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Summary of Contents for URAL Motorcycles Gear Up 2004
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Page 1: Owners Manual
Irbit Motorcycle Factory Irbit Motorworks of America Owners Manual 2004 Model Gear Up, Patrol, Tourist, Troyka www.imz-ural.com... -
Page 3: Table Of Contents
Contents Introduction................................7 Warnings, Cautions, Notes............................9 Chapter 1 Specifications Specifications ................................. 11 Torque Specifications ............................. 15 Chapter 2 Motorcycle Controls and Instruments Motorcycle Controls & Instrumentation ........................17 Controls ................................17 Control and Instrument maintenance ........................25 Chapter 3 Engine Operation Engine Operation and Maintenance ........................ - Page 4 Chapter 7 Running Gear Running Gear ................................. 43 Motorcycle and Sidecar Frames ..........................43 Spring-Loaded Hydraulic Shock Absorber ......................44 Adjustment of Sidecar Installation ..........................45 Front Fork ................................46 Steering Head Bearings............................48 Chapter 8 Wheel & Tires Wheels and Tires ..............................49 Tire Data ................................50 Running Gear Maintenance ............................
- Page 5 Chapter 15 Warranty Warranty ................................75 Warranty Claim Form ............................81 Flat Rate Schedule ............................... 82 Chapter 16 Service Coupons Service Coupons ..............................85 New Address Form ............................... 95 New Owner Form ..............................96 URAL Starting and Running Tips ..........................97...
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Page 7: Introduction
INTRODUCTION Welcome to the URAL Motorcycling Family! Your Ural has been built by the Irbit Motorcycle Factory in Russia and distributed by Irbit Motorworks of America, the United States affiliate of the Irbit Motorcycle Factory. The Ural motorcycle conforms to all applicable US Federal Motor Vehicle Safety Standards and US Environmental Protection Agency regulations effective on the date of manufacture. -
Page 9: Warnings, Cautions, Notes
Important Notice! Statements in this manual preceded by the following words are of special importance: WARNING: EANS 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 11: Specifications
Chapter 1 SPECIFICATIONS GENERAL Patrol & Gear-Up Tourist Maximum speed of motorcycle 95 km/h 59 mph 105 km/h 65 mph Dry mass of motorcycle 736 lb 736 lb. Maximum Gross Vehicle Weight 1344lb. 1344 lb. Noise level below 80db below 80db Fuel consumption 31.3 mpg 31.3mpg... - Page 12 ELECTRICAL Ignition system Electronic Ignition Spark plugs NGK BP7HS or Equivalent Ignition timing Automatic advance Alternator 35 amp / 12 Volt Battery VARTA YB18L-A or equivalent Headlight Hela, 7" round sealed beam TRANSMISSION Clutch Dry double-disk clutch Gearbox 4 speed gearbox with reverse GEAR RATIOS I gear II gear...
- Page 13 RUNNING GEAR Frame Tubular welded Rear wheel suspension Swing arms with spring shock absorbers Front fork Leading link Sidecar Cushioned body (on rubber cushions) and wheel with hydraulic spring shock absorber Sidecar drive Steel shaft driven by final drive. User selectable for engage (Patrol and Gear Up only) ment.
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Page 15: Torque Specifications
TORQUE SPECIFICATIONS Metric US Equivalent Location on Bike 54 to 61 Nm 40 ft/lb to 45 ft/lb cylinder heads 237 to 251 Nm 175 ft/lb to 185 ft/lb fly wheel tightening screws 19 to 30 Nm top 14 ft/lb to 22 ft/lb shock absorber 38 to 49 Nm bottom 28 ft/lb to 36 ft/lb... - Page 16 This page left intentionally blank...
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Page 17: Motorcycle Controls & Instrumentation
Chapter 2 MOTORCYCLE CONTROLS & INSTRUMENTATION Figure 1. Controls and Instrumentation 1 - Speedometer 12 - Gear shift (foot) pedal 2 - Turn indicator lamp 13 - Turn signal switch 3 - Trip odometer reset knob 14 - Horn push-button 4 - Neutral and reverse gear engagement 15 - “High-low”... - Page 18 Clutch Control Lever Font Brake Control Lever Clutch control lever . When the clutch lever is squeezed, the engine is disengaged from the gearbox. When the lever is released, the engine and gearbox are engaged. WARNING: M AKE SURE FINGERS ARE NOT POSITIONED BETWEEN HAND CONTROL LEVERS AND HANDLEBAR GRIPS OR OPERATION OF VEHICLE COULD BE IMPAIRED WARNING: B EFORE STARTING ENGINE...
- Page 19 Gear Shift Foot Pedal Kick Lever Kick lever Is designed to start the engine. On pressing the lever the crankshaft of the engine is actuated through the gearbox. The lever is returned to its initial position by the spring inside the gearbox.
- Page 20 Parking Brake Sidecar Drive Lever Reverse Gear Lever Rear Brake Pedal Parking Brake is used to hold the bike when parked. To engage, depress the rear brake pedal and push down then twist the parking brake lever counter clockwise. Sidecar drive engagement lever is used to engage the drive axle to the sidecar wheel on the Patrol and Gear Up model motorcycles.
- Page 21 Ignition Switch has three fixed positions of the key. The position and switching diagram of the ignition locks are shown above. All electrical systems are off. Voltage is supplied to all electrical systems. Parking Voltage is supplied to running lights only. Note: Leaving the key in the Run or Parking position will discharge the battery.
- Page 22 The indicator lamps are mounted on the instrument board: Alternator failure Turn indicator indicator lamp pilot lamp Head lamp high Gearbox neutral beam indicator indicator lamp lamp Turn indicator pilot lamp indicates that the turn signals are activated. Alternator fault indicator lamp, indicates that the charging system is malfunctioning and needs immediate attention.
- Page 23 Electric Start Button Ignition Cutoff Switch Low and High Beam Light Switch Turn Indicator Switch Horn Push Button...
- Page 24 Throttle Control is on the right handlebar. Turning the twist grip increases engine speed. Ignition Cutoff Switch has two positions, ignition off (up), and ignition on (down). Electric Start Button is located on the right-hand twist grip, below the kill switch. Low and High Beam Light Switch has two positions, high beam (up), and low beam (down).
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Page 25: Control And Instrument Maintenance
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. •... - Page 26 SPEEDOMETER MAINTENANCE After every 10,000 km, remove the speedometer from the motorcycle and add five or six drops of oil into the speedometer where the cable inserts into the speedometer. This will lubricate the speed- ometer internally. To lubricate the speedometer cable, remove the cable from the speedometer and extend it in a straight line.
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Page 27: Chapter 3 Engine Operation
Chapter 3 ENGINE OPERATION PRE-TRIP PRELIMINARIES Pre-Trip Check List 1. Check all lights and the horn for proper operation. 2. Check the brake and clutch levers and/or pedals. 3. Make sure all wheels and the final drive assemblies are securely fastened . 4. - Page 28 AUTOMATIC PETCOCK 1. When starting the engine after the motorcycle has been parked for an extended period of time, or after the fuel tank and/or carburetors have been completely emptied of gasoline (e.g. due to running out of fuel, evaporation, or installation of replacement parts), set the valve to the “PRI”...
- Page 29 Enrichener off Enrichener on The carburetor enricheners provide extra fuel to the mixture. This extra fuel will allow a cold engine to start and run until it has warmed up sufficiently to allow normal operation. Use caution when using the enricheners, as they can easily cause the engine to flood, or foul the spark plugs. The enricheners should only be left on as long as necessary to keep the engine running while cold and should be turned off as soon as possible.
- Page 30 Depending on the engine and ambient temperature, use the carburetor enricheners and starting procedure as follows: Manual Starting (without electric starter) 1. Turn on the ignition and depress the kick lever (see Fig. 1) about 1/4 of its travel (enough to firmly get the ball of your foot on the lever) with either your left foot or right foot, depending on what position is most comfortable with your right hand on the throttle.
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Page 31: Operating Precautions
typically takes about 5-10 rotations to start the engine. As soon as the engine starts, retract both enricheners (after a few seconds). Note: It is very important to back off on the enricheners as soon as the engine will sustain itself without stalling. -
Page 32: Running-In The New Motorcycle
WARNING: S HIFTING TO LOWER GEARS WHEN SPEED IS TOO HIGH MAY SEVERELY DAMAGE THE TRANSMISSION OR CAUSE THE REAR WHEEL TO LOSE TRACTION CAUTION: Do not run the engine at extremely high rpms with clutch disengaged or transmission in neutral. Do not idle the engine unnecessarily for more than a few minutes with the motorcycle standing still. -
Page 33: Chapter 4 Engine Design
Chapter 4 ENGINE DESIGN The motorcycle is equipped with a two-cylinder four-stroke air-cooled engine. The 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. The engine valves are located in the cylinder heads. -
Page 34: Lubrication System
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 . A full-flow paper oil filter is provided in the lubrication system to prolong the engine life. Maintenance of lubrication system. -
Page 35: Fuel System
FUEL SYSTEM The fuel system includes the gasoline tank, the three-way fuel valve with filter and two carburetors. Fuel valve (petcock). The top threaded portion of the valve is screwed into the gasoline tank. The petcock is of an automatic shutoff design. Vacuum from the engine opens the valve when the engine is running. -
Page 36: Ignition System
IGNITION SYSTEM The ignition system incorporates the power supplies, ignition coil, Hall Effect pickup, electronic module, two spark plugs, a set of low and high voltage wires and the ignition switch. The ignition system will provide the spark to the spark plugs from 200 to 6000 RPM. With the engine at rest, the ignition system will draw 100 mA. - Page 37 IGNITION TIMING To set the ignition timing, proceed as follows: -Match the first mark on the flywheel with the center marks on the engine flywheel window. -Loosen the fastening screws of the microprocessor unit and turn it counterclockwise until it stops. -Apply power to the ignition system by switching the ignition on.
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Page 39: Chapter 5 Carburetors
Chapter 5 CARBURETORS 32mm CVK Keihin Seike carburetors are used on of the Ural motorcycle. They are preset with fixed mixture jetting and adjust automatically for altitude variations. This is due to the vacuum activation mechanism of these constant velocity type carburetors. Be sure to check the condition of all carburetor adapters and air pipes every time before riding. -
Page 40: Carburetor Maintenance
CARBURETOR MAINTENANCE The carburetors will require the fuel in the float bowls be drained periodically. This will ensure that any contaminants that have accumulated in the float bowls do not enter the main or idle jets of the carburetors. The fuel can be drained by opening the drains provided on the bottom of the float bowls. -
Page 41: Chapter 6 Power Transmission
Chapter 6 POWER TRANSMISSION The power transmission system of the motorcycle is comprised of the clutch, gearbox, and the final drive. CLUTCH The clutch transmits torque from the engine to the gearbox. Disengage the engine from the gearbox during shifting of the gears and when braking to a stop. The clutch provides for smooth starting of the motorcycle from rest, protects the power transmission parts against damage when the engine speed or drive wheel speed is suddenly changed. -
Page 42: Final Drive
FINAL DRIVE Maintenance of propeller shaft splines and final drive. Remove the final drive from the swing arm and pull the final drive towards the rear of the bike. When the drive shaft is free, coat the drive shaft splines with grease. At the same time, use a grease gun to force grease into the drive shaft universal joint. -
Page 43: Chapter 7 Running Gear
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 44: Spring-Loaded Hydraulic Shock Absorber
SPRING LOADED HYDRAULIC SHOCK ABSORBER The suspension features cam-type adjusters used for varying the preload of the supporting springs to suit the load and the road conditions. The degree of tension on the springs is adjustable allowing two positions. The first (lower) position corresponds to the load due to the motorcycle’s own weight, the driver’s and one passenger’s (sitting in the sidecar) weight;... -
Page 45: Adjustment Of Sidecar Installation
ADJUSTMENT OF SIDECAR INSTALLATION The sidecar should be installed in a definite position relative to the motorcycle. The position is determined by the camber and toe-in of the motorcycle and the sidecar wheels. An incorrectly aligned sidecar will drag the motorcycle to either side and cause extensive tire wear. -
Page 46: Front Fork
FRONT FORK The leading link front fork used on the Tourist and Patrol models use a front lever-type fork with two interchangeable spring-hydraulic shock absorbers. The friction type steering damper is made up of two steel washers, moving and fixed, two fiber washers and tightening bolt with a head. - Page 47 Front fork of leading link type 1-Protective washer; 2- Seal; 3-Cross-piece; 4-Steering column stem nut; 5-Thrust washer; 6- Spring washer; 7-Tightening bolt; 8-Steering column stem; 9-Bearing nut; 10- Top ball radial thrust bearing; 11-Tightening nut; 12-Washer; 13- Leg cover with headlight bracket; 14-Steering column bridge;...
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Page 48: Steering Head Bearings
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 without free play or obvious resistance to turning. WARNING: I MPROPER ADJUSTMENT OF THE STEERING HEAD TOO TIGHT... -
Page 49: Wheels And Tires
Chapter 8 WHEELS AND TIRES The Ural motorcycle is equipped with easily demountable wheels with the cast (aluminum) brake drum on short spokes of the same size on the rear wheels and steel disc and machined hub on the front wheel. Removing wheels. -
Page 50: Tire Data
1.5 Bar 2.5 Bar or 150 kPa or 250 kPa Front & Sidecar Rear tire pressure tire pressure Check inflation pressure and inspect tread for punctures, cuts, breaks, etc., at least weekly if in daily use or before each trip, if used occasionally. WARNING: R IDING WITH EXCESSIVELY WORN UNBALANCED OR IMPROPERLY INFLATED TIRES IS HAZARDOUS... -
Page 51: Running Gear Maintenance
The following tire data labels are mounted on the front frame of your Ural. For motorcycle with sidecar , 19” tire Front: 491 lb. (223 kg) with 4.00 x 19 tire, 19 x 3.00 rim, at 22 psi cold (1.5 Bar) Side: 304 lb. - Page 52 Wheel Construction Two adjustable tapered roller bearings are pressed into the wheel hub, which are prelubricated with LITOL-24 type grease. Depending on motorcycle versions, the wheels with aluminum cast brake drum or disc type may be used. The adjustment of bearings is the same for both styles of wheel. Adjustment of wheel bearings.
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Page 53: Chapter 9 Brakes
Chapter 9 BRAKES BRAKES The motorcycle is equipped with a hydraulic disc brake in front and manual shoe type brakes in the rear and sidecar. The hydraulic disc brake consists of a caliper, brake pads and a wheel disc. The manual shoe type brake consists of a drum, a drum cover, shoes and lever activated cams. The front wheel brake is of the hydraulic disc type. - Page 54 Rear brake adjustment nut Brakes should be “burnished in” during the initial running in period. Follow burnishing procedures carefully. Make approximately 100 stops using 75% of full braking power. This can be done over several periods and need not be done in one session. Choose an area with clean, dry pavement and no obstructions.
- Page 55 The front disc brakes require periodic inspection, but do not require adjustment. The brake pads can be inspected by removing the dust shield from the top of the caliper and checking The front disc brakes require periodic inspection, but do not require adjustment. The brake pads the thickness of the pads.
- Page 56 Brake Reservoir Check the front brake reservoir every service. Wipe off all dirt and avoid any contamination of the brake fluid in the reservoir. Refill the reservoir with only DOT approved 3 or 4 brake fluid. Be careful not to spill brake fluid on the paint, as damage to the paint may occur. To check the brake fluid level in the reservoir, remove the two top screws on the reservoir.
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Page 57: Electrical Equipment
Chapter 11 ELECTRICAL EQUIPMENT The electrical equipment of the motorcycle includes power supplies, auxiliary instruments and electric wiring. Electric power supplies are a battery and an alternator with a built-in rectifier. A single wire system is used for wiring the electric circuits, i.e. a single wire carries power to the electrical devices and the frame and engine serve as the second wire (called the “ground”). -
Page 58: Electrical Circuits
The sidecar spotlight, if equipped, is located on left side of the front of the sidecar. It is operated by activating the switch located just behind the spotlight. The spotlight can be aimed by moving the lever at the rear of the spotlight. Only use the spotlight when the motorcycle engine is running, otherwise the battery may become discharged. - Page 59 WARNING: Do not add any electrical accessories to your Ural motorcycle, as this will immediately void the warranty The fuse box is located beside the left front fork. The #1 in-line fuse is located behind the headlight. The headlight control relays # 1 & 2 are located underneath the fuel tank.
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Page 61: Maintenance Of Motorcycle
Chapter 12 MAINTENANCE OF MOTORCYCLE Maintenance should be performed after the specified total kilometers run irrespective of the mechanical condition of the motorcycle. Different service duties and mechanical condition of the motorcycle may necessitate a change in the intervals. The Lubrication Chart indicating lubrication points of the motorcycle is given in Fig. 35. A sum- mary of lubrication maintenance is given in the lubrication chart. -
Page 63: Lubrication Chart
LUBRICATION CHART ITEM PART TO BE LUBRICATED LUBRICANT Engine crankcase 20W/50 Detergent Oil Transmission 20W/50 Detergent Oil Air cleaner JR Filter Oil Telescopic forks 5wt-10wt Fork Oil Final Drive 80/90 Gear oil Hinges of sidecar collet joint Spindle oil & WD-40 Brake system hinge joints Spindle oil &... -
Page 64: Required Lubrication
REQUIRED LUBRICATION The Ural has been certified for EPA with SAE 20W/50 petroleum based detergent oil. This oil is used in both the engine and transmission. CARE OF MOTORCYCLE PAINT When washing the motorcycle, use a weak stream of cold or slightly heated water. Never use a pressure washer! 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 65: Preservation And Storage
PRESERVATION AND STORAGE If the motorcycle is put in storage for the season, arrange it on supports and proceed with the preservation treatment. Check that the wheel tire pressure is within specifications. Store the motor- cycle away from acids, alkalis, mineral fertilizers and other harmful substances. Prior to placing it in storage, clean the bike thoroughly, drain the carburetors, or start the engine and let it run with the gasoline cock closed to remove gasoline in the float chambers of carburetors. -
Page 66: List Of Individual Tool Set, Spare Parts, Accessories & Documents
Warning: Do not short the terminals together to check for sparking. Before storage, fully charge the batteries, wash the battery surface with water and wipe dry, clean the bolts and nuts of dirt. WARNING: B ATTERIES CONTAIN SULFURIC ACID WHICH CAN CAUSE SEVERE BURNS VOID CONTACT WITH . - Page 67 15. Punch 16. Allen wrench 17. 22mm Round wrench (Patrol only)
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Page 69: Patrol Motorcycle With Engageable Sidecar Drive
Chapter 13 GEAR UP AND PATROL MOTORCYCLE WITH ENGAGEABLE SIDECAR DRIVE DESCRIPTION When engaged by the operator for “off-road” use, the sidecar wheel is driven by a drive shaft connected with the motorcycle main drive with a universal joint. Sidecar Drive Disengaged Sidecar Drive Engaged NOTE: the sidecar drive should only be engaged when the motorcycle is stopped, and only when venturing “off-road”... -
Page 70: Sidecar Maintenance
SIDECAR MAINTENANCE Check before driving that the final drive swing arm, propeller shaft fork and sun gear flange are bolted tightly. Grease the drive shaft splines sufficiently as outlined in the service coupons. Do not over grease the drive shaft splines as this may prevent the drive shaft from moving freely in the hub. The sidecar wheel bearing requires periodic greasing. -
Page 71: Learning To Ride The Ural Motorcycle With Sidecar Accessory
Chapter 14 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: L HAND AND RIGHT... - Page 72 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 Patrol with engageable sidecar wheel handles differently with the sidecar driveshaft engaged and cannot turn on paved roads.
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Page 73: Safe Operating Rules
SAFE OPERATING RULES Before operating your 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 74 unless you are certain that they are experienced, licensed riders and are familiar with the operation of your particular motorcycle. • When leaving the motorcycle unattended, remove ignition key from switch. Protect your motorcycle against theft. • Safe motorcycle operation requires mental awareness and good judgment combined with a defensive driving attitude.
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Page 75: Warranty
Chapter 15 URAL MOTORCYCLES / WARRANTY AGREEMENT Irbit MotorWorks of America, Inc., (IMWA, Inc.) warrants to the first retail purchaser of the URAL® motorcycle from an Authorized IMWA Dealer and each subsequent owner that the motorcycle is free from defects in materials and workmanship for the period stated below. - Page 76 has voided the warranty through improper maintenance, usage, modifications, etc. Any failure of the speedometer assembly on any floor models will require the defective speedometer assembly to be returned to IMWA, Inc. in Redmond, WA. In any of the above cases, Dealer’s State Law and mileage requirements will determine whether the sale of a demonstrator motorcycle shall be considered new or used.
- Page 77 These Warranties Do Not Cover: 1. Failures or required services that are not due to a defect in material or factory workmanship 2. Parts or accessories affected or damaged by: • Lack of required maintenance • Owner abuse • Accident and/or collision •...
- Page 78 Dealer’s and Owner’s Responsibilities Dealer Is Responsible to: • Thoroughly check and road test new units before delivery. • (Please Print!!!) Fill out , sign and send Warranty Registration and Card of Delivery to IMWA, Inc. within 3 business days of the sale of Motorcycle. •...
- Page 79 After IMWA, Inc. inspection of engine or gearbox or final drive: 1. If engine/gearbox/final drive is found to be defective due to factory parts or assembly failure, the appropriate warranty order will be processed and the flat rate for removal and re-installation of the engine/gearbox/final drive will be authorized Failed engines/gearboxes/final drives will be warranted utilizing the following options at IMWA’s discretion...
- Page 80 Warranty Disputes A Dealer may contest a decision by the warranty department regarding a claim rejection or approved amount within 30 days of notification/receipt of credit memo. This must be done in writing along with a copy of the claim in question. After review, the Dealer will be notified of IMWA’s findings. This decision will be final.
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Page 81: Warranty Claim Form
Appendix A Warranty Claim Form Irbit Motorworks of America, Inc. Dealer_________________ ______Authorized #___________Date/__/__/__/ Motorcycle Information VIN # /__/__/__/__/__/__/__/__/__/__/__/__/__/__/__/__/__/ Engine /__/__/__/__/__/__/ Gearbox /__/__/__/__/__/__/ Model ____________ Mileage (km)_________ Owner’s Name______________________ Date of Registration /___/___/___/ Complete Address___________________________________________________________________________ Comments_________________________________________________________________________________ Service Information Technician__________________Start Date /___/___/___/ Completion Date /___/___/___/ Diagnosis of Defect________________________________________________________ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _... -
Page 82: Flat Rate Schedule
Appendix B Flat Rate Schedule For warranty repair work on Ural motorcycles Code Unit or part Job description Allowed Time (in Hrs) for IMWA Authorized Dealers Engine Engine removal/mount with gear box Engine disassembly Engine assembly Engine running-in Cylinder head removal/mount Cylinder removal/mount Piston rings removal/mount (1 piston) Piston removal/mount... - Page 83 Code Unit or part Job description Allowed Time (in Hrs) for IMWA Authorized Dealers Final drive seal (7205039) replacement Drive shaft removal/mount (final drive removed) Front Fork Front fork removal/mount Front fork assy disassembly (total) Front fork assembly (total) Front fork bearings adjustment Wheel &...
- Page 84 Code Unit or part Job description Allowed Time (in Hrs) for IMWA Authorized Dealers Sidecar wind shield assy removal/mount Shock absorber removal/mount Swing arm removal/ mount Seat removal/mount Electrical Wiring diagnosis for short circuit Battery removal/mount Wire harness removal/mount (motorcycle) Wire harness removal/mount (sidecar) Alternator removal/mount Ignition system removal/mount...
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Page 85: Service Coupons
Chapter 16 SERVICE COUPONS IMPORTANT Long and trouble-free enjoyment of your URAL motorcycle depends on following the recommenda- tions outlined throughout the manual and summarized in Chapter 3, together with regular and proper servicing according to the service coupons provided on the following pages. Dependable performance may be anticipated if your motorcycle is entrusted for maintenance to an Authorized IMWA URAL Dealer. - Page 86 SERVICE COUPON NO 1. 500 KM (To be performed between 400 to 600 km) Date_______________ Odometer reading____________ Change engine oil and filter. Change transmission oil. Change final drive oil. Check condition of the gasoline petcock, remove any contaminants, replace in-line fuel filters. Check carburetors while idling for synchronous operation.
- Page 87 Owner’s Signature Service Technician’s Signature SERVICE COUPON NO. 3. 5,000 KM (To be performed between 4,900 to 5,100 km) Date Odometer reading Change engine oil and filter. (See Lubrication List, chapter 11) Check transmission oil level. Check final drive oil level. Inspect air filter element.
- Page 88 SERVICE COUPON NO. 5. 10,000 KM (To be performed between 9,900 to 10,100 km) Date Odometer reading Change engine oil and filter. (See Lubrication List, chapter 11) Change transmission oil. (See Lubrication List, chapter 11) Change final drive oil. (See Lubrication List, chapter 11) Inspect air filter element.
- Page 89 SERVICE COUPON NO. 6. 12,500 KM (To be performed between 12,400 to 12,600 km Date Odometer reading Change engine oil. (See Lubrication List, chapter 11) Check final drive oil level. Inspect air filter element. Check fasteners for proper tightening. Check adjustment of wheel bearings. The maintenance above has been performed as described.
- Page 90 SERVICE COUPON NO. 8. 17,500 KM (To be carried out within 17,400 to 17,600 km Date Odometer reading Clean the air filter, . Change oil in the engine and transmission. (See Lubrication List, chapter 11) Check condition of the gasoline petcock, remove any contaminants, clean and blow out. Check carburetors while idling for synchronous operation.
- Page 91 SERVICE COUPON NO. 9. 20,000 KM (To be performed between 19,900 to 20,100 km) Date Odometer reading Change engine oil and filter. (See Lubrication List, chapter 11) Change transmission oil. (See Lubrication List, chapter 11) Change final drive oil. (See Lubrication List, chapter 11) Inspect air filter element.
- Page 92 SERVICE COUPON NO. 10. 22,500 KM (To be performed between 22,400 to 22,600 km Date Odometer reading Change engine oil. (See Lubrication List, chapter 11) Check final drive oil level. Inspect air filter element. Check fasteners for proper tightening. Check steering column bearings. Check adjustment of wheel bearings.
- Page 93 SERVICE COUPON NO 12. 27,500 KM (To be performed between 27,400 to 27,600 km) Date Odometer reading Change engine oil. (See Lubrication List, chapter 11) Check final drive oil level. Inspect air filter element. Check fasteners for proper tightening. Check steering column bearings. Check adjustment of wheel bearings.
- Page 94 SERVICE COUPON NO. 13. 30,000 KM (To be performed between 29,900 to 30,100 km) Date Odometer reading Change engine oil and filter. (See Lubrication List, chapter 11) Change transmission oil. (See Lubrication List, chapter 11) Change final drive oil. (See Lubrication List, chapter 11) Inspect air filter element.
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Page 95: New Address Form
NEW ADDRESS FORM If you move, please fill out this form and mail to the address below. This will insure that you con- tinue to receive all correspondence from Irbit Motorworks of America. VEHICLE IDENTIFICATION NUMBER OWNER’S NAME _____________________________________________ OLD ADDRESS ______________________________ APT. NO. _______ CITY ________________ STATE ____________ ZIP CODE _________ MY NEW ADDRESS IS: NEW ADDRESS ____________________________ APT. -
Page 96: New Owner Form
NEW OWNER FORM If you purchase a Ural Motorcycle from somebody other than a dealer, please fill out this form and mail to the address below. This will insure that you receive all correspondence from Irbit Motor- works of America VEHICLE IDENTIFICATION NUMBER NEW OWNER’S NAME _____________________________________________ ADDRESS ______________________________ APT. -
Page 97: Ural Starting And Running Tips
URAL - STARTING & RUNNING TIPS Starting the Engine 1. Open carburetor enricheners on both carburetors (pull lever out) if temperature is below 50 degrees. 2. Make sure fuel petcock is open “ON” or prime “PRI” 3. Ignition “RUN,” “KILL,” switch set to “RUN” (down), gearbox in “NEUTRAL”. 4. - Page 98 Pre-Trip Check List 1. Check all lights and the horn for proper operation. 2. Check the brake and clutch levers and/or pedals. 3. Make sure all wheels and the final drive assemblies are securely fastened . 4. Check the carburetor flanges and air filter ducts for integrity and proper alignment. 5.
- Page 99 Here Are Some Helpful Publications To Help You With Your New Ural Learning to Ride The Ural With Sidecar Accessory Available through the Whitehorse Press www.whitehorsepress.com Weav’s Useful Information and Technical Guide to Antique Russian Motorcycles and Sidecars Available through Mike Weaver threeweavers@earthlink.net www.molotovmotors.com...
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