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URAL Motorcycles 2003 Retro Solo, Owner'S Manual

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Contents

Introduction ............................................................................................................................................................. 5
Warnings, Cautions, Notes ....................................................................................................................................... 5

Chapter 1 Specifications

Specifications .......................................................................................................................................................... 7
Torque Specifications ............................................................................................................................................. 10
Conversions .......................................................................................................................................................... 10

Chapter 2 Motorcycle Controls & Instrumentation

Motorcycle Controls & Instrumentation ................................................................................................................... 11
Controls ................................................................................................................................................................ 12
Control Cable Adjustment ...................................................................................................................................... 16
Control Cable Maintenance ................................................................................................................................... 16
Speedometer ......................................................................................................................................................... 16

Chapter 3 Engine Operation

Engine Operation and Maintenance ........................................................................................................................ 17
Pre-Trip Preliminaries ............................................................................................................................................ 17
Starting the Engine ................................................................................................................................................. 17
Operating Precautions ............................................................................................................................................ 21
Running-In the New Motorcycle ............................................................................................................................ 21

Chapter 4 Engine Design

Brief  Description of  Design & Maintenance .......................................................................................................... 23
Lubrication System ................................................................................................................................................ 24
Fuel System ........................................................................................................................................................... 25
Ignition System ...................................................................................................................................................... 26
Ignition Timing ....................................................................................................................................................... 26

Chapter 5 Carburetors

Carburetors ........................................................................................................................................................... 29
Carburetor Maintenance ........................................................................................................................................ 30

Chapter 6 Power Transmission

Power Transmission ............................................................................................................................................... 31
Clutch ................................................................................................................................................................... 31
Gearbox ................................................................................................................................................................ 31
Final Drive ............................................................................................................................................................. 31

Summary of Contents for 2003 Retro Solo

Page 1: ...URAL Motorcycles Owner s Manual 2004 Model Retro Solo Irbit Motorworks of America Inc 15411 NE 95th St Redmond WA 98052 www imz ural com ...

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Page 3: ...ntenance 16 Speedometer 16 Chapter 3 Engine Operation EngineOperationandMaintenance 17 Pre TripPreliminaries 17 StartingtheEngine 17 OperatingPrecautions 21 Running IntheNewMotorcycle 21 Chapter 4 Engine Design Brief Descriptionof Design Maintenance 23 LubricationSystem 24 FuelSystem 25 IgnitionSystem 26 IgnitionTiming 26 Chapter 5 Carburetors Carburetors 29 CarburetorMaintenance 30 Chapter 6 Powe...

Page 4: ...lWiringDiagram 46 Chapter 11 Maintenance MaintenanceofMotorcycle 47 ListofRecommendedLubricants 47 LubricationChart 48 RequiredLubrication 48 Care of Motorcycle Paint 48 Preservation and Storage 49 Battery 50 List of IndividualTool Set Spare Parts Accessories Documents 51 Chapter 12 Safe Operating Rules SafeOperatingRules 53 Chapter 13 Warranty WarrantyAgreement 55 Warranty Claim Form 63 Flat Rate...

Page 5: ... or comments are welcome Write to us or post an e mail on the Ural Discussion bulletin board at www imz ural com Happy Riding Important Notice Statements in this manual preceded by the following words are of special importance WARNING MEANS THERE IS THE POSSIBILITY OF PERSONAL INJURY TO YOURSELF OR OTHERS CAUTION Means there is the possibility of damage to the vehicle NOTE Other information of par...

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Page 7: ...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 9 0 1 Rated horsepower 33 KW 44 2 BHp Rated rotational speed 5600RPM Rated torque 36 ft lbs 3750 RPM Lubrication system Dual system of forced lubrication and splashing Lubricant SAE 20W 50 CARBURETOR Carburetor type 32 C...

Page 8: ...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 3 86 FLUID CAPACITIES Fueltank 5 Gal 19L Reserve 5 Gal 2L Engine 68 oz 2L Transmission 30 6 oz 9 L Final drive 3 74 oz 110 ml ShockAbsorbers 3 5 oz 105 ml RUNNING GEAR FrameTubularwelded Rear wheel suspension Swing arms with spring shock absorbers Front fork Telescopic Brakes Hydraulic...

Page 9: ...tween spark plug electrodes 1 016 0 040 Backlash between tooth faces of bevel gears in final drive 0 1 0 3 0 001 FREE TRAVEL ADJUSTMENTS mm in Hand brake control lever 5 8 0 2 0 3 Clutch control lever 5 8 0 2 0 3 Foot brake drive pedal of full stroke of pedal 25 30 1 0 1 2 ...

Page 10: ...rake lever 19 to 22 Nm 14 ft lb to 16 ft lb alternator gear nut 136 to 163 Nm 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 multiply by 1 056 there are 1 056 quarts per liter To convert from liters to pints mul...

Page 11: ...ear 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 10 Reverse gear lever 11 Kick start lever 5 6 1 2 3 4 7 8 9 ...

Page 12: ...RE 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 brake is actuated...

Page 13: ...ortant to shift smoothly with a constant force and not to kick the gear shift pedal Reverse gear is engaged by pushing forward on the reverse gear selector Reverse gear should only br engaged from neutral or 1st gear after the motorcycle has come to a complete stop When the reverse gear selector is pulled backward the transmission will be in neutral IMPORTANT The green pilot lamp will illuminate w...

Page 14: ...e Off All electrical systems are off Run Voltage is supplied to all electrical systems Parking Voltage is supplied to running lights only Note Leaving the key in the Run or Parking position will discharge the battery Always return the key to the Off position before removing it The indicator lamps are located on the instrument panel Turn Signal High Beam Neutral Indicator Alternator Ignition Switch...

Page 15: ...15 Engine Cutoff Switch Electric Start Switch Headlight Hi Low Beam Switch Turn Signal Switch Horn Switch ...

Page 16: ...t 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 lubricate the throttle control twist grip the lever pins and ends of cables used in the clutch and the throttles SPEEDOMETER MAINTENANCE After every 10 000 ...

Page 17: ... not higher than the top 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 A...

Page 18: ...s stalling due to lack of fuel set the valve to the RES Reserve position and continue driving After refueling remember to set the valve back to ON to avoid running out of fuel completely IMPORTANT When parking the motorcycle for extended periods of time the valve should remain in the ON position WARNING Never leave the motorcycle with the engine turned off and the valve set to PRI as this may resu...

Page 19: ...procedure Aproperly adjusted warm engine should start within a few kicks If the engine doesn t start try the procedure described below in item 3 If it still doesn t start or fire it may be flooded Note Do not completely open the throttle while kicking the engine over since it may flood the engine and the spark plugs may become fouled with gasoline Electric Starting 1 Set carburetor enricheners as ...

Page 20: ...h If one plug fouls and the other doesn t the engine will run unevenly and may cause internal damage When the engine is hot do not choke or enrichen the carburetors To do so risks flooding the engine To start an engine that is flooded first open the throttle fully hold it there and give the engine up to 10 swift kicks If it still doesn t fire take the spark plugs out to see if they are wet with ga...

Page 21: ...HEN SPEED IS TOO HIGH MAY SEVERELY DAMAGE THE TRANSMISSION OR CAUSE THE REAR WHEEL TO LOSE TRACTION CAUTION Do not run the engine at extremely high rpms with clutch disengaged or transmission in neutral Do not idle the engine unnecessarily for more than a few minutes with the motorcycle standing still When operating the Ural motorcycle on the highway please try not to run continuously at speeds ab...

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Page 23: ...tion of 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 atten tion to the cooling fins as their fouling will impair the efficiency of the engine cooling Check en gine...

Page 24: ...ervals 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 of the dipstick if ne...

Page 25: ...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 maintenan...

Page 26: ... 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 plugs when on the road We recommend that you purchase an extra set of these plugs from yourAuthorized Ural Dealer and carry them in the mo torcycle at all times WARNING DO NOT OVERTIGHTEN THE SPARK PLUG WHEN MOUNTING IT ON THE ENGINE SINCE THIS COULD DAMAGE THE C...

Page 27: ...27 Ignition Module Coil 3 8 ...

Page 28: ...28 ...

Page 29: ...he carburetor flanges are in need of replacement use only genuine Ural replacement or Ural recommended parts WARNING TO AVOID SEVERE ENGINE DAMAGE DO NOT MODIFY CARBURETOR SYNCHRONIZATION JETS OR THROTTLE LINKAGE THIS AIR COOLED ENGINE MUST ALWAYS RUN ON BOTH CYLINDERS AS EVENLY AS POS SIBLE WHENEVER ONE CYLINDER IS NOT FIRING STOP THE ENGINE AND DETERMINE THE CAUSE AND CORRECT IT BEFORE PROCEEDIN...

Page 30: ...ns provided on the bottom of the float bowls The fuel filters should also be changed every 10 000 km or when they appear to be dirty or not flowing fuel correctly 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 Fail ure of the adapters will...

Page 31: ...nshift from higher gears To shift up into second third and fourth gear use the front toe plate and push upwards quickly and firmly Since the Ural transmission is a non synchronized design it is very important that the clutch be used when shifting Not using the clutch when shifting can cause damage and void the warranty CAUTION Severe damage due to insufficient lubrication of gears shafts and beari...

Page 32: ...refill the final drive with the specified lubricant Reinsert the upper fill plug and wipe off any excess or spilled oil from the final drive Final Drive Assy Rear Universal Joint Drain Plug Splines Universal Joint Filler Plug ...

Page 33: ...nsion of the springs is adjustable allowing two positions The first lower position corresponds to the load due to the motorcycle s own weight and the driver s the second upper position of moving cam corresponds to the maxi mumload Care of shock absorbers Fill the shock absorber with 105 cm of hydraulic fluid Each time during maintenance check the bolts fixing the top and bottom ends of the shock a...

Page 34: ...justed periodically to avoid excessive play which might cause steering instability When properly adjusted the front fork should turn with just a hint of bearing drag but not free play or obvious resistance to turning The steering head bearings are of a roller bearing type and are designed for the lifetime of the motorcycle WARNING IMPROPER ADJUSTMENT OF THE STEERING HEAD E G TOO TIGHT WILL MAKE TH...

Page 35: ...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 wheel on the motorcycle follow the reverse order of operations Prior to reassem bling wipe the axle and...

Page 36: ...ECTLY MATCHED TO WHEEL RIMS SEE YOUR AUTHORIZED URAL 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 OTHER THAN THOSE SPECIFIED MAY AD VERSELY AFFECT MOTORCYCLE STABILITY PROTECTIVE RUBBER RIM STRIPS MUST BE USED TIRE SIZES ARE MOLDED ...

Page 37: ...um or disc type may be used The adjustment of bearings is the same for both styles of wheel Adjustment of Wheel Bearings The life of wheel bearings is extended by proper adjustment Check the condition of bearings and adjust them every 5000 km To 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 ...

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Page 39: ...ic disc brake in front and hydraulic drum on the rear The hydraulic disc brake consists of a caliper brake pads and a wheel disc The front brake is a hydraulic disc brake The front brake hydraulic reservoir is located on the right handlebar Front Brake Reservoir ...

Page 40: ...40 The rear wheel brake is mounted in the rear hub and is actuated via a hydraulic master cylinder linked to the brake pedal Rear Brake Hydraulic Reservoir Brake Line Differential Dipstick ...

Page 41: ...HAT YOU SEE YOUR IMWA DEALER FOR THESE SERVICES BRAKES MUST BE INSPECTED FOR WEAR AS PER THE SERVICE COUPONS IF THE BRAKE SHOE FRICTION MATERIAL IS 1 16 IN THICK OR LESS THE THICKNESS OF A NICKEL THE SHOES MUST BE REPLACED IMMEDI ATELY FAILURE TO REPLACE PADS WHEN NECESSARY COULD RESULT IN BRAKE MALFUNCTION AND PERSONAL INJURY IF YOU RIDE UNDER ADVERSE CONDITIONS STEEP HILLS HEAVY TRAFFIC ETC MORE...

Page 42: ...42 ...

Page 43: ...nator 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 pressed The horn can be tuned for loudest performance with an adjusting screw located at the rear portion of the horn body Headlight A 7 diameter DOT approved ...

Page 44: ...e melting of the fuse protecting that circuit ELECTRICAL EQUIPMENT MAINTENANCE During the daily preventive inspection check the functioning and the condition of the electrical equipment Inspect and or replace the spark plugs and ignition leads as required in the Service Coupons The gap is readjusted by bending the end of the side electrode Care of alternator In the course of daily inspection check...

Page 45: ...45 The headlight relays are located under the fuel tank Fuse box Inside of headlight bucket ...

Page 46: ...46 Wiring Diagram ...

Page 47: ... special care must be taken to prevent rust from occurring 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 30 6 oz 0 9 L 2 Single Wheel Final Drive 80 90 wt Gearlube 3 5 oz 105 ml 1 68 oz is an approximate measure The exact oil quantity will be whatever is required to bring...

Page 48: ...stream of cold or slightly heated water Never use a pressure washer Do not remove dust and mud by rubbing the surface with a dry cloth as sand particles will degrade the surface and the paint will rapidly lose its brilliance While washing do not use soda solution kerosene citric acids or mineral oils If the surface is stained with mineral oil degrease by wiping with a rag If after removal of mud a...

Page 49: ...ns Store the motor cycle away from acids alkalis mineral fertilizers and other harmful substances Prior to placing it in storage clean the bike thoroughly drain the carburetors or start the engine and let it run with the gasoline cock closed to remove gasoline in the float chambers of carburetors Then spray storage oil WD40 into each cylinder through the spark plug holes Turn the crank shaft by de...

Page 50: ...TER INTERNAL DRINK LARGE QUANTITIES OF WATER FOLLOWED BY MILK OF MAGNESIA VEGETABLE OIL OR BEATEN EGGS CALL DOCTOR IMMEDIATELY Caution When charging the battery disconnect the positive terminal from the battery to prevent damage to the electrical components Never jump start the motorcycle WARNING BATTERIES PRODUCE EXPLOSIVE HYDROGEN GAS AT ALL TIMES ESPECIALLY WHEN BEING CHARGED KEEP CIGARETTES OP...

Page 51: ...keys 2 4 Wrench 14 x 17 1 5 Wrench 19 x 22 1 6 Socket wrench 10 x 12 1 7 Socket wrench 10 x 13 1 Set of Spares 8 Socket wrench 19 x 21 1 9 Wrench 27 mm 1 1 Oil filter element 1 10 Double head wrench 1 2 Fuses 2 11 Spanner wrench 1 3 Touch up paint 1 12 Spanner wrench assembly 1 13 Screwdriver 150 mm 1 Documents 14 Screwdriver 100 mm 1 1 Owner s Manual 1 15 Punch 1 16 Allen wrench 1 17 22mm Round w...

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Page 53: ...ristics under all conditions If you are an 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 co...

Page 54: ...way the other driver may not know you 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...

Page 55: ...ime of purchase of the parts by a Dealer or retail customer 1 Engine 12 months 2 Gearbox 12 months 3 Final drive 12 months 4 Alternator 6 months 5 Electric starter 6 months 6 Ignition 6 months 7 The rest of the motorcycle parts and parts assemblies 30 days The above applies ONLY in cases when Dealer or retail customer identifies defects before using parts and or assemblies or these defects are ide...

Page 56: ... of each coupon Failure to adhere to this requirement will void the warranty 4 All personnel who operates the motorcycle must sign a statement that they have studied the Owner s Manual and have gone through the sidecar motorcycle driving practice before taking the commercially outfitted URAL outfit on the public roads A copy of a signed and dated statement of completion by each driver and instruct...

Page 57: ...ailure to follow running in break in procedure 3 Replacement of expendable maintenance items beyond the first scheduled maintenance including but not limited to spark plugs filters lubricants compliance fittings tires see Owners Manual gaskets fuel line fuses bulbs 4 Paint and or decal fading peeling blistering chipping or rusting 5 Use for the following activities such use will VOID coverage Raci...

Page 58: ...pendix B applied to the Dealer s approved shop hourly rate 1 Dealer will fax a warranty parts request to IMWA Inc on a Warranty Claim Form Appendix A for all warranty parts 2 Irbit MotorWorks of America Inc will review and when approved will ship parts within 48 hrs and notify Dealer if repair will be covered under factory warranty 3 Dealer must submit claims for labor reimbursement within 10 busi...

Page 59: ...receipt of any motorcycle which may involve over 30 days of shop time including order and receipt time for parts service time and delivery time If Dealer fails to notify IMWA Inc in such a case Dealer will be solely responsible for any forced motorcycle repurchase that occurs and may be subject to termination of IMWA Inc Dealership IMWA Inc reserves the right to perform warranty work at its expens...

Page 60: ...be defective in material or factory workmanship under normal use for the applicable period Parts and Labor No charge for replacement of defective parts Your obligation To have required maintenance works performed in accordance with this manual and Service Coupons Failure to have required maintenance performed may result in losing warranty coverage Note The following items are not covered by the No...

Page 61: ...d will meet applicable emission regulations within the time and mileage periods The obligation of Irbit Motorworks of America To repair or replace at its option any part or parts of the emission control systems which are proven to be defective in material or factory workmanship under normal use for the applicable period Parts Labor No charge to you Your obligation To have required maintenance perf...

Page 62: ...for street use 2 Removing or modifying the muffler internal baffles in any way 3 Replacing the air intake cleaner assembly with one not certified to be noise legal for street use 4 Modifying the air intake cleaner assembly in such a way as to make the vehicle no longer noise legal for street use IMPORTANT If you move from your present address or sell your motorcycle please fill out and mail the fo...

Page 63: ... _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Part Description Qty Dlr Cost ____________________ ______________...

Page 64: ...tem disconnection connection to cylinder heads 0 4 1 11 Valve gap adjustment 2 cylinders 0 3 1 12 Clutch disassembly assembly engine removed 0 4 1 13 Air filter assembly removal mount 0 3 2 0 Gear box 2 1 Gear box removal mount rear wheel and final drive removed 0 5 2 2 Gear box removal mount engine removed 0 1 2 3 Gear box disassembly 0 9 2 4 Gear box assembly 1 2 2 5 Gear box adjustment 0 4 3 0 ...

Page 65: ...2 Rear wheel removal mount 0 2 5 3 Wheel alignment and balancing 0 4 5 4 Wheel bearing adjustment 0 3 5 5 Tire removal mount on the rim 0 3 5 6 Brake adjustment per wheel 0 2 6 0 Sidecar 6 1 Sidecar removal mount 0 3 6 2 Sidecar wheel removal mount 0 1 6 3 Sidecar body removal mount 0 3 6 4 Sidecar fender removal mount 0 4 6 5 Shock absorber removal mount 0 2 6 6 Swing arm removal mount 0 2 6 7 Ru...

Page 66: ...0 Electrical 8 1 Wiring diagnosis for short circuit 0 6 8 2 Battery removal mount 0 4 8 3 Wire harness removal mount motorcycle 1 2 8 4 Wire harness removal mount sidecar 0 6 8 5 Alternator removal mount 0 2 8 6 Ignition system removal mount 0 3 8 7 Ignition coil removal mount 0 2 8 8 Horn removal mount 0 1 8 9 Ignition lock removal mount 0 3 8 10 Main switch RH or LH removal mount 0 1 8 11 Any li...

Page 67: ...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 68: ...lumn bearings 9 Check alternator bolts 10 Check brake fluid reservoirs 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 air filter element 4 Check ...

Page 69: ...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 reservoirs 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 7 400 to 7 600 km Date Odometer reading km 1 Cha...

Page 70: ...dling for synchronous operation 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 Electric wiring Tighten connections if required F Fasteners for proper tightening 11 Re pack the grease in wheel bearings adjust the bearings 12 Lubricate A Foot brake pedal sh...

Page 71: ... 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 action of brakes 8 C...

Page 72: ... 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 73: ...etors while idling for synchronous operation B Check steering column bearings adjust if required C The condition and action of the brakes D The tension of wheel spokes Adjust if necessary E Electric wiring Tighten connections if required F Fasteners for proper tightening 11 Repack the grease in wheel bearings adjust the bearings 12 Lubricate A Foot brake pedal shaft B Hinges of foot brake pedal sh...

Page 74: ...00 to 25 100 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 6 Lubricate A Lever pins B Foot brake pedal shaft C Hinges of the foot brak...

Page 75: ...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 76: ...synchronous operation 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 Electric wiring Tighten connections if required F Fasteners for proper tightening 11 Repack the grease in wheel bearings adjust the bearings 12 Lubricate A Foot brake pedal shaft B Hinge...

Page 77: ...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 78: ...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 79: ...hod the problem s may be one or more of the following 1 Engine is flooded i e the spark plugs have been fouled by too much throttle and fuel and will not spark Correction Flooding is corrected 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 ...

Page 80: ...n 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 the dipstick with the filler plug undone See chapter 4 Lubrication System Here Are Some Helpful Publications To Help You With Your New Ural Learning to Ride The Ural With Sidec...

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