Irbit Motorcycle Factory Gear Up 2003 Owner'S Manual Download Page 1

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Irbit Motorcycle Factory

Irbit Motorworks of America

Owners Manual

2003 Model

Gear Up, Patrol, Tourist

www.imz-ural.com

Summary of Contents for Gear Up 2003

Page 1: ...Irbit Motorcycle Factory Irbit Motorworks of America Owners Manual 2003 Model Gear Up Patrol Tourist www imz ural com...

Page 2: ...2...

Page 3: ...ent maintenance 25 Chapter 3 Engine Operation EngineOperationandMaintenance 27 Pre TripPreliminaries 27 StartingtheEngine 27 OperatingPrecautions 31 Running IntheNewMotorcycle 32 Chapter 4 Engine Desi...

Page 4: ...intenance 59 WiringDiagram 60 Chapter 12 Maintenance MaintenanceofMotorcycle 61 ListofRecommendedLubricants 61 LubricationChart 63 RequiredLubrication 64 Care of Motorcycle Paint 64 Preservation and S...

Page 5: ...5 Chapter 15 Warranty Warranty 75 Warranty Claim Form 81 Flat Rate Schedule 82 Chapter 16 Service Coupons Service Coupons 85 NewAddress Form 95 New Owner Form 96 URALStartingandRunningTips 97...

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Page 7: ...ions carefully for maximum motorcycle performance and for your personal motorcycling safety and pleasure Please pay particular attention to the section Learning to Ride the Ural Motorcycle with Sideca...

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Page 9: ...place During this period do not race overload or lug the engine Note the riding procedures described in the section Running In of New Motorcycle Following those procedures will ensure that you have th...

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Page 11: ...Clearance 125 mm 5 in Seat height 840 mm 33 in Wheel base 1470 mm 58 in ENGINE Type 4 stroke overhead valves opposed twin cylinder Displacement 745 cc Cylinder bore 78mm Piston stroke 78mm Compression...

Page 12: ...with reverse GEAR RATIOS I gear 3 6 II gear 2 28 III gear 1 56 IV gear 1 19 Reversegear 4 36 Speedometer drive ratio 0 4 Final drive ratio 4 62 FLUID CAPACITIES Patrol Gear Up Tourist Fuel tank gasol...

Page 13: ...n rear and sidecar wheels Tires 4 x 19 Front 22 psi cold 1 5 Bar 150 kPa Front 22 psi cold Side 22 psi cold 1 5 Bar 150 kPa Side 22 psi cold Rear 36 psi cold 2 5 Bar 250 kPa Rear 36 psi cold CLEARANCE...

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Page 15: ...to 35 Nm 22 ft lb to 26 ft lb final drive to swing arm bolts 16 to 19 Nm 12 ft lb to 14 ft lb oil pump bolt 6 7 to 11 Nm 5 ft lb to 8 ft lb enginesump 14 to 19 Nm 10 ft lb to 14 ft lb final drive case...

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Page 17: ...Neutral and reverse gear engagement 15 High low beam switch indicator lamp 16 Clutch control lever 5 Front brake control lever 17 Steering damper tightening bolt 6 Throttle control twist grip 18 High...

Page 18: ...WARNING BEFORE STARTING ENGINE ALWAYS SHIFT TRANSMISSION TO NEUTRAL TO PREVENT ACCIDENTAL MOVEMENT WHICH COULD CAUSE POSSIBLE DAMAGE TO MOTORCYCLE AND PERSONAL INJURY Caution Always engage the clutch...

Page 19: ...ince the heel toe shift lever is short coupled you will find it easier to shift into a higher gear if you do not use your heel to shift rather the ball of your foot The neutral position is fixed betwe...

Page 20: ...d surface Severe damage to drivetrain will result if the sidecar drive is engaged on pavement Reverse gear lever is used to move the motorcycle in reverse The transmission must be in neutral or 1st ge...

Page 21: ...e is supplied to running lights only Note Leaving the key in the Run or Parking position will discharge the battery Always return the key to the Off position before removing it Ignition Switch has thr...

Page 22: ...dicator lamp indicates that the charging system is malfunctioning and needs immediateattention Gearbox neutral and reverse gear engagement indicates that the gearbox is either in neutral or in reverse...

Page 23: ...23 Electric Start Button Ignition Cutoff Switch Low and High Beam Light Switch Turn Indicator Switch Horn Push Button...

Page 24: ...amper absorbs lateral kicks to the front wheel Turning tightening bolt clockwise in creases friction This can be used while riding over bad roads STEERING DAMPER ADJUSTMENT KNOB WARNING DO NOT TIGHTEN...

Page 25: ...e clutch cable for the carburetors lift of throttles to maximum and equal height CONTROL CABLE MAINTENANCE The daily preventative maintenance involves checking the functioning condition and fastening...

Page 26: ...e 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 s...

Page 27: ...nd not lower than the bottom marks on the dipstick with the filler plug undone See chapter 4 Lubrication System CAUTION When checking the engine oil level be careful that dirt and debris do not contam...

Page 28: ...on for regular use of the motorcycle When set to ON the valve is automatically activated when the engine starts and stops opening and shutting off the supply of fuel to the carburetors 4 After using u...

Page 29: ...e 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 enriche...

Page 30: ...r enricheners as with kick starting Unlike manual starting however the gearbox does not have to be in neutral as the electric starter may be engaged with the clutch lever pulled in or with the gearbox...

Page 31: ...HUS IT IS CRITI CAL TO IMMEDIATELY SHUT THE ENGINE DOWN IF IT APPEARS TO BE RUNNING ON ONLY ONE CYLINDER Additional Warnings Once the engine starts do not allow it to run at a high speed as this could...

Page 32: ...S ESPECIALLY TRUE IMMEDIATELY AFTER THE RAIN BEGINS AND THE OIL FROM THE ROAD SURFACE COMBINES WITH THE WATER When descending a long steep grade downshift and use engine compression together with inte...

Page 33: ...the engine power transmission units and the running gear mechanisms Under normal heating conditions of the engine the temperature of the cylinder heads should not be over 356 F 428 F 180 C 220 C Duri...

Page 34: ...il filter at the intervals shown in the service coupons Set the rubber sealing bush ing into the filter and fit the filter with the bushing onto the adapter of plug then screw the latter into the fron...

Page 35: ...running When the engine is stopped and looses vacuum the petcock automatically shuts off WARNING FILL FUEL TANK SLOWLY TO PREVENT FUEL SPILLAGE DO NOT OVERFILL ABOVE THE BOTTOM OF FILLER NECK INSERT...

Page 36: ...park plugs and operating in conjunction with the Hall Effect pickup Periodically check all wires in the ignition system to be sure they aren t crimped or have loose connections Loose connections will...

Page 37: ...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 Slowly turn the ignition unit clockwise the...

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Page 39: ...he carburetor flanges are in need of replacement use only genuine Ural replacement or Ural recommended parts WARNING TO AVOID SEVERE ENGINE DAMAGE DO NOT MODIFY CARBURETOR SYNCHRONIZATION JETS OR THRO...

Page 40: ...drains provided on the bottom of the float bowls The fuel filters should also be changed every 10 000 km or when they appear to be dirty or blocking fuel Changing the filters will ensure that clean fu...

Page 41: ...disengaged from the gearbox Use the clutch lever for starting from rest and for gear shifting Under conditions of heavy traffic when gears frequently have to be shifted do not slip the clutch too much...

Page 42: ...l final drive maintenance includes tightening the nuts which fasten the final drive to the swinging fork arm Failure to tighten the nuts may result in loose joints and the destruction of the final dri...

Page 43: ...fender 3 Rear fender strap 4 Spring and hydraulic shock absorber 5 Saddle 6 Saddle handle 7 Motorcycle frame 8 Leg adjusting fork 9 15 Sidecar frame legs 10 Colett clamp 11 Collet clamp screw 12 Motor...

Page 44: ...ght the driver s and one passenger s sitting in the sidecar weight the second upper position of the adjuster corresponds to the maximum load When the motorcycle is used under the maximum load adjust t...

Page 45: ...the motorcycle slacken off the bolt clamping the lower rear bracket adjust the position of the bracket relative to the rear tube of the sidecar frame to obtain necessary toe in of the wheels Tighten...

Page 46: ...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 Friction between the steel and the fiber washers ma...

Page 47: ...g 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 15 Front fender clip 16 Front fender 17 left for...

Page 48: ...ring 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 IMPROPER ADJUSTMENT OF THE STEERING H...

Page 49: ...eing to it that the brake disc evenly engages with the brake caliper To remove the rear wheel of the motorcycle lift the motorcycle onto the center stand Undo the rear wheel axle nut and take it off t...

Page 50: ...S WE RECOMMEND YOU SEE YOUR IMWA DEALER FOR THESE SERVICES TIRE DATA WARNING FOR YOUR OWN PERSONAL SAFETY TIRES AND TUBES MUST BE CORRECTLY MATCHED TO WHEEL RIMS SEE YOUR AUTHORIZED IMWA DEALER FOR FU...

Page 51: ...EWALL WARNING WHEN TIRES ARE WORN TO A TIRE CENTER TREAD DEPTHS OF 3 32 IN THEY SHOULD BE REPLACED WHEELAND TIRE MAINTENANCE During the pre trip inspection check air pressure in the tires chapter 1 Ch...

Page 52: ...djust the bearings proceed as follows Remove the wheel from the motorcycle Fit the rear wheel axle without protective cap tighten it by nut with the aid of a bushing 100 mm long with 21 mm ID and 25 3...

Page 53: ...hoes may be used for adjusting the gap between the brake shoes and the brake drum For optimal performance of the brake tighten the brake cable adjuster until there is just the slightest drag on the wh...

Page 54: ...s and drums This procedure will ensure maximum braking performance during the running in period and is essential before raising your top speed after your Ural has been carefully run in after 1 500 km...

Page 55: ...ads The pads should be replaced when less the 1 8 inch of pad is remaining on either pad The brake hose should be inspected periodically for leaks and cracks along the length of the hose as well as th...

Page 56: ...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 Remove the cover and the rubber gaske...

Page 57: ...t in rectifier is driven by the engine camshaft driven gear The alterna tor is secured with two studs on the engine crankcase At the drive side the alternator cover is so designed that by turning the...

Page 58: ...dangerous and can easily burn you Most problems in automotive electrical circuits are caused by poor connections Make sure that all connection points are clean and tight If the flow of electricity thr...

Page 59: ...ries 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 rela...

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Page 61: ...curring and or to removed any rust or oxidation LIST OF RECOMMENDED LUBRICANTS LubricationArea Detergent Oil Quantity Engine 20w 50 Castrol 68 oz 2 0 L 1 Transmission 20w 50 Castrol 34 oz 1 0 L 2 Sing...

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Page 63: ...r collet joint Spindle oil WD 40 7 Brake system hinge joints Spindle oil WD 40 8 Brake pedal shaft Grease 9 Drive shaft universal joint Grease 10 Lever pins end pieces of clutch hand brake cables Grea...

Page 64: ...lannel To repair painted areas each motorcycle is furnished with a bottle of matching touch up paint For patching proceed as follows clean the surface with turpentine rub the damaged spot with a water...

Page 65: ...grease Seal the outlet holes of the mufflers Before starting a trip on the motorcycle that was under preservation proceed with the jobs listed in the section Pre Trip Preliminaries Winter Considerati...

Page 66: ...OTECT EYES WITH SHIELD OR GOGGLES WHEN WORKING NEAR A BATTERY OR ACID KEEP BATTERIES AND ACID OUT OF THE REACH OF CHILDREN CAUTION If battery is filled to a higher level than specified some of the sol...

Page 67: ...67 15 Punch 1 16 Allen wrench 1 17 22mm Round wrench 1 Patrol only...

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Page 69: ...ifferently from the standard single wheel drive motorcycle When the rear wheel and sidecar wheel are locked together on paved surfaces maneuvering is very difficult Forcing the rig to turn on paved su...

Page 70: ...e 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 WARNING The canister is not...

Page 71: ...act that the Ural will not expose you to tipping over at stop signs which has happened all too frequently to beginners as well as experienced solo motorcycle drivers This manual is included with each...

Page 72: ...about 20 feet in diameter Gradually increase your speed until the sidecar wheel lifts from the surface 6 12 inches Then roll off the throttle and ease steering pressure on the grips so it gradually c...

Page 73: ...inexperienced rider we recommend that you obtain information and training in correct motorcycle riding technique Do not exceed the legal speed limit or drive too fast for existing conditions Always r...

Page 74: ...u have it Always signal when preparing to stop or turn All traffic signs including those used for the control of traffic at intersections should be obeyed promptly and to the letter SLOW DOWN signs ne...

Page 75: ...om the time of purchase of the parts by a Dealer or retail customer 1 Engine 12 months 2 Gearbox 12 months 3 Final drive 12 months 4 Alternator 6 months 5 Electric starter 6 months 6 Ignition 6 months...

Page 76: ...of each coupon Failure to adhere to this requirement will void the warranty 4 All personnel who operates the motorcycle must sign a statement that they have studied the Owner s Manual and have gone th...

Page 77: ...ilure to follow running in break in procedure 3 Replacement of expendable maintenance items beyond the first scheduled maintenance including but not limited to spark plugs filters lubricants complianc...

Page 78: ...te schedule Appendix B applied to the Dealer s approved shop hourly rate 1 Dealer will fax a warranty parts request to IMWA Inc on a Warranty Claim Form Appendix A for all warranty parts 2 Irbit Motor...

Page 79: ...eceipt of any motorcycle which may involve over 30 days of shop time including order and receipt time for parts service time and delivery time If Dealer fails to notify IMWA Inc in such a case Dealer...

Page 80: ...es should be given the highest possible priority Please make sure your staff is aware and insure they all understand the topics covered A copy of the bulletin or directive should be posted in a highly...

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Page 82: ...em disconnection connection to cylinder heads 0 4 1 11 Valve gap adjustment 2 cylinders 0 3 1 12 Clutch disassembly assembly engine removed 0 4 1 13 Air filter assembly removal mount 0 3 2 0 Gear box...

Page 83: ...Rear wheel removal mount 0 2 5 3 Wheel alignment and balancing 0 4 5 4 Wheel bearing adjustment 0 3 5 5 Tire removal mount on the rim 0 3 5 6 Brake adjustment per wheel 0 2 6 0 Sidecar 6 1 Sidecar re...

Page 84: ...Electrical 8 1 Wiring diagnosis for short circuit 0 6 8 2 Battery removal mount 0 4 8 3 Wire harness removal mount motorcycle 1 2 8 4 Wire harness removal mount sidecar 0 6 8 5 Alternator removal mou...

Page 85: ...otorcycle serviced regularly at the mileage indicated on the Service Coupons An owner who is qualified and capable of doing his or her own service work is allowed to do so without voiding the manufact...

Page 86: ...ening 8 Check steering column bearings 9 Check alternator bolts 10 Check brake fluid reservoir The maintenance above has been performed as described Owner s Signature Service Technician s Signature SE...

Page 87: ...clutch and brake control cables B Hinges of the foot brake pedal shaft and linkage 9 Check condition and action of brakes 10 Check tires for tread depth greater than 3 32 11 Check fasteners for prope...

Page 88: ...teering column bearings adjust if required C The condition and action of the brakes lubricate the brake shoe fulcrum pins and cams D The tension of wheel spokes Adjust if necessary E The toe in and ca...

Page 89: ...tween 14 900 to 15 100 km Date Odometer reading km 1 Change engine oil and filter See lubrication chapter 11 2 Change transmission oil See lubrication chapter 11 3 Inspect air filter element 4 Check c...

Page 90: ...and blow out 4 Check carburetors while idling for synchronous operation 5 Check final drive gear oil level See Lubrication List chapter 11 6 Lubricate foot brake pedal shaft 7 Check fasteners for prop...

Page 91: ...umn bearings adjust if required C The condition and action of the brakes lubricate the brake shoe fulcrum pins and cams D The tension of wheel spokes Adjust if necessary E The toe in and camber angle...

Page 92: ...00 km Date Odometer reading km 1 Change engine oil and filter See Lubrication List chapter 11 2 Change transmission oil See Lubrication List chapter 11 3 Inspect air filter element 4 Check carburetors...

Page 93: ...ngine oil See Lubrication List chapter 11 2 Check final drive oil level 3 Inspect air filter element 4 Check fasteners for proper tightening 5 Check steering column bearings 6 Check adjustment of whee...

Page 94: ...ration B Check steering column bearings adjust if required C The condition and action of the brakes lubricate the brake shoe fulcrum pins and cams D The tension of wheel spokes Adjust if necessary E T...

Page 95: ...MBER OWNER SNAME_____________________________________________ OLDADDRESS ______________________________APT NO _______ CITY________________ STATE ____________ ZIP CODE _________ MY NEWADDRESS IS NEWADD...

Page 96: ...R NEWOWNER SNAME_____________________________________________ ADDRESS ______________________________APT NO _______ CITY ________________ STATE ____________ ZIP CODE _________ DATE OF SALE ____________...

Page 97: ...cted by removing the spark plugs and drying them 2 Too little fuel is getting to the engine due to low fuel in tank and or plugged fuel lines or fuel petcock Correction Clogged fuel lines or filter ar...

Page 98: ...proper alignment 5 Check the tire tread depth should be greater than 1 8 inch 6 Check the sidecar attachment mounts all mounts should be securely tightened Gasoline level in the fully filled tank sho...

Page 99: ...ors com Here Are Some Helpful Publications To Help You With Your New Ural Learning to Ride The Ural With SidecarAccessory Available through the Whitehorse Press www whitehorsepress com Weav s Useful I...

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