Related Manuals for URAL Motorcycles 2003 Retro Solo
Summary of Contents for URAL Motorcycles 2003 Retro Solo
- Page 1 URAL Motorcycles Owner’s Manual 2003 Model Retro Solo Irbit Motorworks of America Inc. 15411 NE 95th St Redmond WA 98052 www.imz-ural.com...
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Page 3: Table Of Contents
Introduction ................................5 Warnings, Cautions, Notes ............................5 Chapter 1 Specifications Specifications ................................7 Torque Specifications ............................. 10 Conversions ................................10 Chapter 2 Motorcycle Controls & Instrumentation Motorcycle Controls & Instrumentation ........................11 Controls ................................12 Control Cable Adjustment ............................16 Control Cable Maintenance ........................... - Page 4 Chapter 7 Running Gear Running Gear ................................. 33 Spring-Loaded Hydrraulic Shock Absorber ......................33 Front Fork ................................34 Steering Head Bearings ............................34 Chapter 8 Wheel & Tires Wheels and Tires ..............................35 Tire Data ................................36 Wheel and Tire Maintenance ..........................37 Chapter 9 Brakes Brakes ..................................
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Page 5: 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 7: Specifications
Chapter 1 SPECIFICATIONS GENERAL Retro Maximum speed of motorcycle 120 km/h 74 mph Reference fuel consumption at 85% of 14 km/L 33 mpg Dry mass of motorcycle 680 lb. Maximum load-carrying capacity 400 lb. Noise level below 80db OVERALL DIMENSIONS Length 2500 mm / 8 ft Width... - Page 8 ELECTRICAL Ignition system 135.3734.COM-2 (CDI) Ignition coil 135.3705-2 Spark plugs NGK BP7H Ignition timing Automatic spark timer Alternator 35 amp / 12 Volt Battery Interstate #YB18L-A or equivalent Headlight Sylvania Halogen 6024, 7" round sealed beam TRANSMISSION Clutch Dry double-disk clutch Gearbox 4 speed gearbox with reverse gear lever GEAR RATIOS...
- Page 9 CLEARANCES Valves with engine cold 0.15 to 0.1 0.006 to 0.004 Between spark plug electrodes 1.016 0.040 Backlash between tooth faces of bevel gears in final drive 0.1 - 0.3 0.001 FREE TRAVEL / ADJUSTMENTS Hand brake control lever 5 - 8 0.2 - 0.3 Clutch control lever 5 - 8...
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Page 10: 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 11: Motorcycle Controls & Instrumentation
Chapter 2 MOTORCYCLE CONTROLS & INSTRUMENTATION 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 12 Clutch Control Lever Clutch Control Lever Front 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 connected. 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 13 Kick starter is designed to start the engine. On pressing the lever, the crankshaft of the engine is rotated via the gearbox. The lever is returned to its initial position by a spring inside the gearbox. Gear shift lever Kick Starter Reverse Gear Selector Gear shift Lever.
- Page 14 CAUSE POSSIBLE LOSS OF CONTROL OF THE MOTORCYCLE LWAYS USE BOTH BRAKES EVER STOP WITH FRONT OR REAR BRAKE ONLY Ignition Switch has three fixed positions of the key. The positions of the ignition are shown above. All electrical systems are off. Voltage is supplied to all electrical systems.
- Page 15 Engine Cutoff Switch Electric Start Switch Headlight Hi / Low Beam Switch Turn Signal Switch Horn Switch...
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Page 16: Control Cable Adjustment
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 17: 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 18 Prime Position Reserve Fuel Fuel On Position Position 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 running out of fuel, evaporation, or installation of replacement parts), set the valve to the “PRI”...
- Page 19 Enrichener off Enrichener on Manual Starting (without electric starter) 1. Turn on the ignition and depress the kick lever 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.
- Page 20 3. When the engine is cool or cold and the ambient temperature is between40°F-60°F/5°C- 15°C, engage both enricheners to start. As soon as the engine starts, immediately retract the enricheners. Run the engine at moderate speed for 30-60 seconds. If it starts to die, blip the twist grip throttle (rapidly twist part way towards full throttle and then back off) to keep the engine running.
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Page 21: Operating Precautions
OPERATING PRECAUTIONS WARNING: M ’ AKE SURE THAT SIDECAR WINDSHIELD IS IN THE FULL BACK POSITION SO IT DOESN INTERFERE WITH THE RIGHT HANDLEBAR To move the motorcycle from rest, shift to 1 gear only. Avoid releasing the clutch suddenly, because the engine is liable to stall or the motorcycle will start with a jerk. -
Page 23: Chapter 4 Engine Design
Chapter 4 ENGINE DESIGN The motorcycle is equipped with a two-cylinder four-stroke air-cooled engine. The opposed ar- rangement 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 24: 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 25: Fuel System
FUEL SYSTEM The fuel system includes the gasoline tank, the three position fuel valve with filter and two carburetors. Petcock Location Petcock 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 26: 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 29: 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 acti- vation 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 30: Carburetor Maintenance
CARBURETOR MAINTENANCE The carburetors will require the sediment 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 31: Power Transmission
Chapter 6 POWER TRANSMISSION The power transmission of the motorcycle is comprised of the clutch, gearbox, drive shaft and the final drive. CLUTCH The clutch transmits torque from the engine to the gearbox. Disengage the engine from the gear- box during shifting of the gears and during 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 32 Castrol oil and then refill the final drive with the specified lubricant. Reinsert the upper fill plug and wipe off any excess or spilled oil from the final drive. Filler Plug Universal Joint Splines Drain Plug Final Drive Assy Rear Universal Joint...
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Page 33: Running Gear
Chapter 7 RUNNING GEAR SPRING LOADED HYDRAULIC SHOCK ABSORBER The suspension features cam-type adjusters used for varying the pretension of the supporting springs to suit the load and the road condition. The degree of tension of the springs is adjustable allowing two positions.
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