Irbit Motorcycle Factory Gear up 2005 Owner'S Manual Download

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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

IMPROPERLY

INFLATED

TIRES

HAZARDOUS

AND

WILL

ADVERSELY

AFFECT

TRACTION

STEERING

AND

HANDLING

. S

AME

ORIGINAL

EQUIPMENT

TIRES

MUST

USED

. O

THER

TIRES

MAY

NOT

FIT

CORRECTLY

AND

MAY

HAZARDOUS

USE

ECAUSE

TIRES

TUBES

AND

WHEELS

ARE

CRITICAL

SAFETY

ITEMS

AND

SERVICING

THESE

ITEMS

REQUIRES

SPECIAL

TOOLS

AND

SKILLS

RECOMMEND

YOU

SEE

YOUR

IMWA

DEALER

FOR

THESE

SERVICES

TIRE DATA

WARNING: F

YOUR

OWN

PERSONAL

SAFETY

TIRES

AND

TUBES

MUST

CORRECTLY

MATCHED

WHEEL

RIMS

. S

YOUR

AUTHORIZED

IMWA

DEALER

FOR

FURTHER

INFORMATION

. M

ISMATCHING

TIRES

TUBES

AND

RIMS

MAY

RESULT

DAMAGE

THE

TIRE

BEAD

DURING

MOUNTING

MAY

ALLOW

THE

TIRE

SLIP

THE

RIM

POSSIBLE

CAUSING

TIRE

FAILURE

. I

ADDITION

USING

TIRES

OTHER

THAN

THOSE

SPECIFIED

MAY

VERSELY

AFFECT

MOTORCYCLE

STABILITY

. P

ROTECTIVE

RUBBER

RIM

STRIPS

MUST

USED

. T

IRE

SIZES

ARE

MOLDED

THE

TIRE

SIDEWALL

. T

UBE

SIZES

ARE

PRINTED

THE

TUBE

Ural

tires that have been tested by the manufacturer to ensure compliance with DOT requirements

are available from your Authorized

IMWA

Dealer.

1.5 Bar 2.5 Bar

or 150 kPa or 250 kPa

Summary of Contents for Gear up 2005

Page 1: ...Irbit Motorcycle Factory Irbit Motorworks of America Owners Manual 2005 Model Gear Up Patrol Tourist Troyka ...

Page 2: ...2 ...

Page 3: ...ment maintenance 25 Chapter 3 Engine Operation EngineOperationandMaintenance 27 Pre TripPreliminaries 27 StartingtheEngine 27 OperatingPrecautions 31 Running IntheNewMotorcycle 32 Chapter 4 Engine Design Brief Descriptionof Design 33 LubricationSystem 34 FuelSystem 35 IgnitionSystem 37 Chapter 5 Carburetors Carburetors 39 Carburetor Maintenance 40 Chapter 6 Power Transmission PowerTransmission 41 ...

Page 4: ...aintenance 59 WiringDiagram 60 Chapter 12 Maintenance MaintenanceofMotorcycle 61 ListofRecommendedLubricants 61 LubricationChart 63 RequiredLubrication 64 Care of Motorcycle Paint 64 Preservation and Storage 65 Battery 65 List of IndividualTool Set Spare Parts Accessories Documents 66 Chapter 13 Gear Up Patrol Motorcycle With Engageable Sidecar Drive Patrol MotorcyclewithEngageableSidecarDrive 69 ...

Page 5: ...5 Chapter 15 Warranty Warranty 75 Chapter 16 Service Coupons Service Coupons 82 NewAddress Form 92 New Owner Form 93 URALStartingandRunningTips 94 ...

Page 6: ...6 ...

Page 7: ...tions 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 Sidecar It is critical that a beginning sidecar driver becomes thoroughly familiar with the special operating characteristics of sidecar outfits before venturing out on the busy roads Your Owner s Manual c...

Page 8: ...8 ...

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 the most powerful smoothly operating engine after break in Maintenance intervals recommended are based on operational experience under various climatic and road conditions However these intervals may b...

Page 10: ...10 ...

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 ratio 8 6 1 Rated horsepower 23 KW 45 BHp Rated rotational speed 5600RPM Rated torque 52 N M 3750 RPM Lubrication system Dual system of forced lubrication and splashing Lubricant SAE 20W 50 CARBURET...

Page 12: ...x 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 gasoline 5 Gal 19L 5 Gal 19L Reserve gasoline 5 Gal 2L 5 Gal 2L Engine oil 68 Oz 2L 68 Oz 2L Transmission oil 34 Oz 1 L 34 Oz 1 L Final drive gear oil 4 5 Oz 105 ml 3 5 Oz 135 ml Shock Absorbers shock oil...

Page 13: ...on 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 CLEARANCES mm in Valves with engine cold 0 05 to 0 1 0 002 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 0 004 FREE TRAVEL ADJUSTMENTS m...

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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 nuts 25 to 30 Nm 18 ft lb to 22 ft lb nut fastening the pinion bearing Patrol Gear Up rear axle only 68 to 90 Nm 50 ft lb to 66 ft lb nut fastening the pinion bearing 22 to 27 Nm 16 ft lb to 20 ft l...

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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 beam indicator lamp 7 Ignition cutoff switch 19 Ignition Switch 8 Electric Start Button 20 Battery discharge warning lamp 9 Rear brake pedal sidecar wheel brake 21 Parking brake 10 Reverse gear lever...

Page 18: ...D 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 release lever when shifting Serious internal damage may result to the transmission if the clutch release lever is not engaged Front brake control lever When the lever is squeezed the front wheel bra...

Page 19: ...Since 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 between the 1st and 2nd gears It is important to shift smoothly with a constant force and not to kick the gear shift pedal Serious damage may result to the shifting mechanism if the gear shift pedal is ki...

Page 20: ...rd 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 gear for reverse gear to be engaged Rear brake lever is used to actuate the rear brakes WARNING DO NOT APPLY EITHER BRAKE STRONGLY ENOUGH TO LOCK THE WHEELS BECAUSE THIS MAY CAUSE POSSIBLE LOSS OF CONT...

Page 21: ...ge 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 three fixed positions of the key The position and switching diagram of the ignition locks are shown above ...

Page 22: ...ndicator 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 Head lamp high beam indicator indicates that the headlight high beam is activated Speedometer is on the dash board with trip and total odometer The trip odometer is reset to zero by rotating knob Fi...

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

Page 24: ...Damper 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 THE DAMPER TO THE POINT WHERE THE STEERING BECOMES STIFF DOING SO WILL ADVERSELY AFFECT HANDLING QUALITIES AND MAY DAMAGE THE STEERING MECHANISM Parking brake is located on the right side of the mot...

Page 25: ...he 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 of the tie rods cables and braking action Refer to the Service Coupons for lubrication schedule As per the service coupons check the condition of the brakes clean the brake shoes and the active surfa...

Page 26: ...he 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 Apply speedometer lubricating oil or light machine oil at one end and allow it to seep through the length of the cable ...

Page 27: ...and 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 contaminate the oil STARTING THE ENGINE WARNING BEFORE STARTING THE ENGINE MAKE SURE THAT THE GEAR SHIFT MECHANISM IS IN THE NEUTRAL POSITION BETWEEN 1ST AND 2ND GEARS TO PREVENT ACCIDENTAL MOVEMENT WHICH ...

Page 28: ...ion 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 up the main volume of fuel engines starts stalling due to lack of fuel set the valve to the RES position and continue driving After refueling remember to set the valve back to ON to avoid running out ...

Page 29: ...ne 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: ...or 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 in neutral Make sure the Ignition Cutoff Switch is set to Ignition On and push the starter button to turn over the engine 2 When the engine has been standing for several hours but the ambient temper...

Page 31: ...THUS 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 cause abnormal wear of the parts and may lead to seizure of the piston pin and pistons in the cylinders since cold oil flows through the oil ducts with difficulty and fails to ensure sufficient lubr...

Page 32: ...IS 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 intermittent application of both brakes to slow the motorcycle Avoid continuous use of brakes to reduce overheating of the brakes and reduced efficiency While using the motorcycle in summer pay special a...

Page 33: ...f 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 During everyday preventive maintenance clean the engine of mud and dust paying special attention to the cooling fins as their fouling will impair the efficiency of the engine cooling Check engine crankca...

Page 34: ...oil 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 front cover Now screw in the plug Fill the engine with 68 oz oil or until the top mark of the dipstick is reached Let the engine run for 3 5 min Check the oil level again adding oil up to the top groove ...

Page 35: ...s 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 LEAVE AIR SPACE TO ALLOW FOR FUEL EXPANSION FUEL EXPANSION CAN CAUSE OVERFLOW THROUGH THE FILLER CAP VENT ONTO SURROUNDING AREAS AFTER REFUELING MAKE SURE FILLER CAP IS SECURELY TIGHTENED Fuel system...

Page 36: ...spark 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 cause erratic performance and poor fuel economy Spark plugs In certain situations spark plugs can quickly foul with carbon or soot The plugs can be cleaned but it is easier to put in a new set of plu...

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 LED should be on Stop turning the microprocessor unit when the LED turns off Tighten the fastening screws of the microprocessor unit and switch the ignition off ...

Page 38: ...38 This page left intentionally blank ...

Page 39: ...the 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 THROTTLE LINKAGE THIS AIR 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 PROCEEDIN...

Page 40: ... 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 fuel is provided to the carburetors and that there is no fuel starvation The carburetor to cylinder head adapters should be checked for leaks and cracks every trip Failure of the adapters will cause the carburetor fue...

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 as this will accelerate wear of the disks GEARBOX The reverse gear should be engaged from neutral or first gear when the bike has come to a stop Shifting the gears is best accomplished by pushing do...

Page 42: ...al 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 drive cover Change the final drive oil as determined by the service coupons Undo the filler and drain plugs and drain the used oil Fill the casing with fresh 20w 50 Castrol oil and flush the final drive...

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 Motorcycle stand 13 Foot brake pedal 14 Sidecar brake lever 16 Sidecar brake lever axle 17 Rear collet bracket 18 Rear bracket bolt 19 Lever pins 20 Lever 21 Brake tie rod 22 Brake drum cover 23 Sidecar w...

Page 44: ...ight 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 the spring in the sidecar wheel shock absorber simultaneously while adjusting the compression of the spring in the motorcycle shock absorbers Care of shock absorbers Fill the shock absorber with 105 c...

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 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 plumb bob and a ruler Adjust th...

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 makes turning of the front fork more difficult WARNING DO NOT OVER TIGHTEN THE STEERING DAMPER SINCE THE MOTORCYCLE WILL BECOME VERY DIFFICULT TO HANDLE ...

Page 47: ...ng 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 fork leg tube 18 spring and hydraulic shock absorber 19 Brake drum cover thrust link 20 Wheel lever 21 Moving ring 22 Fixed ring 23 Lower ball radial thrust bearing ...

Page 48: ...ering 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 HEAD E G TOO TIGHT WILL MAKE THE MOTORCYCLE VERY DIFFICULT TO STEER THIS ADJUSTMENT IS CRITICAL FOR PROPER HANDLING OF ALL MODELS ...

Page 49: ...eeing 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 together with the washer slacken off the nut on the union bolt of the left hand leg of the swinging arm pull out the rear wheel axle with the help of a wrench bar and removethewheel To reinstall the w...

Page 50: ...LS 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 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 IN ADDITION USING TIRES...

Page 51: ...DEWALL 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 Check axle and spokes for safe fastening be sure to tighten the spokes or fasteners and eliminate play as soon as they get loose or demonstrate excessive play While lubricating consult the Lubrication ...

Page 52: ...adjust 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 30 mm OD or a set of bushing of given size Determine if there is a play by turning the axle but not the wheel on the axle and rocking it slacken off the lock nut Screw the seal nut up to the limit the...

Page 53: ...shoes 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 wheel Then back off the adjustment 1 or 2 turns For checking the gap the cover of the brake drum and final drive crankcase are provided with an inspection hole closed with a rubber plug WARNING Never u...

Page 54: ...es 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 WARNING BECAUSE BRAKE PERFORMANCE IS A CRITICAL SAFETY ITEM WE RECOMMEND THAT YOU SEE YOUR IMWA DEALER FOR THESE SERVICES BRAKES MUST BE INSPECTED FOR WEAR AS PER THE SERVICE COUPONS IF THE BRAKE SHO...

Page 55: ...enuine Ural brake hoses failure to do so could result in front brake failure and voiding the warranty 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 thickness of the pads The pads should be replaced when less the 1 8 inch of pad is remaining on either pad The br...

Page 56: ...l 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 gasket Fill the reservoir to within 1 4 inch of the top Squeeze the brake lever several times to ensure that any air that has been introduced is forced out of the system Replace the rubber gasket the cove...

Page 57: ...lt 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 alternator on the studs the backlash adjustment of the gear mesh gap can be made Electric horn The motorcycle is equipped with a horn which sounds when the ignition is on and the horn button is press...

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 through a wire is interrupted due to a break in the wire or a poor connec tion then the circuit is said to be an open circuit The flow of electricity through a circuit always takes the path of least res...

Page 59: ...ories 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 ...

Page 60: ...60 ...

Page 61: ...ccurring 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 Single Wheel Final Drive 80 90 wt Gearlube 3 5 oz 105 ml Dual Wheel Final Drive 80 90 wt Gearlube 4 5 oz 135 ml 1 68 ozs is an approximate measure The exact oil quantity will be whatever is required to b...

Page 62: ...62 ...

Page 63: ...ar 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 Grease 11 Pins cams of brake shoes Grease 12 Wheel bearing Grease 13 Front forks Spindle oil WD 40 14 Carburetor throttle control twist grip Grease 15 Speedometer flexible drive cable speedometer axle Sp...

Page 64: ...flannel 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 waterproof abrasive cloth and water rub thoroughly paint using a soft brush or a spray gun After patching let the surface dry in air for 15 min then proceed with drying at 212 F 248 F 100 C 120 C with the...

Page 65: ...l 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 Considerations Motorists in many areas of the US experience the use of salt and other chemicals that are applied to road surfaces in the winter Salt or other caustic chemicals should always be removed from your...

Page 66: ...ROTECT 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 solution will be forced out through the vent tube when battery is charging This will not only weaken the solution but also may damage parts near the battery To prevent battery case damage caused by pres...

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

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Page 69: ...differently 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 surfaces with the sidecar drive engaged is extremely hazardous and can result in loss of control of the motorcycle It also voids the warranty The dual wheel drive should be engaged whenever poor tracti...

Page 70: ...ce 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 to be used for fuel or drinking water The ammunition box is not to be used for the storage of live ammunition NOTE Never leave the spotlight on when the motorcycle is not running A dead battery may r...

Page 71: ...fact 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 new Ural sidecar motorcycle outfit Before driving your new Ural carefully study this manual from cover to cover fill in the exam questions review the manual to check your answers and practice all the...

Page 72: ...e 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 comes back down Re peat doing this until you feel comfortable with the wheel in the air Remember the moment you roll off the throttle it will come down When you have mastered flying the chair to the p...

Page 73: ...n 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 reduce speed when poor driving conditions exist High speed increases the influence of any other condition affecting stability and the possibility of loss of control Pay strict attention to road surfac...

Page 74: ...ou 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 near schools and CAUTION signs at railroad crossings should always be observed and your actions governed accordingly Never anticipate a traffic light When a change is indicated from GO to STOP or vice ...

Page 75: ...stems that is found to be defective in material or workmanship under normal use for the applicable time period In cases when warranty repair takes longer than 14 days the warranty time period see Warranty Time Period is extended for the time period of repair during which the motorcycle could not been ridden due to failures IMWA Inc provides warranty for spare parts for the following period of time...

Page 76: ...ong an implied warranty lasts Some states may not allow exclusion or limitation of incidental or consequential damages These Warranties Do Not Cover 3 Failures or required services that are not due to a defect in material or factory workmanship 4 Parts or accessories affected or damaged by Lack of required maintenance Owner abuse Accident and or collision Misuse Normal wear Neglect Improper instal...

Page 77: ...very Fill out sign and send Warranty Registration and Card of Delivery to IMWA Inc within 3 business days of the sale of Motorcycle Accept all eligible motorcycles for warranty service regardless of selling Dealer Keep records of all warranty work Attend service schools as provided by IMWA Inc Submit warranty claims to IMWA Inc IN WRITING within 10 business days of the repair date Obtain authoriza...

Page 78: ...s or 30 000 kilometers 18 641 miles whichever first occurs If an emission related part on your motorcycle is defective the part will be repaired or replaced by IMWA This is your emission control system DEFECTS WARRANTY OWNER S WARRANTY RESPONSIBILITIES As the owner of Ural motorcycle you are responsible for the performance of the required maintenance listed in your owner s manual IMWA recommends t...

Page 79: ...l Protection Agency and the California Air Resources Board Any part or parts replaced under this warranty shall become the property of IMWA In the State of California only emission related warranted parts are specifically defined by the state s Emission Warranty Parts List These warranted parts are carburetors electronic valves air box air cleaner element spark plug ignition coil ignition control ...

Page 80: ...IDENTAL OR CONSEQUESTIAL DAMAGES SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU NO EXPRESS EMISSION CONTROL SYSTEM WARRANTY IS GIVEN BY IMWA EXCEPT AS SPECIFICALLY SET FORTH HEREIN ANY EMISSION CONTROL SYSTEM WARRANTY IMPLIED BY LAW INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE IS LIMITED TO THE EXPRESS EMISSION CONTROL SYSTEM WARRANTY TERMS STATED IN THIS WARRANTY T...

Page 81: ...aler receives a service bulletin or directive the Dealer is responsible for notifying affected customers These bulletins or directives 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 visible place in the Dealership s service department Dealer will ma...

Page 82: ...motorcycle 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 manufacturer s warranty PROVIDED that you sign the Service Coupon and date it after the work has been performed WARNING FOR YOUR PERSONAL WELFARE ALL THE LISTED SERVICE AND MAINTENANCE RECOMMENDA TIONS IN TH...

Page 83: ...tening 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 SERVICE COUPON NO 2 2 500 KM To be performed between 2 400 to 2 600 km Date Odometer reading km 1 Change engine oil and filter See Lubrication List chapter 11 2 Check final drive oil level 3 Inspect ai...

Page 84: ...f 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 proper tightening 12 Check brake fluid reservoir The maintenance above has been performed as described Owner s Signature Service Technician s Signature SERVICE COUPON NO 4 7 500 KM To be performed between...

Page 85: ...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 The toe in and camber angle of the motorcycle and sidecar F Electric wiring Tighten connections if required G Fasteners for proper tightening 11 Repack the grease in wheel bearings adjust the bearings 12 Lubricate A ...

Page 86: ...etween 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 carburetors while idling for synchronous operation 5 Check adjustment of steering column bearings 6 Lubricate A Lever pins B Hinges of the foot brake pedal shaft and linkage 7 Check condition and acti...

Page 87: ... 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 proper tightening 8 Adjust steering column bearings 9 Check battery electrolyte level and fluid level 10 Check air gap in electronic ignition between pickup and rotor 0 010 in The maintenance above has b...

Page 88: ...lumn 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 of the motorcycle and sidecar F Electric wiring Tighten connections if required G Fasteners for proper tightening 11 Repack the grease in wheel bearings adjust the bearings 12 Lubricate A Foot brake ...

Page 89: ...100 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 while idling for synchronous operation 5 Check A Adjustment of steering column bearings B Tension of wheel spokes C Toe in and camber of the motorcycle and sidecar 6 Lubricate A Lever pins B Foot br...

Page 90: ...engine 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 wheel bearings The maintenance above has been performed as described Owner s Signature Service Technician s Signature ...

Page 91: ...eration 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 The toe in and camber angle of the motorcycle and sidecar F Electric wiring Tighten connections if required G Fasteners for proper tightening 11 Repack the grease in wheel bearings adjust the bearings...

Page 92: ...UMBER OWNER SNAME_____________________________________________ OLDADDRESS ______________________________APT NO _______ CITY________________ STATE ____________ ZIP CODE _________ MY NEWADDRESS IS NEWADDRESS ____________________________APT NO ________ CITY_______________ STATE _____________ ZIPCODE _________ Send this form to Irbit Motorworks of America 15411 NE 95th St Redmond WA 98052 or fax to 42...

Page 93: ...ER NEWOWNER SNAME_____________________________________________ ADDRESS ______________________________APT NO _______ CITY ________________ STATE ____________ ZIP CODE _________ DATE OF SALE ________________ MO DAY YEAR PurchasedFrom___________________________________________________ City _____________________State ____________ Zip Code _______________ Send this form to Irbit Motorworks of America 1...

Page 94: ...ected 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 are corrected by blowing through fuel lines from carburetor end to remove any debris from lines Fuel petcock filter can be cleaned by removing and cleaning 3 Little or no spark is available to the engi...

Page 95: ...d 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 should be 10 15 mm in below the lower edge of the tank filler Do not overfill the tank See that the oil level in the engine crankcase is not higher than the top and not lower than the bottom marks on th...

Page 96: ...tors 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 Information and Technical Guide toAntique Russian Motorcycles and Sidecars ...

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Irbit Motorcycle Factory Gear up 2005, Owner'S Manual

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