URAL Motorcycles Bavarian Classic 2001 Owner'S Manual Download

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URAL Classic Motorcycles

Owner’s Manual

2001 Models

(All States)

Deco & Bavarian Classic

Tourist & Patrol

Classic Motorcycles & Sidecars, Inc.

P.O. Box 969

Preston, WA 98050

www.ural.com

Summary of Contents for Bavarian Classic 2001

Page 1: ...1 URAL Classic Motorcycles Owner s Manual 2001 Models All States Deco Bavarian Classic Tourist Patrol Classic Motorcycles Sidecars Inc P O Box 969 Preston WA 98050 www ural com ...

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Page 3: ...ripPreliminaries 19 StartingtheEngine 19 OperatingPrecautions 21 Running IntheNewMotorcycle 22 Chapter 4 Design Maintenance BriefDescriptionofDesign Maintenance 23 Engine 23 LubricationSystem 23 FuelSystem 24 Air Cleaner 25 IgnitionSystem 26 Chapter 5 Carburetors Carburetors 26 Chapter 6 Power Transmission PowerTransmission 29 Clutch 29 FinalDrive 29 Chapter 7 Running Gear RunningGear 31 Motorcycl...

Page 4: ...lectricalEquipmentMaintenance 54 Chapter 11 Maintenance MaintenanceofMotorcycle 55 LubricationChart 56 RequiredLubrication 58 ListofRecommendedLubricants 58 Care of Motorcycle Paint 59 Preservation and Storage 59 Battery 60 List of Individual Tool Set Spare Parts Accessories Documents 62 Chapter 12 Patrol Model Patrol Motorcycle with Engageable Sidecar Drive 63 Description 63 HandlingDifferencesfr...

Page 5: ...butor sLimitedWarrantiesEmissionControlSystem 77 Distributor sLimitedWarranties NoiseControlSystems 78 Distributor sLimitedWarranties ReplacementParts 79 Distributor sLimitedWarranties UralAccessories 80 California Air Resources Board Warranty 81 EPANoiseRegulations 84 ClassicMotorcyclesEmision ControlSystemWaranty 85 Classic Motorcycles Noise Control System Warranty 86 ReportingSafetyDefects 87 C...

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Page 7: ...German and Russian history since it has been continually manufactured with the same general arrangement and outward appearance for the past 60 years after Russian engineers initially copied the BMW s of 1939 It truly is an instant antique as many of our owners have said Since the URAL weighs 700 lb empty with the attached sidecar has a large frontal area and is powered by an old fashioned 649cc en...

Page 8: ...er the boxer is still an air cooled power plant As such it must be carefully monitored during operation to prevent overheating As the gear making and other machine tools in the IMZ plant are vintage ones a careful break in of the engine is very important Neglecting to follow the prescribed speeds during break in or the frequent oil changes will cause this wonderful engine to rebel against its abus...

Page 9: ...ha nisms of the motorcycle takes place During this period do not overload the engine or race the motorcycle in excess of the speeds specified in the section Running In of New Motorcycle Doing so will void the warranty Maintenance intervals recommended are based on operational experience under various climatic and road conditions However these intervals may be extended or reduced following repeated...

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Page 11: ...ght 1100 mm 3 ft 6 in Road Clearance 125 mm 5 in Seat height 840 mm 33 in Wheel base 1470 mm 58 in ENGINE Type 4 stroke overhead valves opposed twin cylinder Displacement 649 cc Cylinder bore 78mm Piston stroke 68mm Compression ratio 9 1 1 Rated horsepower 25 8 KW 35 Hp Rated rotational speed 5600RPM Rated torque Nm 45 Nm 33 2 ft lbs Lubrication system Dual system of forced lubrication and by spla...

Page 12: ...ox 4 speed gearbox with reverse gear lever GEAR RATIOS I gear 3 6 II gear 2 28 III gear 1 7 IV gear 1 3 Reversegear 4 2 Speedometer drive ratio 0 4 Deco BC 65 0 5 Final drive ratio 4 62 FLUID CAPACITIES Tourist Bavarian Patrol Deco Fueltank 5 Gal 19L 5 Gal 19L Reserve 5 Gal 2L 5 Gal 2L Engine 76 oz 2 25L 76oz 2 25 L Transmission 34 oz 1 L 34oz 1 L Final drive 3 5 oz 105 ml 4 5 oz 135 ml Telescopic...

Page 13: ...Tires 4 x 19 3 5 x 18 Front 22 psi cold 1 5 Bar 150 kPa Front 22 psi cold Side 22 psi cold 1 5 Bar 150 kPa Side 22 psi cold Rear 36 psi cold 2 5 Bar 250 kPa Rear 36 psi cold CLEARANCES mm in Valves with engine cold 0 05 to 0 1 0 002 to 0 004 Between spark plug electrodes 1 016 0 040 Backlash between tooth faces of bevel gears in final drive 0 1 0 3 0 004 FREE TRAVEL ADJUSTMENTS mm in Hand brake co...

Page 14: ...reverse gear brake lever 1 8 to 2 0 kgf m 14 ft lb to 16 ft lb alternator gear nut 14 to 16 8 kgt 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 multiply by 1 056 there are 1 056 quarts per liter To convert fr...

Page 15: ...se gear engagement 15 High low beam switch indicator lamp 16 Clutch control lever 5 Front brake control lever 17 Steering damper tightening bolt 6 Throttle control twist grip 18 High beam indicator lamp 7 Ignition cutoff switch 19 Ignition Switch 8 Electric Start Button 20 Battery discharge warning lamp 9 Rear brake pedal sidecar wheel brake 21 Parking brake 10 Reverse gear lever 22 Master battery...

Page 16: ...rter Gear shift foot pedal Fig 1 12 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 easier to shift up if you rotate the heel of your left foot in towards the rear arm before stepping on it with your heel The neutr...

Page 17: ...tch Fig 1 19 has three fixed positions of the key The position and switching diagram of the ignition locks are shown above 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 taking it out...

Page 18: ...indicator switch Fig 1 13 and horn push button Fig 1 14 are combined in one unit on the left hand handle bar control housing Master battery switch Fig 1 21 is under the seat Electric Start Button Fig 1 8 is located on the right hand twist grip below the kill switch The steering damper absorbs lateral kicks on the front wheel Turning tightening bolt Fig 1 17 clockwise increases friction This can be...

Page 19: ...ION When draining and refilling oil be careful that dirt and debris does not contami nate the fresh oil Do not allow draining oil to get on the rear wheel tire or brake compo nents STARTING THE ENGINE WARNING BEFORE STARTING THE ENGINE MAKE SURE THAT THE GEAR SHIFT MECHANISM IS IN THE NEU TRAL POSITION BETWEEN 1ST AND 2ND GEARS TO PREVENT ACCIDENTAL MOVEMENT WHICH COULD CAUSE POSSIBLE DAMAGE TO MO...

Page 20: ...g the engine over since it may flood the spark plugs 1a Electric starter 1 Set carburetor enricheners as with kick starting Unlike manual start ing however the gearbox does not have to be in neutral as the electric starter may be engaged with the clutch lever pulled in or with the gearbox in neutral Make sure the kill switch is set to run and push the starter button to turn over the engine 2 When ...

Page 21: ...NE CYLINDER FOR EVEN JUST A FEW MINUTES COULD OVER HEAT THE CYLINDER AND CAUSE IRREVERSIBLE DAMAGE TO EITHER THE VALVES OR PISTON THUS IT IS CRITI CAL TO IMMEDIATELY SHUT THE ENGINE DOWN IF IT APPEARS TO BE RUNNING ON ONLY ONE CYLINDER Additional Warning Once the engine starts do not allow it to run at a high speed as this could cause abnormal wear of the parts and may lead to seizure of the pisto...

Page 22: ...AND THE OIL FROM THE ROAD SURFACE COMBINES WITH THE WATER When descending a long steep grade downshift and use engine compression together with inter mittent application of both brakes to slow the motorcycle Avoid continuous use of brakes to avoid overheating of the brakes and reduced efficiency While using the motorcycle in summer pay special attention to the condition of the tires Keep them infl...

Page 23: ...he cooling fins as their fouling will impair the condition of the engine cooling Check engine crankcase cylinders and cylinder heads for leaks of oil and fuel Check the engine performance with the motorcycle running Completely follow all maintenance intervals specified in the Service Coupons LUBRICATION SYSTEM The motorcycle engine features a dual lubrication system some parts are force lubricated...

Page 24: ... SYSTEM The fuel system includes the gasoline tank the three way fuel valve with filter and two carburetors Fuel valve petcock The top threaded portion of the valve is screwed into the gasoline tank The lever has three positions Down Reserve Horizontal Off Up On WARNING FUEL VALVE SHOULD ALWAYS BE CLOSED WHEN ENGINE IS NOT RUNNING TO ENSURE AGAINST ACCIDENTALLY FLOODING ENGINE OR SURROUNDINGS WITH...

Page 25: ...e the element off with low pressure water Tap water is OK Always flush from the clean side to the dirty side This removes the dirt and doesn t drive it into the filter After rinsing shake off any excess water and let the filter dry naturally After cleaning always re oil the filter with K N air filter oil Air Cleaner 1 Air Cleaner Body 4 Air Cleaner Lid 2 Filter Element 5 Crankcase Breather Tube 3 ...

Page 26: ...ARNING DO NOT OVER TIGHTEN THE SPARK PLUG WHEN MOUNTING IT ON THE ENGINE SINCE THIS COULD DAMAGE THE CYLINDER HEAD Functioning of ignition system Both plugs fire simultaneously on the left and right hand cylin ders one spark being formed when the compression stroke terminates in one of the cylinders and the other during the exhaust stroke CARBURETORS 32mm CVK Keihin Seike carburetors are used on o...

Page 27: ...27 Enrichener off Enrichener on Use the enricheners only if needed to start a cold engine Turn the enricheners off as soon as the engine has started to prevent the possible fouling of the spark plugs ...

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Page 29: ...r must be engaged from neutral Shifting the gears is best accomplished by pushing down on the toe piece for first gear and to downshift from higher gears To shift up into second third and fourth gear use the heel plate with either heel or toe and push down quickly and firmly CAUTION Severe damage due to insufficient lubrication of gears shafts and bearings can result if the oil level is allowed to...

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Page 31: ...ion of the springs is adjustable allowing two positions The first lower position corresponds to the load due to the motorcycle s own mass the driver s and one passenger s sitting in the sidecar mass the second upper position of moving cam corresponds to the maximum load When the motorcycle is used under the maximum load adjust the spring in the sidecar wheel shock absorber simultaneously while adj...

Page 32: ...decar to the motorcycle slacken off the bolt clamping the lower rear bracket adjust the position of the bracket relative to the rear tube of the sidecar frame to obtain necessary toe in of the wheels Tighten up the bolt fastening the bracket adjust the length of the legs and secure them with bolts Check the lean out of the motorcycle using a level gauge or protractor with a plumb bob and a ruler A...

Page 33: ...etween the steel and the fiber washers makes turning of the front fork more difficult WARNING DO NOT OVER TIGHTEN THE STEERING DAMPER SINCE THE MOTORCYCLE WILL BECOME VERY DIFFICULT TO HANDLE STEERING HEAD BEARINGS The steering head bearings must be adjusted periodically to avoid excessive play which might cause steering instability When properly adjusted the front fork should turn with just a hin...

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Page 35: ...Slacken the nut of the union bolt at the end piece base of the fork left hand leg Screw out the axle turning it clockwise left hand thread and remove the wheel together with the front brake To reinstall the front wheel on the motorcycle follow the reverse order of the above operations seeing to it that the torque stop on the brake cover encompasses the right hand leg of the fork To remove the rear...

Page 36: ...S WE RECOMMEND YOU SEE YOUR URAL DEALER FOR THESE SERVICES TIRE DATA WARNING FOR YOUR OWN PERSONAL SAFETY TIRES AND TUBES MUST BE CORRECTLY MATCHED TO WHEEL RIMS SEE YOUR AUTHORIZED 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 ...

Page 37: ...ICATION ON TIRE SIDEWALL WARNING WHEN TIRES ARE WORN TO A TIRE CENTER TREAD DEPTHS OF 3 32 IN THEY SHOULD BE REPLACED RUNNING GEAR MAINTENANCE During the pre trip inspection check air pressure in the tires chapter 1 Check assembly units and parts for safe fastening be sure to tighten the fasteners and eliminate play as soon as they get loose or demonstrate excessive play While lubricating consult ...

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Page 39: ...e wear of the shoe linings The adjusting bolts of the brake shoes may be used for adjusting the gap between the brake shoes and the brake drum For optimal performance of the brake tighten the brake cable adjuster until there is just the slightest drag on the wheel Then back off the adjustment 1 or 2 turns For checking the gap the cover of the brake drum and final drive crankcase are provided with ...

Page 40: ...0 km WARNING BECAUSE BRAKE PERFORMANCE IS A CRITICAL SAFETY ITEM WE RECOMMEND THAT YOU SEE YOUR URAL 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 SHOES WHEN NECESSARY COULD RESULT IN BRAKE MALFUNCTION AND PER SON...

Page 41: ...ondition of the brakes clean the brake shoes and the active surface of the brake drums lubricate the hinge pins and the cams of the brake linings the joints the linkage of the rear and sidecar wheel brakes the lever axle the parking brake the throttle control twist grip the lever pins and ends of cables used in the clutch the front brake control the control cables used in the clutch the front brak...

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Page 43: ...ine camshaft driven gear The alternator is secured with two studs on the engine crankcase At the drive side the alternator cover is so designed that by turning the alternator on the studs the backlash adjustment of the gear mesh gap can be made Electric horn The motorcycle is equipped with a horn which sounds when the ignition is on and the horn button is pressed The horn can be adjusted with an a...

Page 44: ... in a circuit Fuses are rated in Amps Electrical Circuits Lead acid batteries such as those found in motorcycles are designed for a charging voltage of 14 25 volts Batteries which are subjected to greater than 14 25 volts for extended periods of time can suffer permanent damage due to the electrolyte boiling dry Charging voltage of less than 14 25 volts will result in an inadequate charge delivere...

Page 45: ...45 The fuse box is located beside the The in line fuse is located behind left front fork the headlight ...

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Page 54: ...n the course of daily inspection check the fastening of wires to the alternator terminals fastening of the alternator on the engine crankcase backlash of the gears by listening In case of too little backlash of the drive gear excessive wear and overheating of the alternator bearings take place See alternator description in Electrical Equipment Section Check for proper tightening of nuts of the bin...

Page 55: ...rcycle is given in Fig 35 A sum mary of lubrication maintenance is given in the lubrication chart CosmeticMaintenance The enjoyment and resale value of your vehicle is greatly enhanced by consideration to the look and cosmetic perfection of your vehicle Due to the numerous metal surfaces on a sidecar rig special care must be taken to prevent rust from occurring and or to removed any rust or oxidat...

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Page 57: ...e oil WD 40 8 Brake pedal shaft Spindle oil WD 40 9 Universal joint of drive shaft grease Grease cup 10 Lever pins and end pieces of clutch and Grease hand brake cables 11 Pins and cams of brake shoes Grease 12 Wheel bearing Grease 13 Front forks Spindle oil WD 40 14 Carburetor throttle control twist grip Grease 15 Speedometer drive flexible shaft and Industrial oil or speedometer axle spindle oil...

Page 58: ...chart shows the amounts and brands of oil and oil treatment used originally in your motorcycle LIST OF RECOMMENDED LUBRICANTS Lubrication Area Detergent Oil Quantity Hyper Lube Total Volume Supplement Lubrication Fluids Engine 20w 50 Castrol 64 oz 1 9 L 12 oz 350 ml 76 oz 2 25 L Transmission 20w 50 Castrol 22 oz 650 ml 12 oz 350 ml 34 oz 1 0 L Final Drive Single Wheel Drive 80 90 wt Gearlube 2 0 o...

Page 59: ...ir for 15 min then proceed with drying at 212 F 248 F 100 C 120 C with the aid of heat reflector or an electric lamp until the coat is perfectly dry Bear in mind that enamels are flammable Color match may not be perfect due to humidity fading temperature and other variables The painted surfaces of the motorcycle feature natural gloss In case some dull spots appear remedy them by polishing as follo...

Page 60: ...ers is recommended for those areas with salt and or fine gravel or sand See your dealer for details BATTERY Storage batteries on the motorcycle should function at ambient air temperature from 40 C to plus 60 C 40 F to 140 F As the battery is in service regularly check the voltage for 13 8 14 2 V do not allow the battery to discharge use only distilled water to maintain the normal level of electrol...

Page 61: ...TE AREA WHEN CHARGING BATTERY ALWAYS PROTECT HANDS AND PROTECT EYES WITH SHIELD OR GOGGLES WHEN WORKING NEAR A BATTERY OR ACID KEEP BATTERIES AND ACID OUT OF THE REACH OF CHILDREN CAUTION If battery is filled to a higher level than specified some of the solution will be forced out through the vent tube when battery is charging This will not only weaken the solution but also may damage parts near t...

Page 62: ...rger 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 2 Driving the URAL Sidecar Motorcycle 1 16 Allen wre...

Page 63: ...ently from the standard single wheel drive motorcycle When the rear wheel and sidecar wheel are locked together on paved surfaces maneuvering is very difficult Forcing the rig to turn on paved surfaces with the sidecar drive engaged is extremely hazardous and can result in loss of control of the motorcycle It also voids the warranty The dual wheel drive should be engaged whenever poor traction is ...

Page 64: ...ted tightly Grease the moveable slot joint of the drive shaft sufficiently every 5 000 kilometers Do not over grease the slotted hub of the propeller shaft as it may prevent the slotted shaft from moving freely in the hub The bearing unit of the sidecar wheel where an oilless bearing is installed in requires no mainte nance ...

Page 65: ...s as well as experienced solo motorcycle drivers Even though special skills are required these skills are not difficult to master They are clearly defined in the Driving the URAL Sidecar Motorcycle manual This manual is included with each new URAL sidecar motorcycle outfit Before driving your new URAL carefully study this manual from cover to cover fill in the exam questions review the manual to c...

Page 66: ... circle about 20 feet in diameter Gradually increase your speed until the sidecar wheel lifts from the surface 6 12 inches Then roll off the throttle and ease steering pressure on the grips so it gradually comes back down Re peat doing this until you feel comfortable with the wheel in the air Remember the moment you roll off the throttle it will come down When you have mastered flying the chair to...

Page 67: ...racteristics under all conditions If you are an inexperienced rider we recommend that you obtain information and training in correct motorcycle riding technique For the sidecar motorcycle carefully study the Driving the URAL Sidecar Motorcycle 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 th...

Page 68: ... Do not presume too much when you have the right of 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 according...

Page 69: ...de car rig and distributed by Classic Motorcycles Authorized URAL Dealer A dealer within the United States Canada or Mexico authorized to sell URAL motorcycles distrib uted by Classic Motorcycles First Purchaser The original buyer of a new URAL from an Authorized URAL Dealer WARRANTY RESPONSIBILITIES The Distributor Classic Motorcycles To repair or replace at its option any part which is proven to...

Page 70: ...service interval costs Your warranty coverage will not be voided if you choose to perform the maintenance yourself Failures which occur due to improper maintenance are not covered under this warranty Your URAL dealer is your best source for scheduled maintenance on your URAL Regardless of who performs your maintenance if warranty repairs are needed your URAL dealer may ask you for documentation wh...

Page 71: ... an implied warranty lasts Some states may not allow exclusion or limitation of incidental or consequential damages Your Legal Rights These warranties give you specific legal rights You may also have other rights which very from state to state These Warranties Do Not Cover Failures which are not due to a defect in material or factory workmanship Parts or accessories affected or damaged by lack of ...

Page 72: ... Warranty Exclusions For Tires and Replacement Parts Please refer to the This Warranty Does Not Cover section of these warranties for a listing of additional items and circumstances that are not covered DISTRIBUTORS LIMITED WARRANTIES NEW MOTORCYCLE Classic Motorcycles warrants to the first retail purchaser and subsequent purchasers of this URAL motorcycle that the motorcycle is free from defects ...

Page 73: ...overed component repairs per formed during each visit The URAL DFS Advantage Service Agreement pays the rest Pickup Delivery Reimbursement Pickup and delivery reimbursement is available when a breakdown to a covered component disables your vehicle Substitute Vehicle Reimbursement If your vehicle has a breakdown to a covered component reimbursement is available for your out of pocket substitute veh...

Page 74: ...echa nism Primary drive case if damaged as a result of the failure of a covered primary drive compo nent Drive Axle Assembly Components Shaft driven Vehicles and ATV s Differential housing transaxle housings final drive housing all internally lubricated parts of the foregoing axle shafts constant velocity joints universal joints drive shafts locking hubs hub bearings locking rings supports retaine...

Page 75: ... Plans 72 Month Protection The URAL DFS Advantage plan protection covers your new current model year URAL or IMZ for an additional 36 month protection after the 36 month protection outlined above has expired These plans are available from your dealer at very affordable prices Non Eligible Products The following products are not eligible for The URAL DFS Advantage Service Agreement New vehicles sol...

Page 76: ...ic Motorcycles The obligation of Classic Motorcycles To replace any tire which is proven to be defective in material or factory workmanship under nor mal use until the tire tread is worn to the service limit specified in this manual At that point there will be no further warranty consideration regardless of the tire s age or mileage Your obligation To practice proper tire care and prudent motorcyc...

Page 77: ...verloading misalignment improper mounting during replacement of after repair or installation on unsuitable rims tires rendered unserviceable due to abuse or misuse such as towing a trailer tube type tires fitted without inner tubes tires which have been repaired tires whose sidewalls have been modified by the addition or removal of material tires with superficial weathering checking or cracking ti...

Page 78: ...ective in material or factory workmanship under normal use for the applicable period Parts Labor No charge to you Your obligation To have required maintenance performed in accordance with the Maintenance Schedule contained in this manual Failure to have required maintenance performed may result in losing coverage under this warranty Claims for repairs or adjustments found to be caused solely by de...

Page 79: ...is manual and Service Cou pons Failure to have required maintenance performed may result in losing warranty coverage Note The following items are not covered by the Noise Control System Warranty Failures which arise as a result of misuse alterations or accident Replacing removing or modifying any portion of the Noise Control System with parts not certified to be noise legal for street use loss of ...

Page 80: ...he color match of painted components DISTRIBUTOR S LIMITED WARRANTIES URAL ACCESSORIES Warranty Time Period Duration Three Months Bolt on Accessories other than audio equipment If installed on an unsold URAL motorcycle motorcycle s warranty period applies to the accessory as well If installed on a URAL motorcycle which is already in service motorcycle s remaining warranty period or a period of thr...

Page 81: ...ilometers 18 641 miles whichever first occurs If an emission related part on your motorcycle is defective the part will be repaired or replaced by Classic Motorcycles This is your emission control system DEFECTS WARRANTY OWNER S WARRANTY RESPONSIBILITIES As the motorcycle owner you are responsible for the performance of the required maintenance listed in your owner s manual Classic Motorcycles rec...

Page 82: ...ather air cutoff valves fuel tank cap for evaporative emission controlled vehicles oil filler cap pressure control valve fuel vapor separator canister igniters breaker governors ignition coils ignition wires ignition points condensers and spark plugs if failure occurs prior to the first scheduled replacement and hoses clamps fittings and tubing used directly in these parts Since emission related p...

Page 83: ...EPT AS SPECIFICALLY SET FORTH HEREIN ANY EMISSION CONTROL SYSTEM WARRANTY IMPLIED BY LAW INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE IS LIMITED TO THE EXPRESS EMISSION CON TROL SYSTEM WARRANTY TERMS STATED IN THIS WARRANTY THE FOREGOING STATEMENTS OF WARRANTY ARE EXCLUSIVE AND IN LIEU OF ALL OTHER REMEDIES SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIE...

Page 84: ... has been removed or rendered inoperative by any person AMONGTHOSEACTSPRESUMEDTOCONSTITUTETAMPERINGARETHEACTSLISTED BELOW 1 Replacing the muffler s and or the entire exhaust system with parts not certified to be noise legal 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 u...

Page 85: ...ator or company vehicle prior to sale at retail on the date it is first placed in service The following items are not covered by the emission control system warranty 1 Failures which arise as a result of misuse alterations accident or non performance of maintenance as specified in the Owner s Manual and the Service Coupons 2 The replacement of parts such as spark plugs fuel and oil filters etc use...

Page 86: ...cle is designed and built so as to conform at the time of sale with applicable regulations of the US Envi ronmental Protection Agency Standards within 1 year or 3 728 miles 6 000 kilometers whichever occurs first The warranty period shall begin on the date the motorcycle is delivered to the first retail purchaser or if the motorcycle is placed in service as a demonstrator or company vehicle prior ...

Page 87: ...the National Highway Traffic Safety Administra tion NHTSA in addition to notifying Classic Motorcycles If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign For this rea son it is very important for you to notify Classic Motorcycles of any change of address or own ership There i...

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Page 89: ...d 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 and then fax or mail a copy of it to the above address for inclusion in the owner s permanent file records The copy of the completed Service Coupon must be received by the company within 30 days of the work being performed in order to qualify as service int...

Page 90: ...r tightening 8 Check steering column bearings 9 Check alternator bolts 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 91: ...and brake control cables B Hinges of the foot brake pedal shaft and linkage 9 Check condition and action of brakes 10 Check tires for tread depth greater than 3 32 11 Check fasteners for proper tightening 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...

Page 92: ...ration B Check steering column bearings adjust if required C The condition and action of the brakes lubricate the brake shoe fulcrum pins and cams D The tension of wheel spokes Adjust if necessary E The toe in and camber angle of the motorcycle and sidecar F Electric wiring Tighten connections if required G Fasteners for proper tightening 11 Re pack the grease in wheel bearings adjust the bearings...

Page 93: ...etween 14 900 to 15 100 km Date Odometer reading km 1 Change engine oil and filter See lubrication chapter 11 2 Change transmission oil See lubrication chapter 11 3 Inspect air filter element 4 Check carburetors while idling for synchronous operation 5 Check adjustment of steering column bearings 6 Lubricate A Lever pins B Hinges of the foot brake pedal shaft and linkage 7 Check condition and acti...

Page 94: ...ing km 1 Change 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 adjustment of wheel bearings The maintenance above has been performed as described Owner s Signature Service Technician s Signature ...

Page 95: ...eration B Check steering column bearings adjust if required C The condition and action of the brakes lubricate the brake shoe fulcrum pins and cams D The tension of wheel spokes Adjust if necessary E The toe in and camber angle of the motorcycle and sidecar F Electric wiring Tighten connections if required G Fasteners for proper tightening 11 Repack the grease in wheel bearings adjust the bearings...

Page 96: ...100 km Date Odometer reading km 1 Change engine oil and filter See Lubrication List chapter 11 2 Change transmission oil See Lubrication List chapter 11 3 Inspect air filter element 4 Check carburetors while idling for synchronous operation 5 Check A Adjustment of steering column bearings B Tension of wheel spokes C Toe in and camber of the motorcycle and sidecar 6 Lubricate A Lever pins B Foot br...

Page 97: ...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 98: ...eration B Check steering column bearings adjust if required C The condition and action of the brakes lubricate the brake shoe fulcrum pins and cams D The tension of wheel spokes Adjust if necessary E The toe in and camber angle of the motorcycle and sidecar F Electric wiring Tighten connections if required G Fasteners for proper tightening 11 Repack the grease in wheel bearings adjust the bearings...

Page 99: ...ne is started a negative pressure at the air intake butterfly valve will draw outside air in through the canister vent and flush the trapped vapors through a second tube into the intake manifold for pro cessing by the engine Butterfly Valve The butterfly valve is a vacuum driven valve which either opens or closes the intake manifold to outside air In the resting state the valve completely seals th...

Page 100: ...resting state the valve seals the carburetor vent lines from outside air During engine operation negative pressure from the accompanying 1 way valve activates the breather valve and opens the carburetor vent lines to atmospheric pressure This allows the carburetor float valves to operate normally Air Box The air box is a sealed container which conducts outside air to the engine intake manifold thr...

Page 101: ... to the butterfly valve actuator This vacuum causes the actuator to open the butterfly valve This action allows outside air to enter the air box The pulsating negative pressure from the carburetor inlets is also passed to another 1 way valve where it is converted to a constant vacuum This vacuum is then used to open the breather valve When the breather valve is open it allows atmospheric pressure ...

Page 102: ...ure to the butterfly valve actuator by venting the butterfly valve actuator to atmospheric pressure This causes the butterfly valve to close sealing the main opening of the air box to the atmosphere Any gaso line vapors in the intake manifold remain sealed within the engine Butterfly Valve ...

Page 103: ...MBER X T B 7 6 4 A OWNER SNAME_____________________________________________ OLD ADDRESS ______________________________ APT NO _______ CITY ________________ STATE ____________ ZIP CODE _________ MY NEW ADDRESS IS NEW ADDRESS ____________________________ APT NO ________ CITY _______________ STATE _____________ ZIP CODE _________ Send this form to Classic Motorcycles P O Box 969 Preston WA 98050 or f...

Page 104: ...MBER X T B 7 6 4 A NEWOWNER SNAME_____________________________________________ ADDRESS ______________________________ APT NO _______ CITY ________________ STATE ____________ ZIP CODE _________ DATE OF SALE ________________ MO DAY YEAR PurchasedFrom___________________________________________________ City _____________________State ____________ Zip Code _______________ Send this form to Classic Moto...

Page 105: ...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 cock Correction Clogged fuel lines or filter are corrected by blowing through fuel lines from carburetor end to remove any debris from lines Fuel cock filter can be cleaned by removing and clean...

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