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URAL Motorcycles 2000 -10 series, Repair Manual, Page: 4 / 193

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URAL Motorcycles 2000 -10 series Repair Manual Download Page 4

 

 

 

10.3  Substitute Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

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Chapter 11: Conversion Tables 

  

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Appendix

 

# 1 Wiring Schematics  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
# 2 Troubleshooting Guides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  

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Summary of Contents for 2000 -10 series

Page 1: ...Year 2000 Repair Manual ...

Page 2: ...ndshield and Fairing 62 Chapter 3 Sidecar 3 1 Description and General Specifications 65 3 2 Installation and Removal 66 3 3 Sidecar Alignment 67 3 4 Frame Attachment 69 3 5 Suspension 70 3 6 Sidecar body 71 3 7 Handling Differences Between Single Dual Wheel Drive 72 3 8 Driven Sidecar Wheel 73 3 9 Fender 77 3 10 Upholstery 77 Chapter 4 Engine 4 1 Description and General Specifications 78 4 2 Repai...

Page 3: ...Drive 138 7 3 Removing and Reinstalling Propellor Shaft 138 7 4 Removing and Reinstalling the Rear Swing Arm 139 7 5 Driveshaft and Universal Joint Repair 139 7 6 Final Drive Disassembly 141 7 7 Repairing the Final Drive 143 7 8 Final Drive with Driven Sidecar Wheel Sportsman 145 Chapter 8 Electrical 8 1 Description and Specifications 147 8 2 Maintenance and Troubleshooting 147 8 3 Battery 149 8 4...

Page 4: ...10 3 Substitute Parts 167 Chapter 11 Conversion Tables 168 Appendix 1 Wiring Schematics 2 Troubleshooting Guides 169 179 ...

Page 5: ...sembled parts have to be cleaned and thoroughly checked for the following Sliding and rolling surfaces for wear and freedom from scoring marks all metal parts particularly castings tempered parts and welded joints as well for cracks and corrosion and rubber parts for suitableness As a rule all gaskets and tab washers are to replaced upon reassembling When disassembling parts attention has to be pa...

Page 6: ...satisfy himself that neither his nor the operator s safety will be jeopardized by the service methods selected Wear eye protection while using any of these tools hammers arbor or hydraulic presses gear pullers spring compressors and slide hammers Be especially cautious when using pulling pressing or compressing equipment The forces involved can cause parts to fly out with considerable force and ca...

Page 7: ...1100 mm 3 ft 6 in 1060 mm 3 ft 8 in Road Clearance 125 mm 5 in Seat height 840 mm 33 in 810 mm 32 in Wheel base 1470 mm 55 in ENGINE Type 4 stroke overhead valves opposed twin cylinder Displacement 649 cc Cylinder bore 78 mm 3 07 in Piston stroke 68 mm 2 68 in Compression ratio 8 5 Rated horsepower 35 Rated rotational speed 5600 RPM Rated torque Nm 45 Nm 398 7 in pound Ignition system Contactless ...

Page 8: ...fting foot pedal GEAR RATIOS TOURIST SPORTSMAN UTILITY SOLO CRUISER I gear 3 6 3 6 II gear 2 28 2 28 III gear 1 7 1 7 IV gear 1 3 1 3 Reverse gear 4 2 N A on Solo 4 2 on 10 mdls Speedometer drive ratio 0 4 0 5 Final drive Pair of bevel gears with propeller shaft Final drive ratio 4 62 3 89 FLUID CAPACITIES TOURIST 10 Models Sportsman Solo Gasoline tank 19 L 5 Gal 19L 5 Gal 18 5 L 4 9 Gal Reserve 2...

Page 9: ...10 s Front side 25 psi cold Rear 36 psi cold CLEARANCES mm in Valves with engine cold 0 05 0 002 Between spark plug electrodes 0 50 0 65 0 020 0 026 Between brake shoes and drum 0 3 0 70 0 012 0 028 Backlash between tooth faces of bevel gears in final drive 0 1 0 3 0 004 Between rotor and ignition pickup 0 3 0 4 012 016 FREE TRAVEL ADJUSTMENTS mm in Hand brake control lever 5 8 0 2 0 3 Clutch cont...

Page 10: ...ing the pinion bearing 2 2 to 2 8 kgf m 16 ft lb to 20 ft lb reverse gear brake lever 1 8 to 2 0 kgf m 14 ft lb to 16 ft lb generator gear nut 14 0 to 16 8 kgf m 100 ft lb to 120 ft lb steering stem nut CONVERSIONS To convert from mm to in divide by 25 4 there are 25 4 mm per inch To convert from liters to gallons divide by 3 785 there are 3 78 liters per gallon To convert from liters to quarts mu...

Page 11: ...including documentation as follows Tools Set of Spares Wrench 7 x 8 mm Inner tube patch kit Wrench 10 x 12 mm Oil filter element Wrench 13 x 14 mm Kick starter pedal sleeve Wrench 14 x 17 mm Fuses Wrench 19 x 22 mm Socket wrench 10 x 12 mm Documents Socket wrench 10 x 13 mm Owner s Manual Socket wrench 19 x 21 mm Driving the URAL Sidecar Manual Wrench 27 mm except with Solo models Double head wren...

Page 12: ...iods of time in the maintenance cycle operation primarily with the sidecar accessory attached or for owners who want to take extra care to keep their machines in tip top condition The Light Duty schedule is the minimal maintenance that an owner should perform to keep the factory warranty in place It is acceptable when the machine is used primarily in ideal climates with very little dust or contami...

Page 13: ...system Spindle oil WD 40 Every 5 000 km 9 Brake pedal shaft Spindle oil WD 40 Every 2 500 km 10 Universal joint of propeller shaft grease cup Grease Every 10 000 km 11 Lever pins and end pieces of clutch and hand brake cables Clutch front brake and throttles control cables Grease Spindle oil WD 40 Every 5 000 km Every 5 000 km 12 Pins and cams of brake shoes Grease Every 5 000 km 13 Wheel hub Grea...

Page 14: ...Table 1 2 1 cont d Lubrication diagram ...

Page 15: ...t oil rated for air cooled engines This oil can be used in both the engine and transmission The Authorized URAL Dealer should be prepared to make recommendations for all lubricants best suited to local conditions For operation below 32º F SAE 10W 40 oil is recommended Tune up To help prolong the service life of the motorcycle it is essential to inspect the machine frequently and make repairs promp...

Page 16: ... sidecar motorcycles equipped with a reverse gear make sure that reverse is not engaged If ignition is switched on the green neutral light on the instrument panel should illuminate when the transmission is in neutral however the neutral light will also be on if the motorcycle is in reverse gear Check to be sure that the reverse lever is in the forward position or manually roll the motorcycle forwa...

Page 17: ...speed with the throttle control twist grip fully closed Start driving the motorcycle only after having warmed up the engine with the engine running steadily at low speed In cold seasons do not run the engine at high RPM during initial 3 km or drive at a speed exceeding 30 mph until the engine is fully warmed up If the engine doesn t start on the first kick kick it through aggressively four or five...

Page 18: ...ypically takes about 3 to 5 seconds to start the engine As soon as the engine starts push in both enricheners Then follow the running procedure described in Starting the Engine also in section 1 3 NOTE It is very important to back off on the enricheners as soon as the engine will sustain itself without sputtering The URAL can foul plugs quickly as soon as one minute if the engine is run too rich I...

Page 19: ... a sidecar motorcycle equipped with windshields carrying heavy loads or operating in hot weather WARNING When riding on wet roads or under rainy conditions braking efficiency is greatly reduced and caution should be used when applying the brakes accelerating and turning This is especially true immediately after the rain begins and the oil from the road surface combines with the water When descendi...

Page 20: ...level Transmission and final drive lubricants can be changed per the normal maintenance schedule summary The running in period for the motorcycle is divided into two stages up to 1 000 km and from 1 000 up to 2 500 km When running in keep the speeds within the limits stated in the following Table Even on a thoroughly run in motorcycle Ural advises not exceeding the listed maximum speeds Table 1 3 ...

Page 21: ...e for defects as well as repairing specific problems Inspection Look over the motorcycle carefully to see that all the equipment is complete especially frame fasteners wiring controls suspension and brakes Look for lubricant leakage from seals including engine transmission final drive wheel bearings and shock absorbers The following outline may serve as a guide A Frame no significant dents cracks ...

Page 22: ...ial is 0 120 inch 3 mm F Front fork no play in the steering head bearings no play of the leading link in the fork legs springs not broken or seized shock absorbers not leaking fluid acceptable condition of casings and guards NOTE The fork should rotate freely in the steering column without any noticeable play clicks or notching The tolerated play of the bottom tips of the fork legs should be withi...

Page 23: ...earing should not exceed 0 012 inch 0 3 mm Driveshaft propeller shaft runout is tolerated within 0 040 inch 1 mm K Exhaust system tightness of joints no major dents or damage no rust holes in mufflers L Sidecar no abnormal noises in body to frame joints rubber cushions supporting body intact no cracks major dents or rust through in sidecar frame swing arm fender or sidecar body sidecar to motorcyc...

Page 24: ...into 1st gear the motorcycle should not lurch forward As the clutch lever is smoothly released The motorcycle should begin to move ahead smoothly without lurching With the clutch fully released quickly roll on the throttle The motorcycle should immediately pick up speed without the clutch slipping The gearbox should shift smoothly without jumping out of any gear When stopping the brakes should app...

Page 25: ...e coasting distance is normal but the engine won t exceed 55 mph the engine needs at least a tune up and maybe repair Normal fuel consumption of a URAL on level pavement at 55 mph should be approximately 2 gallons 7 8 L per 100 km for the sidecar outfit and 1 5 gallons 6 L per 100 km for a solo machine Fuel mileage decreases as engine performance deteriorates Normal oil consumption should not exce...

Page 26: ...especially when motorcycle drags in travel with throttle valve lowered only partially Discontinue operation Repair the engine Engine crankcase at points of bearing location Dull low tone knocks Main bearings to crankshaft Warm Under load and once throttle valves are suddenly open Discontinue operation Repair the engine In the area of gears location Frequent clattering metallic rolling rattling inc...

Page 27: ... gear Variable Having adjusted clearance between gears by turning generator frame continue to run the motorcycle normally Front end of engine Frequent metallic clink Breather to front cover Warmed Idle running Operation can be continued Inspect breather having removed timing cover at first chance ...

Page 28: ... 6 mm Wipe and if need be clean the contacts using fine file C If there is no spark when checking as described above coil is faulty C Faulty ignition coil C Change faulty ignition coil D Break in low voltage wiring D Recover wiring E Ignition module defective E Replace Ignition module F No gap between rotor and moving coil pickup F Adjust gap equal to 0 2 0 3 mm G Contaminated contacts of plug con...

Page 29: ...ression 10 Valves not seating properly due to carbon deposit 10 Repair the engine decarbonize and grind in valves Engine Knocking 1 Knocks disappear once ignition is delayed 1 Advanced early ignition 1 Retime engine 2 An expert mechanic determines the cause by listening to the running engine 2 Piston pins pistons cylinders crankpins main bearings are worn 2 Repair the engine Engine fails to develo...

Page 30: ...mmed in cover seat Breather fouled with aluminum deposit and scoring of locating surface in cover seat Repair the engine Clutch slips 1 Clutch fails to engage fully due to misadjusted controls 1 Check whether clutch lever play is sufficient 1 Readjust controls by turning the adjusting screw so as to provide clutch lever tip play within 5 to 8 mm 2 Driven disks oily 2 Check when dismantling or insp...

Page 31: ...rbox Turn over the gear of reverse gear on bracket pin or replace starting gear Shifting of gears is difficult Seizing of gear shifting forks on shaft or in quadrant slots Repair the gearbox Inspect and replace worn parts if need be Noise in gearbox 1 Gear teeth worn out 1 Repair the gearbox Change worn out gears 2 Clutch or main shaft bearings worn 2 Ditto Change worn out bearings Gear noise in f...

Page 32: ...proper tension of all spokes Play of wheel on axle and wobble of wheel 1 Gland nut loose and out of position 1 Check by visual inspection 1 Drive the gland nut home then slacken by 1 8 of a revolution and safety it 2 Bushings or wheel roller bearings worn out 2 Make sure that the cause of trouble is not as described in p p 1 Without removing the wheel check for wobble 2 Repair the wheel Adjust tig...

Page 33: ...ction 2 After readjustment as instructed in p 1 brake shoes are slipping Brake shoe linings of rear wheel brake oily or soiled 2 Remove wheel wash brake shoes in gasoline and wipe dry If oiling persists check quantity and quality of oil in final drive and condition of seal 3 After readjustment as instructed in p 1m brake shoes are slipping Brake shoe linings worn 3 Using adjusting bolts readjust c...

Page 34: ... depressed Check that contacts are clean and tightened Check that wiring is intact especially wire terminals of light switch 1 No contact A on terminal of horn wire lug B on terminal of wires in plug and socket connector C on terminal in light turn key contact D on ground through switch body and handlebar If necessary clean contact surfaces of wire lug recondition wiring tighten up terminals 2 Bre...

Page 35: ... steadily Worn alternator brushes Replace brush assembly 2 Some internal fault of regulator 2 Replace voltage regulator assembly 3 Some internal fault of alternator 4 Check and replace alternator With motorcycle running pilot lamp is blinking Poor contact on terminals of alternator Clean and tighten wire lugs and terminals Direction indicators fail to light up although their switch is cut in Check...

Page 36: ...mponents assembly units it is important to carefully check critical dimensions which should fall within the values set by the factory as listed in Table 1 5 1 The maximum tolerated limits of wear and clearances between the principal wear parts of the engine are given in Table 1 5 2 These tables will help determine fitness of parts and components for further service Most URAL engine components such...

Page 37: ...with the help of a sponge a soft hair brush or a flannel rag and water but do not allow separate water drops to dry out on the surface Finally polish the painted surfaces with a dry soft flannel The painted surfaces of the motorcycle feature natural gloss If some dull spots appear remedy them by polishing as follows Take a well mixed solution of wax polishing compound and having washed the dull sp...

Page 38: ...per of pin within 0 0025 White 21 000 20 9975 Black 20 9975 20 9550 Red 20 9950 20 9925 Green 20 9925 20 9900 White 20 9930 20 9905 Black 20 9905 20 9880 Red 20 9880 20 9855 Green 20 9855 20 9830 0 0045 0 0045 0 0045 0 0045 0 0095 0 0095 0 0095 0 0095 Color index of group is marked on bore of one of pin end faces and on one of bosses inside the piston 6601238 01 Piston pin outer diameter 0 010 21 ...

Page 39: ...0 035 6601026 Crank mechanism assy size between cheek and journal 0 105 17 4 0 200 0 340 6601208 Cage width 17 0 17 6601233 Connecting rod width of big end 17 2 0 035 0 165 0 370 6601207 Cage 49 7 0 100 6601027 Connecting rod assy 0 018 50 0 300 0 418 6601203 Crankpin 0 010 40 0 006 6601208 Cage 0 17 42 1 990 2 176 6601201 Crank front journal 35 0 08 207 Ball bearing 0 003 35 0 015 0 020 0 083 0 0...

Page 40: ...9 14 0 016 0 052 Z101 01437 Rockshaft 0 030 15 0 055 Z101 01057 Left hand rocking arm 0 027 15 0 030 0 082 Z101 01437 Rockshaft 0 030 15 0 055 Z101 01058 Right hand rocking arm 0 027 15 0 030 0 082 6201507 Valve seat 0 110 38 2 0 060 Z101 01502 503 Cylinder head 0 050 38 0 210 0 310 6601524 Intake valve seat 0 110 41 2 0 060 Z101 1502 503 Cylinder head 0 050 41 0 0210 0 310 6201505 Valve guide 0 0...

Page 41: ...Crank Mechanism of subsection 2 Cylinder to piston 0 200 Measure piston in plane square to pin axis at point 5 mm from the piston lower edge Piston pin 0 015 Hole in piston to fit pin 0 020 Piston to piston pin 0 010 Connecting rod small end bush 0 025 Piston pin to connecting rod small end bush 0 030 Compression ring height 0 050 Piston groove to piston ring 0 150 by depth Piston groove to oil co...

Page 42: ...ame is coupled to the motorcycle frame by ball pins and collet clamps 10 and 17 and two adjustable frame legs 9 and 15 The sidecar frame is large diameter welded steel tubing and incorporates pads on the rear member for rubber body support cushions The sidecar swing arm is connected to its frame by rubber silent block bushings The swing arm is suspended by a spring loaded hydraulic shock absorber ...

Page 43: ...r 4 Spring loaded hydraulic shock 13 Brake pedal 23 Sidecar wheel axle absorber 14 Sidecar wheel brake lever 24 Protective hood 5 Seat Saddle or Tractor 15 Sidecar frame leg 25 Tie rod nut 6 Strap 16 Sidecar wheel brake rod 26 Sidecar fender 7 Motorcycle Frame 17 Rear collet clamp bracket 27 Rubber member of 8 Leg adjusting fork 18 Rear bracket fastening bolt body suspension 9 Sidecar frame leg 19...

Page 44: ...al 19 Ignition lock 9 Rear brake pedal and sidecar wheel brake 20 Alternator indicator light 10 Reverse gear lever 11 Kick start lever 21 Master battery switch under seat Not pictured The handle bar is mounted on the front fork through two brackets secured on the cross piece of the front fork The handle bar is adjustable in the brackets The carburetor throttle control twist grip 6 is linked to the...

Page 45: ...d through the accelerating gear The lever is returned to its initial position by the spring inside the gearbox The Gear shift foot pedal 12 Also see Fig 4 9 5 item 1 is a two arm type When the front arm is pressed shifting from high to lower gears takes place When the rear arm is pressed shifting from low to higher gears takes place Since the heel toe shift lever is short coupled you will find it ...

Page 46: ...he position and switching diagram of the ignition lock are given in Fig 2 2 2 Running position I Voltage is supplied to the ignition via the Cutoff Switch horn stop signal switches neutral pilot lamp turn indicator interrupter and head and tail lamps NOTE II position is not to be used for US import models due to DOT regulations but the switch should not be left in the II position which could disch...

Page 47: ...amper to the point where the steering becomes stiff Doing so will adversely affect handling qualities This is particularly critical for the Solo model Fork lock The motorcycle is provided with a fork lock with an individual key The lock is mounted on the left hand side of the head tube of the motorcycle frame Fig 2 2 3 To lock the motorcycle turn the handle bar fully to the right insert the key tu...

Page 48: ...sconnect front brake cable from brake drum cover unplug the electrical connectors undo the nuts fastening the handlebar brackets to the fork cross piece and remove the handlebar Reverse the sequence of the operations when reinstalling the handlebar CAUTION Do not attempt to over tighten any of the small screws fastening switches or levers to the handlebar The tightening torque of the handlebar bra...

Page 49: ... grip tube rotation set the cable tips into the twist grip slider and lubricate the points of the twist grip tube rotation set and screw up the upper half of the body secure the screw fastening the switch body set the cable tips into the twist grip slider reinstall the throttles and secure the covers adjust the twist grip rotation with an adjusting screw and lock it with a nut ...

Page 50: ...ssive play When inspecting the handlebar pay special attention to the brackets which fasten it to the fork cross piece and check the bracket end for cracks Replace the brackets if defects are revealed To remove the brackets from the tube unscrew the nut or the bolt fastening the handlebar tube to the brackets insert a wedge such as a screwdriver tip into the slot and spread the bracket slot to per...

Page 51: ...rk left tip and use a radius wrench to turn off the seal assembly pull the fork leg tip down from the fork leg tube together with the shock absorber and the spring drain oil from the fork leg tip remove the circlips fastening the lower bushing of the fork leg tube remove the lower bushing the upper bushing of the fork leg tube and the seal assembly slacken by two to three turns the nut of the clam...

Page 52: ...en the steel and the fiber washers makes turning of the front fork more difficult WARNING Over tightening the steering damper can make it very difficult to steer With the Solo model setting the steering damper too tight makes it very difficult to balance Over tightening the damper on the sidecar motorcycle may cause the operator to initiate sudden weaving at highway speeds Leading Link Fork The le...

Page 53: ...15 Union bolt 16 Steering column bridge 17 Friction washers 18 Spring 19 Collar 20 Seal collar 21 Seal spring 22 Supporting ring 23 Upper bushing 24 Fork leg tube 25 Fork leg tip 26 Pin 27 Damper body tube 28 Damper body cone 29 Damper fastening 30 Lower bushing 31 Lower guide of damper 32 Damper piston 33 Spring ring 34 Damper rod 35 Damper tube nut 36 Rubber seal 37 Moving washer 38 Bottom angul...

Page 54: ... bearing absorber 4 Nut of steering column 11 Tightening nut 19 Brake drum cover tie rod stem 12 Washer 5 Supporting washer 13 Leg housing with headlight 20 Wheel lever 6 Spring washer bracket 21 Moving washer 7 Clamping bolt 14 Steering column bridge 22 Steering column bridge 8 Steering column stem 15 Shock absorber 23 Lower radial thrust ball 16 Front fender bearing ...

Page 55: ...ube bushing upper 0 100 36 0 075 0 260 6308113 01 Fork leg tube bushing upper 42 0 100 630 007 Fork leg tip right hand 0 100 42 0 000 0 200 6608151 Steering column stem 0 145 28 0 100 6308155 Steering column bridge 0 045 28 0 055 0 145 6308155 Steering column bridge 0 15 34 0 010 72081 2 Radial thrust ball bearing 34 0 012 0 010 0 027 Table 2 3 2 Maximum Tolerated Limits of Clearances and Wear of ...

Page 56: ... protect paint lay bars on tank Unlock and slacken off nut 4 of the steering column stem remove tightening nuts 11 of the fork legs and remove cross piece 3 with the nut Tighten bearing nut 9 until snug release it 1 8 1 6 of revolution and check bearing clearance The front fork should rotate freely with no perceptible play Reinstall the cross piece in place tighten up the nuts including lock nut 4...

Page 57: ...he race as it cools When installing a new bearing race ensure that the bearing land in the frame is clean and free of burrs which could prevent true seating of the race Use a suitable puller to draw the bearing races into the steering head without distorting or damaging the parts To reinstall the front fork reverse the sequence of the operations When reassembling the fork in the steering column pa...

Page 58: ... wheels are interchangeable NOTE When removing brake shoes make sure that they are replaced in the exact position they came from If installed upside down the brake may not work Figure 2 5 1 Front Wheel Brake 1 Top brake lever 9 Brake lever spring 2 Inspection hole plug 10 Adjusting screw 3 Brake shoe 11 Tie rod 4 Adjusting bolt locknut 12 Locknut 5 Adjusting bolt 13 Tie rod fork 6 Brake shoe sprin...

Page 59: ...ubbing on the brake drum will overheat and cause rapid wear of the linings Tight shoes may even expand sufficiently to seize the drum However if the gap is too large the brake cannot be applied with full force Brake shoe gap can be measured through inspection holes in the cover of the brake drums and final drive case Inspection holes are closed with rubber plugs Brake Adjustment Note The front bra...

Page 60: ...al before raising your top speed after your URAL has been carefully run in after 2 500 km WARNING Because brake performance is a critical safety item we recommend brakes be inspected and adjusted at every service interval Brakes must be inspected for wear every 2 500 5 000 km If the brake shoe friction material is 1 16 in thick or less the thickness of a nickel the shoes must be replaced If the mo...

Page 61: ...used as a drive wheel The aluminum hub contains a brake drum and connects to the steel rim via heavy gauge spokes of equal length Individual spokes can be replaced if damaged Wheel bearings are installed in each wheel Figure 2 6 1 Motorcycle Wheel 1 Tire 2 Tire flap 3 Spokes 4 Brake drum 5 Roller bearings 6 Thrust washer 7 Right hand distance bushing 8 Intermediate bushing 9 Left hand distance bus...

Page 62: ...s are adjusted as follows 1 Remove the wheel from the motorcycle 2 Fit the rear wheel axle less the protective hood tighten it by nut with the aid of a bushing 100 mm long with 21 mm bore and 25 30 mm O D or any spacers which will allow the axle nut to snug up the bearings 3 Determine whether there is play by turning the axle but not the wheel on the axle and rocking it in the hub 4 Slacken off th...

Page 63: ...ront and rear motorcycle axles should be tightened to correct torque on installation Correct axle torque is 55 foot pounds 75 Nm Checking Wheel Condition Having removed the wheel and prior to repairs check wear of tires and possible damage cracks and dents of the wheel rim wear on the brake drum surface wear in the wheel bearings and spacers radial and side runout of the rim and tire presence and ...

Page 64: ...repair To remount the tire and the inner tube proceed as follows 1 Check that no spoke nipples protrude inside rim If spoke ends protrude beyond the head of the nipple the spoke should be ground flush with a grinder or file 2 Fit on the rim flap to protect the inner tube from being punctured by spokes or spoke nipples Position the hole in the rim flap to coincide with the valve stem hole in the ri...

Page 65: ...sen locknut undo the seal nut and remove the left hand distance bushing 2 Insert the mandrel on the wheel axle on the splined hub side and press out the end roller bearing intermediate bushing second roller bearing cone and right hand distance bushing 3 Using mandrel 345 324 3 press out the thrust washer and the roller bearing cup Wash and inspect the dismantled parts Change any defective parts Re...

Page 66: ...the hub the wheel rim is cracked dented or bent beyond repair Before proceeding to replace either the hub or the wheel rim compare the cost of a new wheel against the probable labor required to respoke and true the wheel plus replacement parts There are shops that specialize in respoking and truing wheels Shock Absorbers and Springs Suspension except for front tubular forks is by hydraulic shock a...

Page 67: ...d valve nut 26 Rod guide 5 Buffer 16 Rebound valve spring 27 Seal spring 6 Barrel nut 17 Rebound valve retainer 28 Container nut seal 7 Shock absorber body 18 Rebound valve plate 29 Seal holder 8 Working cylinder 19 Rebound valve throttle plate 30 Seal washer 9 Rod 20 Intake valve plate 31 Rubber seal of rod 10 Check ring 21 Bypass valve spring 32 Felt seal of rod 11 Moving cam 22 Bypass valve ret...

Page 68: ...rse order but without pressing the latch 2 9 Windshield and Fairing Different URAL models may be equipped with windshields or handlebar fairings of various design Semi Fairing When assembling the URAL Semi Fairing loosely connect the metal parts then attach the Slipstreamer windshield and gradually snug up the fasteners Do not overtighten fasteners attaching the plastic windshield which could caus...

Page 69: ...on slot 1 over location 1 3 A rubber washer has been provided if necessary to prevent contact between the chrome hardware and painted fork covers 4 Replace the bolt into location 1 one on each side of the headlight do NOT tighten completely at this time 5 Connect one end of the bracket link to slot 2 and the other side of the bracket link to location 2 which is the turn signal mount 6 Tighten all ...

Page 70: ...cover 4 Spring loaded hydraulic shock 13 Brake pedal 23 Sidecar wheel axle absorber 14 Sidecar wheel brake lever 24 Protective hood 5 Bench Seat 15 Sidecar frame legs 25 Tie rod nut 6 Strap 16 Sidecar wheel brake rod 26 Sidecar wheel nut 7 Motorcycle frame 17 Rear collet clamp bracket fender 8 Leg adjusting fork 18 Rear bracket fastening bolt 27 Rubber member of 9 Sidecar frame legs 19 Lever pins ...

Page 71: ...mposed of two vertical chromed steel tubes connected by a steel cross piece and a clear plastic windshield The windshield is held in position by a vinyl apron attached to the body clips via straps The windshield is tilted forward to aid in passenger entry and tilted back for operation A tonneau cover is supplied to enclose the passenger area Normally the tonneau cover is attached under the windshi...

Page 72: ... pins of the motorcycle frame 4 Unscrew the bolt and push the front clamping jaws out of the socket far enough to allow them to spread over the ball pin 5 Raise the front end of the sidecar frame to fit the clamping arms on the front ball pin and tighten the bolt loosely 6 Attach the rear clamp in a similar manner If the rear clamp doesn t center on the ball support the rear of the sidecar loosen ...

Page 73: ...ar to the straight edge and to keep both straight edges in contact with the tires Recommended toe in is 3 8 inch 10 mm That is toe in is correct when spacing between the two straight edges at the front axle is 3 8 inch 10 mm less than that at the rear axle Toe in is adjusted by easing off the fastening bolt holding the lower rear clamping bracket in the sidecar frame and sliding the clamping brack...

Page 74: ...pecifications snug up all connectors then recheck toe in Fine tuning of leanout is accomplished by road testing the motorcycle Tighten all bolts securely Tightening torques are collet clamping bolts 25 ft lb 40 Nm sidecar tie rods 33 ft lb 4 Nm Road Testing The true test of toe in and lean out adjustment is a road test preferably on a smooth straight level paved road with typical camber slanting o...

Page 75: ...the ball pins welded to the motorcycle frame A cotter pin prevents the jaws from rotating as the bolt is screwed in or out NOTE The OEM bolt has a comparatively small head diameter which tends to round off and dimple in the end of the clamp tube Metric bolts with a standard head diameter are available at hardware outlets in the thread diameter length and pitch suitable for this use When replacing ...

Page 76: ...ng brake drum Reinstall the swing arm in reverse sequence with the shock absorber and brake housing attached Do not tighten up the bolts at the pivot brackets until the wheel has been reinstalled and the swing arm is in position to support the sidecar again CAUTION It is necessary to compress the shock spring slightly to enable the swing arm to be pulled into position for attachment Use care to av...

Page 77: ...ift off the body complete with seat and windshield The steel sidecar body can be repaired and painted by standard automotive body shop practices The trunk lid pivots on heavy gauge steel straps with a riveted hinge Check that the hinge is not fractured The strap can be removed and repaired by welding then repainted Whenever the strap hinges are removed the straps and body metal under the strap sho...

Page 78: ...hus it is not recommended that the Sportsman sidecar wheel ever be lifted for more than a few seconds during normal operation Lifting of the Sidecar wheel should be limited to low speed training in a parking lot with extreme care taken to reduce engine speed as soon as the sidecar wheel is lifted WARNING OPERATORS SHOULD ALSO BE ADVISED NOT TO ATTEMPT SLIDING TURNS IN EITHER DIRECTION WITH THE SPO...

Page 79: ...joints The final drive incorporates an asymmetrical differential that supplies approximately 70 of the torque to the motorcycle rear wheel and 30 of the torque to the sidecar wheel Figure 3 8 1 Main Drive Ä Sportsman Model 1 Gear case 11 Sun gear 21 Retainer 31 Roller 2 Differential body 12 Main drive case cover 22 Driving gear 32 Needle roller 3 Epicycle gear 13 Rear wheel axle 23 Seal 33 Spacer ...

Page 80: ... Sportsman Model 1 Swinging arm 6 Ball bearing 11 Bolt 2 Braking drum cover 7 Protective ring 12 Shock absorber silent block 3 Slotted hub 8 Spacer 13 Propeller shaft 4 Sidecar pin 9 Ring 14 Universal joint 5 Ball bearing 10 Spacer ring ...

Page 81: ... of the sidecar drive shaft After the first 2 500 kilometers change the oil in the final drive gear case Check the oil level every 2 500 kilometers Oil level must not be lower than the oil gauge tip Grease the movable slot joint of the propeller shaft sufficiently every 5 000 kilometers Do not over grease the slotted hub of the propeller shaft which could hydraulically limit movement of the slotte...

Page 82: ...gear flange with seal and ball bearing must be installed The bronze ring should be positioned onto the sun gear neck next after the steel ring After putting the main drive together check and adjust the side play of the conical gears by tightening or loosening the nut in the case cover When side play of 01 to 0 3mm is achieved fix the nut with the retainer Overhaul of the sidecar wheel shaft bearin...

Page 83: ...jelly can be used on electrical contacts to control rust 3 10 Upholstery The sidecar seat components are a plywood base covered by springs cotton batting and a vinyl type fabric that is folded over and secured to the base The seat and back are removable When installing the seat place the seat back in position first holding it up in position so that the metal straps on the back are behind the bulkh...

Page 84: ...cal in design and interchangeable A gasket is fitted between the cylinder and the crankcase to control oil seepage Pistons have three milled grooves for the piston rings which have straight locks The piston is coupled to the connecting rod by means of a floating piston pin with circlips The engine crankshaft is a pressed assembly made up of two crank portions with counterweights and pressed in cra...

Page 85: ...her 26 Sump 5 Rear journal of crankshaft 16 Seal 27 Drain hole plug 6 Starter Generator 17 Breather tenon 28 Oil trap 7 Crankshaft cheek 18 Front ball bearing housing 29 Seal 8 Front journal of crankshaft 19 Ball bearing 30 Ball bearing 9 Generator gasket 20 Timing pinion 31 Flywheel fastening bolt 10 Camshaft bearing 21 Oil trap 32 Crank pin 11 Generator gear 22 Oil filter 33 Roller bearing 34 Re...

Page 86: ...h rod 20 Gasket 34 Crankshaft cheek 7 Push rod tube 21 Ignition plug 35 Oil trap 8 Cylinder 22 Duct for oil out of cylinder head 36 Cylinder fastening nut 9 Piston 23 Gasket 37 Carburetor 10 Cylinder head 24 Oil drain tube of cylinder 38 Spark plug tip 11 Valve 25 Compression rings 39 H V wire 12 Valve spring 26 Piston pin 40 Filler plug with dipstick 13 Adjusting bolt 27 Oil rings 41 Oil pump dri...

Page 87: ...oil flow into rear in cylinder head bearing housing 19 Tube for lubrication of timing gears 7 Crankcase sump 20 Oil duct for lubrication of friction parts 8 Oil duct to oil filter in cylinder head 9 By pass valve 21 Inner cavity of push rod tube for oil flow 10 Oil filter 22 Oil drain duct out of cylinder head 11 Main oil line 23 Filler plug with dipstick 12 Piston oil rings 24 Oil pump gear 13 Ho...

Page 88: ...vice life The crankcase serves as the oil reservoir for the engine The single stage oil gear pump 24 is driven from the camshaft through a gear and connecting bar 2 Oil is primed into the engine crankcase through the hole in the left hand side of the engine block normally capped with the dipstick 23 The dipstick has two grooves showing the upper and lower oil level limits Oil level is checked with...

Page 89: ...the bolt fastening the speedometer drive bushing remove the drive and shift it aside then reinstall the bolt 10 Disconnect the wire from the neutral switch 11 Slacken off the engine upper fastening nuts and those of the stand bracket remove the bracket and the engine fastening plate 12 Slacken off the nuts of the engine lower fastening studs 13 Remove the spring of the rear brake lever 14 Place a ...

Page 90: ...re 4 3 1 Engine Valve Timing Gear 1 Push rod 13 Lower retainer 2 Push rod housing 14 Outer valve spring 3 Hose 15 Inner valve spring 4 Breather pipe 16 Upper retainer 5 Camshaft gear 17 Valve block 6 Breather tenon 18 Rocker arm 7 Breather 19 Adjusting bolt 8 Seal 20 Adjusting bolt locknut 9 Camshaft 21 Rockshaft 10 Exhaust valve 22 Intake valve 11 Valve guide 23 Tappet guide 12 Exhaust branch 24 ...

Page 91: ...nce with a feeler gauge Lock the adjusting bolt with the locknut 20 and check the clearance again In the course of running in check after 500 km and as required but at least once every 2 500 km Readjust clearances on the cold engine only The following symptoms indicate valve problems loss of compression in the cylinder drop in engine power increase in fuel consumption difficulties in starting the ...

Page 92: ...quired tools and fixtures are Tool 345 553 for removing valve springs Indicator with stand Inside caliper with 8 mm indicator head Micrometer from 0 to 25 mm Mandrel 345 047 3 for pressing in and out the valve guide bushing Reamer 055 150 3 8 mm diameter for reaming the valve guide bushing Gauge 403 747 for checking straightness of hole in valve guide bushing Puller with set of tools 345 326 3 345...

Page 93: ...ength of spring in free state mm 6201419 01 outer valve spring 4 43 Resilience of spring When compressed to 34 mm P 145 168 N 14 8 17 2 kgf When compressed to 35 75 mm P 296 343 N 12 15 25 85 kgf 6201420 01 valve spring inner 3 39 Resilience of spring When compressed to 30 5 mm P 96 5 111 N 14 8 17 2 kgf When compressed to 35 75 mm P 296 343 N 12 15 25 85 kgf Remember that the compression power an...

Page 94: ...e ready to install the new guide heat the head to 390 F 200 C Place the cold valve guide on the mandrel 345 047 3 and quickly press the guide in place Deck height of the valve guide should be 20 mm measured from spring washer land on head to top of guide without spring washer in place Guide should be enough of a press fit in the head casting that the guide does not fall out even when the head is h...

Page 95: ...o the intake and exhaust ducts of the cylinder head There should be no detectable seepage of kerosene for at least one minute If necessary the valves can be lapped to achieve a tighter seal Lapping in the valve to cylinder head seat Fit a spring around the valve stem between the valve head and guide to help lift the valve off the seat approximately 3 to 6 mm 1 Coat the valve head face with a thin ...

Page 96: ...er shaft off the support brackets Clean the parts inspect and take necessary measurements Visually inspect the rockshaft rocker arms support brackets and spring washers for cracks dents or scores Check that the valve stem contact area of the rocker arm is not worn flat If there is any detectable play in the rocker assemblies measure wear of rockshaft and the bores of the rocking arms If the wear o...

Page 97: ...gine to TDC so the pushrods are not attempting to compress the valves Ensure that there is clearance between the rocker arms and valves before torquing the head If there is no push rod clearance check that the push rod is in place in the tappet cap turn the adjusting bolt in further and ensure that the crankshaft is at TDC with the tappet completely lowered If the camshaft has been serviced check ...

Page 98: ... with the lock nut rotate the engine through at least one revolution and confirm correct clearance Before installing the valve cover in place lubricate the rockshaft through the central oil holes in the shaft Fig 4 3 7 Adjustment of Expansion Clearance ...

Page 99: ...ect for scores on the cylinder bore NOTE If there is visible damage to the cylinder bore such as deep scores obvious ring ridge or warpage consider replacing the entire cylinder piston assembly If the cylinder appears to be serviceable measure the bore with the inside caliper at several different angles and depths For example three different depths measured both in line with the piston pin and at ...

Page 100: ... should be replaced If leaks from the oil drain tube or push rod tubes are evident clean the parts with degreaser and reseal with high temperature wicking sealant gasket shellac or locktite Removing and Reinstalling the Piston and Piston Rings cylinder removed Required tools piston pin remover tool 345 439 3 piston ring remover tool 346 066 3 mandrel tool 346 035 and tapered tip for mounting the w...

Page 101: ...ustion chamber walls get fouled with carbon the engine loses power while the consumption of fuel rises If reported oil consumption is greater than 1 pint per 500 miles 250 g per 100 km and compression increases with added oil it indicates a problem with piston ring bore fit Check wear of the cylinder play of the piston rings in the piston grooves deposits of carbon and sticky residue in the piston...

Page 102: ... 04 to 0 08 mm oil rings 0 001 to 0 003 inch 0 025 to 0 065 mm If the actual clearance exceeds the top limit given above by 0 001 inch 0 03 mm try the fit of a different new piston ring If with a new ring fitted on the clearance is still in excess of the upper limit replace both the piston and rings NOTE Whenever a cylinder is removed from a motorcycle with more than 20 000 km operation it is advi...

Page 103: ...y the color marking on the inside surface of the pin at one end to match the marking on the holes of the piston bosses and the connecting rod small end bushing Intermixing of piston pins and connecting rods from adjacent size groups is not recommended Reassemble the piston and piston rings in the following sequence 1 Have mandrel tool 346 035 available 2 Lubricate the piston pin with oil 3 Heat th...

Page 104: ...he cylinder turn the piston rings on the piston so that the ring gaps are not aligned and lubricate the cylinder face with motor oil When mounting the left hand cylinder see that the holes in the gasket are in line with the oil holes in the crankcase When mounting the cylinder on the piston use clamping ring tool 345 037 to compress the piston rings in place Fig 4 4 4 NOTE Make sure that the seali...

Page 105: ... gearing To measure timing gear backlash 1 Set up the backlash indicator 450 182 and fasten it on the upper right hand threaded hole Measure the clearance between the gearing teeth then remove the tool Fig 4 5 2 2 Set up the end play indicator 450 212 and fasten it on the right hand threaded hole Measure the end play then remove the tool Fig 4 5 3 Timing gear backlash in a new engine should be wit...

Page 106: ... on the intake lobe then rotate the tool to push the camshaft out Having removed the shaft wash the parts inspect and make necessary measurements The required tools are micrometers capable of measuring 0 to 1 inch 0 to 25 mm and 1 to 2 inch 25 to 50 mm Check the condition of the ball bearing at the camshaft front end lubricate the bearing with engine oil and carefully turn it by hand If there is a...

Page 107: ...ces of the tappets for wear or pitting and check for cracks in the points where the tips are pressed in Observe the inner spherical surface which contacts the sphere of the push rod Replace damaged or worn tappets The clearance between the tappet and guide should be within 0 10 mm 004 in In case of excessive clearance change the tappet or guide to restore correct clearance Reinstall the tappets in...

Page 108: ...nt cover 3 Disconnect all the wiring from the ignition coil terminals and remove the ignition coil remove two screws 4 Remove the distributor cover undo the screw fastening the automatic advance timer and remove the timer together with the distributor cam 5 Take out the high voltage wires together with the rubber bushings 6 Turn off the screws fastening the cover and remove the latter by knocking ...

Page 109: ...ump the gearing should rotate easily without seizing If there is any evidence of seizing disassemble the pump inspect the parts carefully and replace any substandard parts If facilities are available check pump performance using a light oil spindle oil grade B3 At a speed of 670 RPM the oil pump should develop a pressure of at least 56 psi 0 4 Pa or 4 kgf cm2 at a volume of 35 to 44 gallons per mi...

Page 110: ...e checking procedure 1 Close all oil holes in the engine block with rubber plugs including the holes through which oil is fed to the left hand cylinder to the housings of front and rear bearings and to the hole in the duct on the pump fastening plane Attach a hose to feed water under pressure to the system 2 Inspect all the oil lines checking them for leaks of water 3 If leakage is revealed drain ...

Page 111: ...urning in the central screw of the remover remove the flywheel from the crankshaft tapered end Fig 4 7 1 6 Take off the remover 7 Having dismantled the flywheel wash and inspect the parts if necessary replace worn out parts To reinstall the flywheel 1 Fit the flywheel on the tapered end of the crankshaft make sure that the rubber seal is correctly fitted on the flywheel hub and that the key coinci...

Page 112: ... 1 Abnormal rattling squeaking or knocking in the main bearings or connecting rod big ends 2 Bent connecting rods or excessively worn small end bushings 3 Obvious play in rod lower ends Removing and Reinstalling the Crankshaft Engine out of frame transmission clutch flywheel camshaft cylinders pistons and oil pump removed Required tools are Puller 345 339 3 for removing the timing drive gear and p...

Page 113: ... catchers Inspect all parts visually and make necessary measurements Dimensions of parts and tolerated wear limits are listed in Table 4 8 1 Parts worn beyond the limits or out of tolerance should be either repaired or replaced Crankshaft Inspection and Repair Required tools and fixtures are inside calipers with measuring range of 1 5 inch 32 mm and 2 5 inch 55 mm mandrel 345 333 3 for pressing of...

Page 114: ...nd mated pairs of parts Wear on diameter Out of round and taper Diameter clearance Measuring point and method Crankpin to rollers to connecting rod big end 0 100 Crankpin 0 050 Connecting rod big end 0 050 Cylinder face 0 150 Out of round 0 070 In five points Cylinder to piston 0 200 Measure piston in plane square to pin axis to pin axis at point 5 mm from the piston lower edge Piston pin 0 015 Ho...

Page 115: ...bushing Measure the radial play in the connecting rod big end using a dial indicator by resting the feeler pin on the big end in the centers Fig 4 8 3 The radial play must be within 004 inch 0 10 mm Measure the axial side play between the crankshaft cheeks and the connecting rod big end using a feeler gage Axial play must be within 008 to 013 inch 0 20 to 0 34 mm Fig 4 8 4 Measure the runout of cr...

Page 116: ...4 into the connecting rod small ends choose the mandrel color to match that of the small end holes Measurements should be taken in two positions of the crankshaft Fig 4 8 6 a and b The difference in measurements should not exceed 0 5 mm 0 2 in If otherwise straighten out the crankshaft by carefully knocking with a copper hammer against the respective sides of the journals Thereupon check the runou...

Page 117: ...ousing 6 Coat the crankcase rear sealing surface of the crankcase with gasket cement fit a gasket on the rear bearing housing and press it into the crankcase taking care to align the bolt holes 7 Prior to reassembly clean the thread and surfaces from old paint and degrease them 8 Fasten the bearing housing with bolts having coated the threads with enamel painting half of the whole thread or use a ...

Page 118: ...n bearing lands loose studs stripped thread loose flaring or pressing in of pipes wear of the camshaft rear bearing bushing scores on the oil pump drive bushing wear or scores in the holes for the breather on the gearbox cover Defective parts must be replaced or repaired There are metal based casting rebuild materials which can be used to repair surfaces such as bearing lands and gasket surfaces I...

Page 119: ... Shafts with reverse gear engaged 1 Gear of clutch shaft IV gear 2 Clutch shaft bearing 3 Clutch shaft seal 4 Clutch shaft 5 Clutch release rod 6 Clutch shaft sleeve 7 Packing ring 8 Front gearing cover washer 9 Main shaft bearing 10 Engagement sleeve of III IV gears 11 Oil washer of main shaft 12 Gear of main shaft IV gear 13 Main shaft sleeve 14 Gearbox case 15 Gear of secondary shaft III gear 1...

Page 120: ...f the engagement sleeve of the 1st and 2nd gears Bronze bushings are pressed into the gear holes of the kick starter intermediate and I gear of the main shaft The gears are lubricated through labyrinth cavities in the casing and bores in the shafts The kick starter Fig 5 1 1 consists of shaft 4 with pawl 7 the kick lever with the pedal return spring 1 and kick starter gear 3 The shaft is supported...

Page 121: ... 1 4 Kick Starter 1 Return spring 2 Kick starter shaft bushing 3 Kick starter gear 4 Kick starter shaft 5 Pawl spring 6 Spring pin 7 Pawl 8 Pawl axle 9 Pawl release 10 Kick starter buffer pin 11 Buffer plug a Pawl engaged b Pawl disengaged ...

Page 122: ...rk shaft 12 Shift fork of 3rd and 4th gears 13 Shaft fork of 1st and 2nd gears 14 Nut 15 Pawl crank lever 16 Sleeve 17 Seal Fig 5 1 6 Schematics of Gear Shift Adjustment Mechanism The reverse gear engagement mechanism consists of a separate quadrant 10 with a shaft and reverse gear engagement lever 9 Reverse can only be engaged from either 1st gear or neutral Shifting from reverse to forward autom...

Page 123: ...to neutral position The bracket with an intermediate gear will not move and the gear is set in neutral position When the reverse gear engagement quadrant is turned further the bracket with an intermediate gear travels along the shaft the reverse gear is engaged and simultaneously the gear shift quadrant is blocked thus possibility of simultaneous engagement of two gears is excluded When the revers...

Page 124: ...hest one and vice versa The main application of the lever however is to set the gearbox sleeves into the neutral position The principal parts included in the gearbox Fig 5 2 1 are the split box with covers the clutch shaft and the main shaft with gears and shift sleeves the gear shift mechanism and the kick starter The gear shift mechanism is illustrated in Fig 5 1 5 The hand gear change lever on ...

Page 125: ...edometer driven gear 5 Clutch shaft sleeve 16 Gear III and IV shift fork 26 Main shaft seal 6 Clutch shaft 17 Hole for oil feed to gears 27 Driving plate of 7 Clutch release rod 18 Gear III of main shaft flexible coupling of 8 Main shaft ball bearing 19 Gears I and II shaft fork propeller shaft 9 Main shaft 20 Gear II of main shaft 28 Main shaft nut 10 Front bearing cap 21 Gear shift quadrant 29 C...

Page 126: ...er 1 Return spring 2 Kick starter shaft bushing 3 Kick starter gear 4 Kick starter shaft 5 Pawl spring 6 Spring pin 7 Pawl 8 Pawl axle 9 Pawl release 10 Kick starter buffer pin 11 Buffer plug A Pawl engaged B Pawl disengaged ...

Page 127: ... screws into the case until the locknuts touch the case 4 Remove the black plastic cap located in the right side of the gearbox above the reverse gear lever 5 Place a 10 mm wrench over the nut located on the right side of the gearbox above the reverse gear lever 6 Position your body as follows use your left foot to press the gearshift pedal hold the 10 mm wrench positioned as described in number 5...

Page 128: ...el while keeping pressure on the shift pedal If you felt no click at all you should screw out the upper adjusting screw still pressing the front of the pedal shift until you feel a definite click 9 Now your URAL gearbox is adjusted You may want to repeat number 6 and 8 procedures again to double check that the wrench stops immediately after the click is felt After adjustments tighten the locknuts ...

Page 129: ...tening bolt located under the right hand cylinder which fasten the gearbox to the engine crankcase 7 Shift the gearbox to the rear and remove it from the frame Reinstall the gearbox on the engine in the reverse order Important before reinstalling the gearbox attend to the following 1 Center the hub splines in the clutch driven disks making use of crank handle 345 316 3 or the splined end of tool 3...

Page 130: ...se mechanism when Dismantling the gearbox in general Clutch becomes difficult to engage or release Oil weeps through the central hole in the clutch shaft When inspecting check The condition of the slider rubber ring The thrust surface case hardened of the slider The rod tip fitted into the thrust bearing Mushrooming or metal transfer at rod tip Condition of the clutch release rod oil seal Squarene...

Page 131: ...ckstarter lever wedge knock out the wedge with an aluminum hammer and remove the lever 4 Turn off two screws fastening the bushing of the kickstarter shaft to the front wall of the gear case and carefully relieve the kickstarter return spring of primary tension 5 Turn off seven bolts fastening the gear case cover 6 Hammer slightly the clutch shaft end and the cover projections to force the shafts ...

Page 132: ... against the ratchet face insert a cotter pin into the hole of the quadrant shaft at the side of free end of the spring spread apart the ends of the cotter pin 8 Set the spring on the reverse gear engagement quadrant shaft 9 Insert the quadrant shaft into the gear case cover hole 10 Set the reverse gear engagement lever on the shaft splines and secure it To reinstall the gearbox shafts 1 Bring the...

Page 133: ...max min max 6204201 Clutch shaft 0 017 25 0 002 205 Ball bearing 0 003 25 0 013 0 001 0 030 6204201 Clutch shaft 0 017 20 0 002 12004 Roller bearing 0 003 20 0 013 0 001 0 030 Z103 04326 Quadrant Pin 0 017 20 0 002 304 Ball Bearing 0 003 20 0 013 0 025 0 005 205 Ball bearing 0 004 52 0 017 Z103 04101 Gear case 0 007 52 0 023 0 025 0 027 304 Ball bearing 0 004 52 0 017 Z103 04101 Gear case 0 008 52...

Page 134: ...119 10 Kickstarter shaft front bushing 0 035 18 0 016 0 068 6204401 Kickstarter shaft 20 0 021 Z103 04110 Gear Case Cover 0 085 20 0 025 0 025 0 106 Z103 04236 Main Shaft 0 040 26 0 070 6204211 6204212 6 204213 0 033 26 0 040 0 103 Z103 04236 Main shaft 0 040 23 4 0 070 Z103 04062 Gear 1 assy 0 033 23 4 0 040 0 103 Z103 04304 I and II gear shift fork 0 160 5 0 240 Z103 04221 I and II gear shift sl...

Page 135: ...the side cover should not exceed 0 3 mm 012 in Gear shift forks Having removed the forks inspect them and measure wear Table 5 6 2 lists the wear limits for the shift fork parts Table 5 6 2 Maximum Tolerated Limit of Clearances and Wear Between the Principal and Mating Members of Gearbox mm Parts and Mating Members Wear on diameter Diameter clearance Axial clearance Main shaft to main shaft gearin...

Page 136: ...ear of friction surfaces condition of teeth of the speed gears as well as those of the gear engaging sleeves The gear engaging sleeves should travel freely along the main shaft sleeves and the shaft sleeves should move with ease along the main shaft splines Replace any damaged or excessively worn parts Lubricate the main shaft splines with motor oil when reassembling Fit the oil baffles with the b...

Page 137: ...replacing the lock press it in the body so that the rear end of the lock body is pressed in flush with the finished gear case end Reassembly of Cover with Gear Case The tools required for reassembly are mandrel 346 298 for pressing the gear case on the cover with shafts spanner 36x41 For reassembly 1 Install the cover with shafts with the joint face upwards 2 Coat a gasket on both sides with gaske...

Page 138: ... in slowly with a soft hammer then tighten the lock nut to 15 7 19 6 Nm 1 6 2 0 kgf m 14 Set the gearshift clutches in the neutral position by turning the reverse gear engagement pedal with the front arm downwards to the limit and check the shafts for ease of rotation 15 Check performance of the kickstarter and its spring 16 Axial displacement of the kickstarter shaft up to 1 3 mm 05 in can be tol...

Page 139: ... left grip connected via a cable to a lever on the back of the gearbox When the lever is squeezed the clutch rod is pressed against the pressure plate the friction plates are separated and power is interrupted between the engine and gearbox Figure 6 1 1 Figure 6 1 1 Clutch 1 Release rod 7 Adjusting screw 14 Driven plate 2 Rod seal 8 Clutch release lever 15 Pressure plate 3 Rod tip 9 Lever axle 16 ...

Page 140: ...otorcycle To remove the clutch release mechanism 1 Remove the clutch release arm if required 2 By pressing on the front end of the clutch release rod remove the clutch release slider the thrust ball bearing the rod tip and finally the clutch release rod 3 Wash the disassembled parts and inspect them change faulty parts as needed Reinstall the clutch release mechanism in the following sequence 1 Fi...

Page 141: ...worn out parts Proceed with inspection and repairs of the clutch release mechanism when Dismantling the gearbox in general Clutch becomes difficult to engage or release Oil weeps through the central hole in the clutch shaft When inspecting check The condition of the slider rubber ring The thrust surface case hardened of the slider The rod tip fitted into the thrust bearing Mushrooming or metal tra...

Page 142: ...mm the springs should achieve loads rated by the color marking on the spring ends as follows N kgf gray 170 186 17 5 19 black 157 170 16 17 5 6 5 Clutch Reassembly Insert the springs of the same color marking into the respective flywheel sockets 1 Fit the clutch pressure plate on the flywheel pins and make sure that the thrust planes of the springs have entered the respective recesses of the press...

Page 143: ...ng 26 Propeller shaft collar 3 Gasket 15 Double row ball bearing 27 Flexible joint driven disk 4 Crankcase bushing 16 Adjusting washer 28 Packing ring 5 Needle bearing roller 17 Universal joint fork seal 29 Needle bearing 6 Casing seal 18 Protective washer 30 Wedge belt 7 Seal cover 19 Universal joint splined fork 31 Bearing nut 8 Rear wheel axle 20 Lock ring 32 Gasket 9 Seal spring 21 Universal j...

Page 144: ... EP gear oil SAE 80 or 90 Every 10 000 km lubricate the needle bearings of the universal joint cross Dismantle the final drive and using a grease gun stuff grease into the cross through the grease cup 7 2 Removal and Installation of Final Drive To remove the final drive together with the propeller shaft 1 Set the motorcycle on the center stand and remove the rear wheel 2 Slacken off the wing nut o...

Page 145: ...le of it s arc the swing arm should be positioned parallel to the bottom tubes of the frame Reinstall the spring loaded hydraulic shock absorbers The tightening torque of the pins is 55 foot pounds 75 Nm Tightening torque of the shock absorber bolts is Top 20 foot pounds 27 Nm Bottom 30 foot pounds 40 Nm 7 5 Driveshaft and Universal Joint Repair Dismantling and reassembling the universal joint wit...

Page 146: ...oss inserting it into the splined fork of the universal joint with the pins with the grease nipple facing out Fig 7 5 2 3 Fit the rubber sealing collars and holders on the inserted pins of the universal joint cross 4 Press in the needle bearings Ensure that the universal joint cross pin enters the bearing without disturbing the needles and that the bearing is fitted not deeper than required for in...

Page 147: ... inner cavity by rotating the drive in both directions Drain the solvent 3 If it is necessary to remove the brake lever mark the position of the lever on the brake cam before removing Unscrew the nut fastening the brake cam lever and by knocking slightly with a soft hammer drive the cam axle out of the arm When reassembling ensure that the brake lever is installed at 33 degrees angle back from the...

Page 148: ...ance bushing and holding the hub by hand knock slightly against the axle end to press the cover from the bearing 8 Press the ball bearing from the driven gear hub through the holes in the gear using a drift for the purpose Take care to keep the bearing from cocking when removing 9 Unscrew the nut fastening the pinion gear bearing by turning it clockwise left hand thread and remove the sealing ring...

Page 149: ...ted limits of clearances and wear between the principal mating members of the final drive and the propeller shaft mm Maximum tolerances Name of parts and mating members wear on diameter diameter clearance Measuring point and method Ring gear hub splines Tooth thickness 0 75 Propeller shaft cross pins journal 0 05 On working surfaces of journals Final drive gears Tooth thickness Ring gear hub beari...

Page 150: ...rth through the limit of lash and note the dial gauge reading Final drive gear backlash should be within 0 003 to 0 006 inch 07 to 0 16 mm If the backlash is incorrect change the adjusting shims on the ring gear substituting thicker or thinner shims to achieve backlash within tolerance If new gears or pinion bearings have been installed gear tooth contact should also be checked 1 Remove the ring g...

Page 151: ...al from the cover 3 Remove the epicycle gear with two sets of rollers and seal and spacer from the case 4 Remove the driven conical gear with the hub 5 Remove the needle rollers from the splines in the hub in the gear case 6 Proceed further as described for the standard single wheel drive final drive assembly Before tightening the nut in the case cover the sun gear flange with seal and ball bearin...

Page 152: ...al 23 Sidecar wheel axle absorber 14 Sidecar wheel brake lever 24 Protective hood 5 Seat Saddle or Tractor 15 Sidecar frame legs 25 Tie rod nut 6 Strap 16 Sidecar wheel brake rod 26 Sidecar wheel nut 7 Motorcycle frame 17 Rear collet clamp bracket fender 8 Leg adjusting fork 18 Rear bracket fastening bolt 27 Rubber member of 9 Sidecar frame legs 19 Lever pins body suspension NOTE For further descr...

Page 153: ...y for long term parking The switch is located above the storage battery The electrical connections are subject to corrosion even on new machines Any electrical circuit problems should be traced down and solved Often the problem is simply an oxidized electrical connection which can be solved by scraping the metal clean and applying an anti oxidizing lubricant such as petroleum jelly 8 2 Maintenance...

Page 154: ...harge of the storage battery If it is low recharge overnight with a 2A charger Every 20 000 km clean the alternator cover cavity at the slip rings end Then blow through the alternator with compressed air to remove brush and copper dust ...

Page 155: ...y connections Do not allow the battery to remain discharged for more than 24 hours Prolonged discharging will cause permanent sulfation of plates A discharged battery will freeze and crack if left exposed to sub freezing temperatures WARNING Batteries contain sulfuric acid which if spilled on skin will cause severe burns Avoid contact with clothing skin and especially eyes Always protect hands and...

Page 156: ...o saturate the plates Top up with acid as needed to maintain upper level line in each cell 3 Start charging no sooner than 20 minutes but no later than 2 hours after filling with electrolyte Battery Charging new or used batteries CAUTION When charging the battery disconnect the positive terminal from the battery to prevent damage to the electrical components Never jump start a motorcycle CAUTION D...

Page 157: ...connect the wires from the battery terminals Undo the nut which holds the battery fastening band and remove the battery Reinstall the battery in the reverse sequence Clean the terminals and apply acid proof grease to the connections to help prevent corrosion in service CAUTION To prevent short circuiting the battery always disconnect the negative terminal first then the positive terminal When conn...

Page 158: ...lly charged either having been recently run on the motorcycle or via the Battery Charging procedure Visually inspect the battery for possible electrolyte leaks especially from cracks in the cells check good connection of the battery posts and check that electrolyte level remains at the top mark in each cell Test the battery with a hydrometer Warning Battery acid is corrosive and will burn skin rap...

Page 159: ... Be certain that the alternator has a good ground to the engine and that the alternator light illuminates when the ignition is switched on If all the wiring connections appear to be correct but the alternator does not appear to have sufficient output test the alternator The alternator can be tested on the motorcycle Start the engine and while the engine is running remove the positive wire from the...

Page 160: ...e engine rotate the alternator slightly secure it and start the engine again With incremental adjustments of the alternator position the gear noise may be minimized which is the correct position for operation Alternator Repair The brushes should contact the slip rings over at least 80 of their working surfaces and should be free from chips Chipped brushes or brushes worn to 10 mm or less should be...

Page 161: ...less ignition system with electronic ignition timing is used The ignition coil has two high voltage terminals each supplying one of the cylinder spark plugs and operating in conjunction with the moving coil pickup Figure 12 Moving Coil Ignition Pickup 1 pickup base 4 rotor carrier 2 pickup 5 bolt 3 pickup rotor 6 electronic amplifier Periodically check all wires to be sure they aren t crimped or h...

Page 162: ... on the engine crankcase 2 Slacken the screws fastening the pickup base and turn it so that the mark on the pickup rotor matches mark 0 on the pickup base then tighten the screws 3 Check the gap between the rotor and the moving coil pickup and adjust if required Pickup coil gap should be 008 to 012 in 0 2 to 0 3 mm Note If the rotor mark is not visible after matching the flywheel mark with M3 the ...

Page 163: ...xtra set of spark plugs The lower portion of the plug shell is threaded M14 X 1 25 with an 11 mm length of thread Spark gap of 040 in is set between the side electrode and the bottom end of the central electrode Always use a crush washer when installing a spark plug preferably a new crush washer WARNING Do not over tighten the spark plug when mounting it on the engine since this could damage the c...

Page 164: ...rn indicator Turn indicator UA BULB 5 25 0 Front 1607 3726010 Rear 1617 3726010 Headlight A single 7 diameter DOT approved dual filament sealed halogen beam headlight is used on the U S URAL The headlight should be adjusted so that the high beam is horizontal when the motorcycle is in its normal loaded condition Stop Light The stop light is activated by either the front brake lever or the rear foo...

Page 165: ... completed through either left or right side turn signal lights On the sidecar motorcycle the right side turn lights are on the sidecar fender A single turn indicator lamp on the dashboard flashes with either left or right turn selection Troubleshooting The turn signal relay requires a minimum of 12 volts to function correctly With the engine not running a low battery or with the engine running at...

Page 166: ...osed of metal connectors riveted onto a composite bakelite insulator Cracking of the insulator will allow the fuse contacts to lose tension Cracked insulators can be repaired by gluing with a high strength instant gel adhesive The metal contacts of fuses must be clean and free of oxidation to reduce electrical resistance Some wire connections to assemblies such as turn lights are made by a screw c...

Page 167: ...ear it can be removed Reinstall the fuel tank in reverse sequence Note Before reinstalling the fuel tank it is a wise precaution to remove the fuel valve fuel cock and flush any resident debris from the tank outlet Inspect the fuel tank for cracks dents peeling of paint etc The fuel tank can be tested for leaks by submerging it in water with a regulated air hose connected to the fuel fitting and p...

Page 168: ...o be effective it must first break the fuel into tiny particles in the form of vapor and then mix the fuel with air in a proper ratio so it can burn without leaving excess fuel or air Troubleshooting When the carburetor setting is not correct various irregularities in engine performance are noticeable These irregularities can be traced to two basic causes When air fuel mixture is too rich The engi...

Page 169: ...ssion Repair replace or adjust as necessary Poor idle or stalling Idle speed adjustments are unequal twin carburetor models and multi carburetor models using individual throttle stop adjustments Equalize throttle stop settings Clogged idle and low speed air bleed Disassemble carburetor and chemically clean All causes listed under HARD STARTING Carburetor Maintenance and Repair To remove the carbur...

Page 170: ... filter material oiled To remove the air cleaner undo the center coupling bolt Lift the air cleaner up as a unit and pull it out of the frame towards the left To provide greater clearance for removing the air cleaner it helps to hold down the kick starter pedal with your foot Take care to catch the gasket under the filter To reinstall the air cleaner reverse the sequence of operations taking care ...

Page 171: ...engine performance and should be replaced with stock URAL components to avoid engine damage and violation of EPA regulations To remove the exhaust system 1 Undo the nuts fastening the passenger footrests and those of the engine front stud slacken off the clamp bolts and remove the clamps clips from the stud 2 Compress the rear suspension and remove the passenger footrests 3 Take off the union bran...

Page 172: ...y with spring Final drive casing 1 6205033 Universal joint fork assy with spring Final drive bearing nut 1 6206006 10 Rubber packing Wheel hub 4 Z101 08159 Seal Steering column 2 Z101 08019 Collar and spring assy Seal body of fork leg tip 2 Z101 08123 Seal Seal body of fork leg tip 2 6326152 Container nut seal Seal casing of spring loaded hydraulic shock absorber 3 6326155 Rubber seal Seal casing ...

Page 173: ...g the motorcycles in countries with hot and tropical climate it is recommended to use more viscous oils If humidity is above normal use oils with anti corrosive additives 10 3 Substitute Parts Standard North American automotive and aviation supplies may be substituted for any specific Russian sealants lubricants abrasives or cleaners Automotive bearings of equivalent grade or higher may be substit...

Page 174: ... 0 002 pt US liquid pints cc cubic centimeters 0 00106 qt US liquid quarts L liters 1000 cc cubic centimeters L liters 0 264 gal US liquid gallon cu in cubic inches 16 387 ml milliliters cu in cubic inches 16 387 cc cubic centimeters oz US fluid ounces 29 574 cc cubic centimeters oz US fluid ounces 0 0296 L liters pt US liquid pints 473 18 cc cubic centimeters qt US liquid quarts 946 35 cc cubic c...

Page 175: ...The switch carries electricity from a single output to one of three possible outputs If two or more switches are ganged then they move together with each other Resistor Passive device used to reduce the flow of electricity from one part of a circuit to another Coil Many turns of wire which act as an electromagnet when electricity flows through the wire Fuse A fuse is a fusible link of metal that i...

Page 176: ... to melt The melting wires are extremely 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 connection then the circuit is said to be an open circuit The flow of electricity through a cir...

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Page 185: ...d the horn sound this time No Go to step 5 Yes Great You fixed it 5 Using an ohmmeter measure the resistance of the horn between its two connectors Is the resistance of the horn approximately 5 ohms No Replace the horn Yes Go back to step 1 You ve missed something 6 Make sure the bike is in neutral Did the neutral indicator light illuminate No Go to step 7 Yes Go to step 8 7 Use a short piece of w...

Page 186: ...ooting Guide 1 Turn the ignition key to the middle on position Does anything electrical work at all No Go to step 2 Yes Go to step 5 2 Is the master switch in the on position No Turn the switch to the on position Go to step 1 Yes Go to step 3 3 Check the battery voltage Is the battery voltage approximately 12 volts No Charge the battery Yes Check the battery terminal connections Clean and tighten ...

Page 187: ...o to step 10 Yes Replace any bulbs if required Go to step 10 10 Activate the right turn signal switch Is at least one right turn signal light flashing No Check the fuses note that there is a hidden fuse behind the headlight bucket which supplies power to the turn signals turn signal bulbs turn signal flasher unit Replace as required Yes Replace left or right turn signal bulbs as required Go to ste...

Page 188: ...g fault indicator lamp Is the lamp illuminated No Normal operation of charging system No fault observed Normal operating voltage for the electrical system with the engine running will be 14 volts 0 5 volts Yes Go to step 3 3 Observe the alternator shaft Is it turning No Make the required mechanical repairs Yes Go to step 4 4 Stop the engine Remove the alternator unit Remove the rear cover Remove t...

Page 189: ...following tests either outside or in an area where there is adequate ventilation and ensure that there is no source of ignition near the motorcycle 1 Turn on the master switch Turn the ignition switch to the middle on position Turn the fuel petcock to the on position Pull out the choke knob on each carburetor Press the electric start button Did the electric starter motor do anything No Go to step ...

Page 190: ...tricted flow of fuel from the fuel petcock Make sure the fuel petcock is turned on No Fill the fuel tank with fuel and go to step 1 Yes Check the fuel supply hoses and fuel filters for restrictions Reconnect the fuel lines and filters and go to step 5 7 Use a voltmeter and check for 12 volts on the red wire of the ignition module located under the front engine cover Did you measure 12 volts with t...

Page 191: ...ewdriver to carefully form a jumper between the starter solenoid tab and the starter solenoid stud which has the wires connected to it Did the starter solenoid motor activate No Go to step 12 Yes If the starter motor activated with the screwdriver bypass but not with the electric start button then there are several things which need to be checked Start with the fuse holder assembly Look for any bl...

Page 192: ...ouching anything metal on the bike Turn the master switch back on Briefly tap the metal connector in your fingers to the other metal stud connector on the starter solenoid that is closest to the starter motor Did the motor start momentarily Turn off the master switch and return the heavy wire to its original terminal No Replace or repair the starter motor Yes Replace the starter solenoid ...

Page 193: ...ouching anything metal on the bike Turn the master switch back on Briefly tap the metal connector in your fingers to the other metal stud connector on the starter solenoid that is closest to the starter motor Did the motor start momentarily Turn off the master switch and return the heavy wire to its original terminal No Replace or repair the starter motor Yes Replace the starter solenoid ...

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