URAL Motorcycles 750cc Series, Repair Manual

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Faults, diagnostics and remedy
Fault Remedy
When switched on the starter does not rotate, the starting relay does not operate
1. The battery wrong or totally exhausted 1. Charge or replace the battery
2. The battery terminals are badly corrupted, wire ends
dirty or loosen 2. Clean the terminals and wire ends, tighten the ends
and apply protective stuff on.
3. Short circuit in winding, to ground cut in the starting
relay winding 3. Replace the starting relay
4. The starting relay faulty 4. Replace the starting relay or clean its contacts
5. The circuit supplying the winding of starting relay
broken 5. Check wires and their connections in the circuit
6. Faulty contacts of the ignition switch 6. Replace the contacts of the ignition switch
7. Wires powering the starting relay broken 6. Check the wires and their connections in the circuits:
battery to the starting relay and to the starting relay
connector
8. Armature of the starting relay seized 8. Remove the relay and provide easy move of the
armature
When the starter on the armature does not rotate or rotates too slowly
1. The battery wrong or totally exhausted 1. Charge or replace the battery
2. The battery terminals are badly corrupted, wire ends
dirty or loosen 2.Clean the terminals and wire ends, tighten the ends
and apply protective stuff on.
3. Loosen ends of wires connecting the power train with
ground 3.Tighten connections
4. Contact studs of the starting relay loosen or nuts
fastening the wires loosen 4. Clean and tighten the contacts
5. Collector burnt, brushes seized or worn out 5. Clean the collector, replace the brushes
6. Cut or short circuit in stator or armature windings 6. Remove the stator or armature
When the starter on the starting relay repeatedly operates and then switches off
1. The battery exhausted 1. Charge the battery
2. Cut or short circuit in the restraining coil of the
starting relay 2. Replace the starting relay
3. Voltage drop in the circuit powering the starting relay
because of wire ends badly corrupted Check wiring and the connections from the battery to the
starter connector
When the starter on the armature rotates but the flywheel does not
1. Idle run coupling slips 1. Check the starter on the test bench, replace the
coupling
2. Coupling lever broken or jumped out 2. Replace the lever or set its shaft to the proper location
3. Drive ring broken 2. Replace the coupling
Strange noise from with armature rotating
1. Bearing bushings or webs of armature shaft badly
worn out. 1. Replace the starter or clutch housing
2. Loosen fastening of the starter or cover on the drive
side broken 2. Tighten fastening nuts or repair the starter.
3. The starter is skewed 3. Check the starter fastening
4. Loosen fastening of the starter armature (the armature
touches the pole) 4.Tighten the fastening screw
5. Gear teeth or flywheel teeth are broken Replace the drive or the flywheel
6. The gear won’t disconnect from the flywheel
- The drive lever jammed
- The sleeve on the splined shaft of the armature seized
- Broken or week springs of starter relay or of coupling
- The lock ring off from the coupling hub
- Armature of starting relay seized 6. Make one the following operations
- Replace the lever
- Clean the splines and oil them with engine oil
- Replace the coupling or starting relay
- Replace damaged parts
- Replace or fix the starter relay
The damages and faults are fixed by replacing the parts.
The rebuilding of the starter must only be performed in a specialized shop.
Replacing the starter brushes
-Undo two bolts fastening the stator
-Remove the cap protecting the gasket and brushes’ springs
Undo two nuts in the rear fastening the brush holder terminals and remove the brushes along
with the holder
.
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