Maintenance of Motorcycle) Preservation and Storage If the motorcycle is put in storage for the season, arrange it on supports (timbers) and proceed with the preservation treatment. Check that the wheel tire pressure is within specifications. Store the motorcycle away from acids, alkalis, mineral fertilizers and other harmful substances.
  • Page 109 Chapter 11 (Maintenance of Motorcycle) Figure 36. Layout of Bearings and Seals Seals Mounted on Motorcycle (Fig. 36) Part No. Description Location Clutch shaft seal 6204010 Gearbox, Front Side assembly Gear case RH cover seal Gearbox cover, RH 6204017 assy Side 1.90 RH gearcase cover Gearbox cover, LH...
  • Page 110 6205033 U-joint fork seal, assy Final drive case 6206006-10 Rubber packing assy Wheel nut assy. 6308121 Seal collar Fork leg 7203207-A Clutch release slider ring Clutch release slide Seals of clutch release 7203213-20 Clutch release rod Collar type seal & spring 7205039 Final drive case assy...
  • Page 111 Chapter 11 (Maintenance of Motorcycle) Battery Storage batteries on the motorcycle should function at ambient air temperature from -40°C to plus 60°C/ 40°F to 140°F. As the battery is in service: regularly check the voltage generator-regulator for 13.5 - 14.5 V across the charging voltage do not allow the battery to remain discharged for more than 24 hours.
  • Page 112 WARNING: Batteries contain sulfuric acid which can cause severe burns. Avoid contact with skin, eyes or clothing. ANTIDOTE: External — flush with water. INTERNAL — drink large quantities of water followed by milk of magnesia, vegetable oil, or beaten eggs. Call doctor immediately.

  • Page 113: List Of Individual Tool Set, Spare Parts, Accessories & Documents

    Chapter 11 (Maintenance of Motorcycle) List of Individual Tool Set, Spare Parts, Accessories & Documents DESCRIPTION DESCRIPTION Tools Accessories 1. Wrench 7 x 8 1. Air Pump 2. Wrench 10 x 2. Air Pressure Gauge 3. Wrench 13 x 3. Ignition keys 4.
  • Page 114 2. Driving the URAL Sidecar 14. Screwdriver Motorcycle 100 mm (except with Solo models) 15. Pliers 3. Owner's 16. Tool kit pouch Video...
  • Page 115 Chapter 12 Sportsman Motorcycle with Driven Sidecar Wheel Description The sidecar wheel is driven by a propeller shaft connected with the motorcycle main drive with a differential gear (Fig. 37 & Fig. 38). The following units that have been redesigned to produce the driven sidecar wheel are: A.

  • Page 116: Handling Differences From The Single Wheel Drive

    Chapter 12 (Sportsman Motorcycle with Driven Sidecar Wheel) Handling Differences from the Single Wheel Drive Since the sidecar wheel is driven, the Sportsman motorcycle handles differently from the standard Tourist (single wheel drive) motorcycle. Turning left, especially when accelerating from a stop is much easier since the driven sidecar wheel helps to pull the sidecar forward to the left.

  • Page 117: Sidecar Maintenance

    Chapter 12 (Sportsman Motorcycle with Driven Sidecar Wheel) Sidecar Maintenance Check before driving that the final drive swing arm, propeller shaft fork and sun gear flange are bolted tightly. After the first 2,500 kilometers, change the oil in the main drive gearcase and then check the oil level every 2,500 kilometers.
  • Page 118 Chapter 12 (Sportsman Motorcycle with Driven Sidecar) The Main Drive and Differential To knock down the main drive: Remove the two bolts attaching the propeller shaft fork to the sun gear flange and move the fork in the direction of the side-car giving access to the rear wheel axle nut.
  • Page 119 Figure 37. Main Drive 1 - Gear case 11 - Sun gear 21 - Retainer 31 - Roller 2 - Differential 12 - Main drive case 22 - Driving gear 32 - Needle roller body cover 3 - Epicycle gear 13 - Rear wheel axle 23 - Seal 33 - Spacer...
  • Page 120 1 - Swinging arm 6 - Ball bearing 11 - Bolt 7 - Protective 12 - Shock absorber silent 2 - Braking drum cover ring block 3 - Slotted hub 8 - Spacer 13 - Propeller shaft 4 - Sidecar pin 9 - Ring 14 - Universal joint 5 - Ball bearing...

  • Page 121: Learning To Ride The Ural Motorcycle With Sidecar Accessory

    Chapter 13 Learning to Ride the Ural Motorcycle with Sidecar Accessory The URAL sidecar motorcycle, since it has three wheels, behaves quite differently from either a solo motorcycle or a car. For these reasons the following label has been attached to your motorcycle tank: WARNING: Left-hand and right-hand turns may be dangerous.
  • Page 122 URAL : When you accelerate, the URAL will pull slightly to the right due to the inertia and drag of the sidecar. When you let off the gas it will pull slightly to the left due to the inertia of the sidecar. Note: The Sportsman (driven sidecar wheel) model handles differently than the single wheel drive models (see chapter 12).

  • Page 123: Safe Operating Rules

    Chapter 13 (Learning to Ride the ural Motorcycle with Sidecar Accessory) Safe Operating Rules Before operating your new URAL it is your responsibility to read and follow operating and maintenance instructions in this manual and follow these basic rules for your personal safety. Know and respect the Rules of the Road in your state.
  • Page 124 approved helmet, clothing and footgear suited to motorcycle riding. Bright or light colors are best for greater visibility in traffic especially at night. Avoid loose flowing garments and scarves. The exhaust pipes and mufflers get very hot when the engine is running and remain too hot to touch for some time after the engine is shut off.
  • Page 125 Chapter 13 (Learning to Ride the Ural Motorcycle with Sidecar Accessory) Tire Data WARNING: For your own personal safety, tires and tubes must be correctly matched to wheel rims. See your Authorized URAL Dealer for further information. Mismatching tires, tubes and rims may result in damage to the tire bead during mounting or may allow the tire to slip on the rim, possible causing tire failure.
  • Page 126 cold Rear: 516 lb. (234 kg) with 3.50 x 18 tire, 18 x 3.00 rim, at 32 psi cold WARNING: Maximum inflation pressure must not exceed specification on tire sidewall. WARNING: When tires are worn to a tire center tread depths of 3/32 in, they should be replaced.

  • Page 127: Troubleshooting

    URAL STARTING & RUNNING TIPS Starting The Engine 1. Open carburetor enricheners (marked "choke" on lever) on both carburetors (push lever down). 2. Make sure fuel cock is open "O" or on reserve "P." Fuel cock handle in 6 or 12 o'clock position. 3.
  • Page 128 3. Little or no spark is available to the engine due to a low battery, (dim headlight), loose ignition wires. Correction: Dead battery is corrected by charging battery, loose or broken ignition wires are corrected by replacing broken wire(s) or by re-connecting wire(s) at either the spark plug cap(s) or at the ignition coil under the distributor box cover at the front of the engine.

This manual is also suitable for:

Tourist 1998Sportsman 1998Solo 1998Utility 1998Imz-8.103-10Imz-8.103-40 ... Show all

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