URAL Motorcycles cT 2022 Owner'S Manual Download Page 9

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MODEL SPECIFICATIONS

Model

Gear Up / Ranger

Engine and transmission

Displacement, cc

745

Engine type

OHV air cooled 2 cylinder 4 stroke "boxer"

(flat twin)

OHV air cooled 2 cylinder 4 stroke "boxer"

(flat twin)

Valve per cylinder

Bore and stroke (mm x mm)

78 x 78

Maximum power (kW)

29.19 @ 5615 rpm

Maximum torque (Nm)

53.38 @ 4141 rpm

Compression

10.5:1

Fuel system

Throttle body EFI

Starting

Electric & Kick start

Clutch

Double-disc dry

Transmission type

Manual

Speeds

4 forward 1 reverse

Primary drive (rear wheel)

Driveshaft

Final drive ratio

4.62

Engagable sidecar wheel drive

Yes, driveshaft

Physical measures

Overall length, mm

2 280

Overall heights, mm

1 100

Overall width mm

1 700

Seat height, (unladen), mm

835

Ground clearance, (unladen), mm

125

Dry weight, kg

352 (362 with coupling device)

381 (391 with coupling device)

Chassis

Front suspension

IMZ leading link fork

Rear suspension

Double sided swing-arm with two Sachs

hydraulic spring shock absorbers, 5x

adjustable

Double sided swing-arm with two Sachs

hydraulic spring shock absorbers, 5x

adjustable

Sidecar suspension

Single sided swing-arm with Sachs hydraulic

spring shock absorber, 5x adjustable

Single sided swing-arm with Sachs hydraulic

spring shock absorber, 5x adjustable

Wheels

2.15X18 or 2.15x19 Aluminum rims with steel

spokes

2.15X19 Aluminum rims with steel spokes

Tires

Heidenau K28 4.00-18"

Heidenau K28, K37 4.00-19"

Front brake

4-piston fixed Brembo caliper with 295mm

floating NG rotor

4-piston fixed Brembo caliper with 295mm

floating NG rotor

Rear brake

2-piston fixed Brembo caliper with a 265mm

floating NG rotor with a standalone

mechanical parking brake caliper by JJuan

2-piston fixed Brembo caliper with a 265mm

floating NG rotor with a standalone

mechanical parking brake caliper by JJuan

Sidecar brake

2-piston fixed Brembo caliper with 245mm

floating NG rotor

2-piston fixed Brembo caliper with 245mm

floating NG rotor

Other

Fuel grade

95 Octane minumum,

98 Octane recommended

95 Octane minumum,

98 Octane recommended

Fuel tank capacity (liters)

17.5

Reserve (liters)

app. 3.5

Estimated fuel economy, l/100km

4.4

Estimated range, km

250-300

Recommended max cruising speed (km/h)

105

Max permissible weight, kg

610

Trunk volume, (liters)

Electrical

Alternator

Denso, Peak Output 40 Amp @ 14vdc, 560 Wt Denso, Peak Output 40 Amp @ 14vdc, 560 Wt

Battery

YTX20-BS

Headlight

Spark plugs

NGK BPR7HS-10

Warranty

2-years parts and labor unlimited mileage

Model

Gear Up

Engine and transmission

Displacement, cc

745

Engine type

OHV air cooled 2 cylinder 4 stroke "boxer"

(flat twin)

OHV air cooled 2 cylinder 4 stroke "boxer"

(flat twin)

Valve per cylinder

Bore and stroke (mm x mm)

78 x 78

Maximum power (kW)

29.19 @ 5615 rpm

Maximum torque (Nm)

53.38 @ 4141 rpm

Compression

10.5:1

Fuel system

Throttle body EFI

Starting

Electric & Kick start

Clutch

Double-disc dry

Transmission type

Manual

Speeds

4 forward 1 reverse

Primary drive (rear wheel)

Driveshaft

Final drive ratio

4.62

Engagable sidecar wheel drive

Yes, driveshaft

Physical measures

Overall length, mm

2,280

Overall heights, mm

1,100

Overall width mm

1,700

Seat height, (unladen), mm

835

Ground clearance, (unladen), mm

125

Dry weight, kg

352 (362 with coupling device)

381 (391 with coupling device)

Chassis

Front suspension

IMZ leading link fork

Rear suspension

Double sided swing-arm with two Sachs

hydraulic spring shock absorbers, 7x

adjustable

Double sided swing-arm with two Sachs

hydraulic spring shock absorbers, 7x

adjustable

Sidecar suspension

Single sided swing-arm with Sachs hydraulic

spring shock absorber, 7x adjustable

Single sided swing-arm with Sachs hydraulic

spring shock absorber, 7x adjustable

Wheels

2.15X18 or 2.15x19 Aluminum rims with steel

spokes

2.15X19 Aluminum rims with steel spokes

Tires

Heidenau K28 4.00-18"

Heidenau K37 4.00-19"

Front brake

4-piston fixed Brembo caliper with 295mm

floating NG rotor

4-piston fixed Brembo caliper with 295mm

floating NG rotor

Rear brake

2-piston fixed Brembo caliper with a 265mm

floating NG rotor with a standalone

mechanical parking brake caliper by JJuan

2-piston fixed Brembo caliper with a 265mm

floating NG rotor with a standalone

mechanical parking brake caliper by JJuan

Sidecar brake

2-piston fixed Brembo caliper with 245mm

floating NG rotor

2-piston fixed Brembo caliper with 245mm

floating NG rotor

Other

Fuel grade

95 Octane minumum,

98 Octane recommended

95 Octane minumum,

98 Octane recommended

Fuel tank capacity (litres)

19.0

Reserve (litres)

app. 3.5

Estimated fuel economy, l/100km

4.4

Estimated range, km

250-300

Recommended max cruising speed (km/h)

105

Max permissible weight, kg

610

Trunk volume, (litres)

Electrical

Alternator

Denso, Peak Output 40 Amp @ 14vdc, 560 Wt

Battery

YTX20-BS

Headlight

Spark plugs

NGK BPR7HS-10

1-4

Summary of Contents for cT 2022

Page 1: ...2022 OWNERS MANUAL Gear Up_LH cT_LH imz ural com au ...

Page 2: ...Intentionally left blank ...

Page 3: ... and for your personal motorcycling safety and pleasure It is critical that a beginning sidecar driver becomes thoroughly familiar with the special operating characteristics of the sidecar outfit before venturing out on busy roads Your Owner s Manual contains instructions for operation maintenance and minor repairs Major repairs require the attention of a skilled mechanic and the use of special to...

Page 4: ...D MAINTAIN YOUR MOTORCYCLE PLEASE PAY SPECIAL ATTENTION TO NOTICES IN THIS MANUAL MARKED AS FOLLOWS CAUTION INDICATES POSSIBILITY OF EQUIPMENT FAILURE THAT MAY RESULT IN YOUR MOTORCYLE BEING UNSAFE TO OPERATE IF INSTRUCTIONS ARE NOT FOLLOWED WARNING INDICATES A VERY STRONG POSSIBLILITY OF INJURY TO YOURSELF AND OTHERS OR LOSS OF LIFE IF INSTRUCTIONS ARE NOT FOLLOWED NOTE PROVIDES HELPFUL INFORMATI...

Page 5: ... and Instrumentation 2 Motorcycle Operation 3 Service Maintenance Sections Lubrication 4 Engine Chassis Maintenance 5 Electrical 6 EFI Troubleshooting 7 Consumer Information Sections Warranty Information 8 Emission Control Information 9 Owner Documents 10 Schematics 11 ...

Page 6: ...tion Page Service Rules 1 2 Model Identification 1 3 Model Specifications 1 4 Torque Chart 1 5 Clearance and Adjustment Specifications 1 6 Tire Data 1 6 Periodic Maintenance Chart 1 7 Motorcycle Storage and Care 1 8 1 1 ...

Page 7: ... 6 Clean all parts with non flammable solvents prior to reassembly after servicing 7 Always replace seals O rings gaskets and cotter pins when reassembling 8 If you remove self locking nuts they should always be replaced with new ones 9 Be responsible with solvents cleaners and waste oils Always dispose of them in accordance with your local regulations WARNING IF THE ENGINE MUST BE RUNNING TO PREF...

Page 8: ...ped on the frame directly above the label List Your VIN Here Engine Number The engine number is stamped on the left side of the engine This is the second number List Your Engine Number Here Gearbox Number The gearbox number is stamped on the left side of the gearbox directly above the shift lever List Your Gearbox Number Here 1 3 ...

Page 9: ... BS YTX20 BS Headlight H4 H4 Spark plugs NGK BPR7HS 10 NGK BPR7HS 10 Warranty 2 years parts and labor unlimited mileage 2 years parts and labor unlimited mileage Model cT Gear Up Engine and transmission Displacement cc 745 745 Engine type OHV air cooled 2 cylinder 4 stroke boxer flat twin OHV air cooled 2 cylinder 4 stroke boxer flat twin Valve per cylinder 2 2 Bore and stroke mm x mm 78 x 78 78 x...

Page 10: ... 88 64 9 Sidecar Swing Arm Mounting Bolts 88 64 9 Front Fork to Pivot of Swing Arm Mounting Bolts 50 36 9 Lower Sidecar Frame Mounting Bolts 88 64 9 Sidecar Strut Mounting Bolts 88 64 9 Spoke Nipple 3 5 to 5 5 2 6 to 4 0 Drive Train Engine Gearbox and Final Drive Drain Plugs 22 16 2 Cylinder Head Nuts 50 36 9 Valve Cover Bolts 12 8 8 Oil Pump Drive Gear Cap Bolt 10 7 4 Final Drive to Swing Arm Mou...

Page 11: ...oe In 2wd 3 to 8 0 125 to 0 315 Lean Out 1 to 2 degrees 1 to 2 degrees TIRE DATA Location Type Recommended PSI Front Heidenau K28 K37 4 0x19 Gear Up_LH Heidenau K28 4 0x18 cT_LH 32 PSI Cold Rear Heidenau K28 K37 4 0x19 Gear Up_LH Heidenau K28 4 0x18 cT_LH 36 PSI Cold Sidecar Heidenau K28 K37 4 0x19 Gear Up_LH Heidenau K28 4 0x18 cT_LH 32 PSI Cold Spare if equipped Heidenau K28 K37 4 0x19 Gear Up_L...

Page 12: ... I I I I I Tightness of spokes I I I I I I I Tightness of fasteners I I I I I I I I Disc brake pads disc hoses calipers and cylinders lever travel I I I I I I I Brake fluid level I I I I I I I R Check operations of parking brake I I I I Clutch throttle and odometer cables clutch lever travel I I I I I I I I Bearings of the motorcycle and sidecar swing arms 2wd linkage on 2wd models Retro reverse l...

Page 13: ... the motorcycle for a short ride prior to any long trips CLEANING It is important to maintain your motorcycle properly and clean it on a regular basis Use the following guidelines when washing your motorcycle Make sure the engine is completely cool Use warm soapy water and wash thoroughly Avoid water entering the air filter and electrical components After washing dry the motorcycle with a cloth Lu...

Page 14: ...2 Foot Controls 2 3 Ignition Switch 2 4 Indicator Lamps 2 4 Speedometer Functions 2 5 Speedometer Operation 2 6 Parking Brake 2 7 Reverse Pedal 2 7 Kick Starter 2 8 2wd Engagement Lever 2 8 Hydraulic Spring Shock Absorbers 2 9 Hydraulic Steering Damper 2 9 2 1 ...

Page 15: ...eer and control the motorcycle Front Brake Lever Pulling the lever will actuate the front brakes WARNING IF THE BRAKE LEVER FEELS SPONGY DO NOT RIDE THE BIKE AND CONTACT YOUR DEALER Starter Button Press the button to engage the starter motor WARNING WHEN USING THE STARTER ALWAYS BE SURE THE GEARBOX IS IN NEUTRAL Engine STOP Switch Toggle the switch forward to stop the engine Toggle back to run Thr...

Page 16: ...hift use the heel portion of the shift lever to down shift use the toe portion of the shifter Rear Brake Lever Pressing the rear brake lever actuates the rear and sidecar brakes WARNING IF THE BRAKE LEVER FEELS SPONGY DO NOT RIDE THE BIKE AND CONTACT YOUR DEALER 2 3 ...

Page 17: ...dicator Lamp will illuminate when gearbox is in neutral 6 Turn Signal Indicator Lamp flashes when signals are active 7 Low Fuel Level Indicator While on level ground lamp will flash when fuel level is low and become solid when on reserve level approx 1 Gal NOTE FUEL LAMP CAN GIVE FALSE INDICATION DUE TO SLOSHING WHILE RIDING CHECK LAMP ON LEVEL GROUND 3 Position Switch In the Off position the engi...

Page 18: ...vehicle is moving ODO Odometer ODO accumulates total distance traveled RT Riding Timer 1 Calculates total running time since last RESET 2 Counter automatically begins with movement TT Total Riding Timer 1 Calculates total riding time from the beginning of the bike 2 TT data is stored in memory and cannot be reset HRTT Total Hour Meter 1 Calculates total engine operation time NOT ACTIVE 12 24 hour ...

Page 19: ...n increments the flashing digit by 1 position Press MODE button to confirm the digit setting and jump to next digit or next setting screen to be set Press MODE button for 2 seconds on any setting screen to finish and go to normal mode 12 24 Hour Clock Set up Clock displays 12 or 24H in XX XX XX format and AM PM when you select 12H option Use MODE and RESET buttons as described above in Data Progra...

Page 20: ...CAUTION OPERATING THE MOTORCYCLE WHILE THE PARKING BRAKE IS ENGAGED CAN DAMAGE THE BRAKE SYSTEM Reverse Engagement Lever The reverse lever is located on the right side of the gearbox near the foot peg Pulling the lever back while in Neutral will engage the reverse gear Push the lever forward to put the gearbox back into Neutral and use forward gears CAUTION THE REVERSE LEVER MUST BE IN THE FULL FO...

Page 21: ... 2wd CAUTION 2WD SHOULD ONLY BE USED FOR LOOSE ROAD CONDITIONS AND OR OFF ROAD PURPOSES WARNING USE OF 2WD ON THE STREET CAN MAKE THE MOTORCYLE DIFFICULT TO STEER POSSIBLY RESULTING IN LOSS OF CONTROL Kick Start Lever To use the kick start lever rapidly press the lever downward with your foot as shown WARNING WHEN USING THE KICK STARTER ALWAYS BE SURE THE GEARBOX IS IN NEUTRAL 2 8 ...

Page 22: ...to increase spring preload using the supplied wrench in your tool kit Adjustable Damper 16 Position The steering damper is fully adjustable to accommodate different riding styles and conditions Rotate the adjustment rod clockwise to increase dampening and counter clockwise to reduce dampening CAUTION OVER ROTATION OF THE ADJUSTMENT ROD CAN DAMAGE THE DAMPER AND OR CAUSE FLUID LEAKS 2 9 ...

Page 23: ...3 Motorcycle Operation Page Pre ride Inspections 3 2 Initial Ride Instructions 3 2 Sidecar Safety 3 3 Starting Procedures 3 5 Run In 3 6 Motorcycle Use and Loading 3 6 3 1 ...

Page 24: ...not ride the bike as it may be unsafe 6 Inspect all cables to insure they are not pinched or routed improperly also inspect the clutch cable for correct free play 7 Check for any loose fasteners and tighten as necessary 8 Be sure any luggage is secured before riding INSTRUCTIONS FOR INITIAL RIDE The following steps should be taken prior to and during your first ride 1 Read the entire owner s manua...

Page 25: ... kg 100 lbs of ballast in the sidecar during your initial training Although an experienced driver can safely drive the Ural with an empty sidecar a beginner should always have ballast or a passenger in the chair Check with your local Dealer to find out your particular state s sidecar driver s license requirements When you accelerate the Ural will pull slightly to the left due to the inertia and dr...

Page 26: ...ou ll find that the sidecar will lift much more readily when it is empty especially if you enter a decreasing radius turn such as a freeway off ramp at too high a speed This is why we recommend generally carrying about 45 kg 100 lbs or more in the sidecar WARNING BALLAST WEIGHT SHOULD ALWAYS BE PROPERLY SECURED IN THE SIDECAR AND CENTERED FOR BEST BALANCE 3 4 ...

Page 27: ...IGHT FOUND ON PAGE 4 2 CAUTION DO NOT ACCELERATE WHILE STARTING THE BIKE DO NOT RUN STARTER FOR MORE THAN 5 SECONDS NEVER STAND IN FRONT OF THE MOTORCYCLE WHILE THE ENGINE IS RUNNING STARTING THE ENGINE WHEN WARM OR HOT Use the following instructions when starting a warm or hot engine 1 Check that you have enough fuel 2 Switch ignition on 3 Be sure the transmission is in neutral 4 Switch the kill ...

Page 28: ...eparing your sidecar outfit for a trip Remember sidecars and their handling characteristics differ from their two wheeled counterparts Air cooled Heat is detrimental to air cooled engines When planning for a ride consider a few factors before choosing your route What is the ambient temperature Will I have a passenger or additional payload What is the best route for the speed I will be able to main...

Page 29: ...duce speed and or make periodic cooldown stops Make it a habit on longer trips to check oil at fill ups and cooldown rest stops High temperatures and sustained speed can lead to higher level of oil consumption Off Road Off road riding includes but is not limited to fire roads desert trails snow covered obstructed rutted pot holed rock covered paths quarries beaches mud holes etc or any environment...

Page 30: ...ould be to specification to avoid excessive clutch slippage while navigating rough roads loose sand or gravel mud etc Being overloaded on the road and particularly over continuous rough terrain will deteriorate the sidecar bodies rubber suspension faster than normal When loaded and off road navigate obstacles slowly and cautiously reduce speed over rough terrain Recommend Max Additional Payloads G...

Page 31: ...n consider where accessories are to be mounted to maximize handling and safety Do mount factory authorized accessories with common sense in logical locations that avoid weakening substrates or anywhere that would jeopardise chassis integrity Don t mount accessories in areas that will affect driver control inhibit or limit steering function pull throttle cables limit brake pedal accessibility etc D...

Page 32: ...tigated to determine the source and assess the situation Have you felt a loss of power a shudder while stopping or maybe the brake lever feels different Any changes that cannot be attributed to road conditions wind etc should be investigated as soon as is safe to do so Know your warranty Know the limits of your warranty coverage as outlined in the owner s manual Purchase a road side assistance pro...

Page 33: ...Fluids Lubricants Capacities 4 2 Lubrication Diagram 4 3 Lubrication Points 4 4 Engine oil and filter replacement 4 5 Gearbox oil replacement 4 7 Final drive oil replacement 4 8 Drive Shaft Lubrication 4 9 Cable Lubrication 4 10 4 1 ...

Page 34: ...tul Moly Grease Clutch Shaft Splines N A Motul Moly Grease Drive Wheel Splines Spline Flanges N A Motul Moly Grease Wheel Axles N A Motul Tech Grease 300 Brake Linkage and Pivots N A Motul Tech Grease 300 Cables N A Motul E Z Lube NOTE URAL MOTORCYCLES EXCLUSIVLEY USES MOTUL FLUIDS AND LUBRICANTS DURING INITIAL ASSEMBLY URAL MOTORCYCLES RECOMENDS MOTUL FLUIDS AND LUBRICANTS FOR ALL SERVICE INTERVA...

Page 35: ...LUBRICATION DIAGRAM 4 3 ...

Page 36: ...Sidecar Drive Shaft Splines 2wd Motul Moly Grease 7 Axles Motul Tech Grease 300 8 Sidecar Mounting Pivots Motul Tech Grease 300 9 Sidecar Brake Linkage Bushing Motul Tech Grease 300 10 Clutch Shaft Splines Motul Moly Grease 11 U Joints Motul Tech Grease 300 12 Front Brake Mount Axle Bushings Motul Tech Grease 300 13 Clutch Cable Motul E Z Lube 14 Front Brake Lever Pivot Bolt Motul Tech Grease 300 ...

Page 37: ...place remove the oil filter NOTE AN OIL FILTER WRENCH MAY BE REQUIRED FOR REMOVAL CAUTION BE SURE TO REMOVE THE OIL FILTER SEALING RING FROM THE ENGINE COVER TO AVOID OIL LEAKS Step 3 Be sure to clean any metal contaminates from the drain plug and replace the drain plug sealing washer Step 4 Re install drain plug and washer and torque to specification 4 5 ...

Page 38: ...O NOT OVER TIGHTEN THE OIL FILTER Step 6 Fill engine with 2 6L of recommended motor oil Step 7 Start the engine and let run for 30 seconds confirming you have no oil leaks at filter Step 8 Check oil level oil should be full to the upper mark on the dipstick add oil as needed Dipstick should be dipped not screwed in when checking the oil level NOTE ALWAYS DISPOSE OF MOTOR OIL PROPERLY 4 6 ...

Page 39: ...d replace the drain plug sealing washer Step 3 Re install drain plug and washer and torque to specification Step 4 Fill the gearbox with 0 9L of recommended gear oil Step 5 Check oil level by threading the dipstick into the case Oil should be full to the upper mark Add fluid as needed Step 6 Re install fill plug and torque to specification NOTE ALWAYS DISPOSE OF MOTOR OIL PROPERLY 4 7 ...

Page 40: ...es from the drain plug and replace the drain plug sealing washer Step 3 Re install drain plug and washer and torque to specification Step 4 Fill the final drive with 115ml 2wd or 90ml 1wd of recommend gear oil Step 6 Check oil level by threading the dipstick into the case Oil should be full to the upper mark Add fluid as needed NOTE ALWAYS DISPOSE OF GEAR OIL PROPERLY 4 8 ...

Page 41: ... Sidecar Drive Shaft On 2wd models only the sidecar drive shaft has two grease zerks located at each u joint grease these joints per the maintenance intervals or after off road use Drive Wheel Splines The rear wheel drive splines should be greased per the maintenance intervals or after off road use 2wd models also have drive splines located on the sidecar wheel splines should be greased per the ma...

Page 42: ...E Z Lube per the maintenance intervals You should also lubricate all cables before and after extended periods of storage and or after off road use To lubricate the cables pull back the protective covers and apply lube directly to the cable as shown You can also use cable lubrication tools available by aftermarket companies 4 10 ...

Page 43: ...tment 5 9 Sidecar Brake System Maintenance 5 10 Front Wheel Removal Installation 5 11 Rear Wheel cT_LH 1WD Removal Installation 5 15 Rear Wheel Gear Up_LH 2WD Removal Installation 5 18 Sidecar wheel Removal Installation 5 22 Using the Spare Wheel 5 23 Spoke Maintenance 5 27 Wheel Bearing Replacement Diagrams 5 28 Tyre Tube Replacement 5 29 Sidecar Alignment 5 30 Sidecar Alignment Diagram 5 31 5 1 ...

Page 44: ...Step 3 Remove the paper filter element for the housing and inspect for debris The filter should be replaced per the maintenance intervals and or as need during inspections Step 4 Re install the filter in reverse order Be sure the replacement filter is fully seated in the air box housing and the lid is properly installed prior to tightening the retaining bolts CAUTION A DIRTY OR CLOGGED AIR FILTER ...

Page 45: ... towel Step 2 Remove the timing plug located on the right side of the engine case Slowly rotate the engine using the kick start lever until both valves are closed and the TDC top dead center mark located on the flywheel is centered in the window Step 3 Using a feeler gauge check the free play on both valves to confirm they are within specifications 5 3 ...

Page 46: ...rance is within specifications Step 6 Replace the valve cover gasket bolt seals and re torque the valve cover bolts Step 7 Repeat the process on the right side by rotating the engine with the kick starter 360 degrees Again both valves will be closed and the TDC mark should be centered in the window CAUTION OPERATING THE ENGINE WITH IMPROPERLY ADJUSTED VALVES CAN LEAD TO POOR PERFORMANCE AND POSSIB...

Page 47: ...AINTENANCE Step 1 Remove the retaining pin safety clips Step 2 Carefully drive the retaining pins out of the caliper using a small punch or drift Step 3 Remove the brake pads by pulling them out the top of the caliper 5 5 ...

Page 48: ...ty clips Step 6 Confirm the brake fluid level is full in the reservoir and add as needed to FULL line DO NOTE OVER FILL CAUTION OPERATING THE MOTORYCLE WITH WORN BRAKE PADS CAN CAUSE DAMAGE TO THE BRAKE ROTORS WARNING OPERATING THE MOTORCYCLE WITH WORN BRAKE PADS BELOW THE MINIMUM THICKNESS CAN RESULT IN POOR BRAKING AND POSSIBLE ACCIDENT WARNING OPERATING THE MOTORCYCLE WITH LOW FLUID LEVEL CAN C...

Page 49: ...Remove lower shock mounting bolt and swing the shock back to access brake caliper Step 2 Remove the caliper mounting bolts and remove the caliper Step 3 Remove the caliper safety clip and carefully remove the retaining pin out of the caliper A punch or drift may be used 5 7 ...

Page 50: ...ep 6 Confirm the brake fluid level is full in the reservoir and add as needed to FULL line DO NOT OVER FILL CAUTION OPERATING THE MOTORYCLE WITH WORN BRAKE PADS CAN CAUSE DAMAGE TO THE BRAKE ROTORS WARNING OPERATING THE MOTORCYCLE WITH WORN BRAKE PADS BELOW THE MINIMUM THICKNESS CAN RESULT IN POOR BRAKING AND POSSIBLE ACCIDENT WARNING OPERATING THE MOTORCYCLE WITH LOW FLUID LEVEL CAN CAUSE LOSS OF...

Page 51: ...d to the parking brake handle and be sure the parking brake is in the off position Step 2 Adjust the cable to remove excess free play by tightening lower adjustment nut NOTE ADJUST CABLE FOR MINIMAL FREEPLAY WITHOUT DRAG ROTATE WHEEL AND INSPECT FOR FREE ROTATION 5 9 ...

Page 52: ...INTENANCE Step 1 Remove the caliper mounting bolts Step 2 Remove the caliper from the sidecar swing arm Step 3 Remove the caliper safety clip and carefully drive the retaining pin out of the caliper with a punch or drift 5 10 ...

Page 53: ... DO NOT forget to install the safety clip Step 7 Confirm the brake fluid level is full in the reservoir and add as needed to FULL line DO NOTE OVER FILL CAUTION OPERATING THE MOTORYCLE WITH WORN BRAKE PADS CAN CAUSE DAMAGE TO THE BRAKE ROTORS WARNING OPERATING THE MOTORCYCLE WITH WORN BRAKE PADS BELOW THE MINIMUM THICKNESS CAN RESULT IN POOR BRAKING AND POSSIBLE ACCIDENT WARNING OPERATING THE MOTO...

Page 54: ...T WHEEL REMOVAL INSTALLATION Step 1 Raise front wheel off the ground Step2 Remove the lower caliper mounting bracket bolts Step 3 Loosen the front axle bolt NOTE FRONT AXLE BOLT IS LEFT HANDED TRHEADS 5 12 ...

Page 55: ...en the 2 axle pinch bolts Step 5 Remove the axle from the wheel Remove the front wheel with the caliper bracket Step 6 To re install the wheel place the caliper mount into the wheel first Step 7 Position the wheel on the bike and install the axle 5 13 ...

Page 56: ... 8 Reinstall and tighten the axle bolt NOTE FRONT AXLE BOLT IS LEFT HANDED TRHEADS Step 9 Tighten the 2 axle pinch bolts according to specification Step 10 Re attach the caliper with mounting brackets and tighten according to specification 5 14 ...

Page 57: ...H 1WD REMOVAL INSTALLATION Step 1 Place the motorcycle on the center stand Step 2 Remove the parking brake caliper using a 5mm hex key wrench Step 3 Allow the parking brake caliper to drop down and out of the way 5 15 ...

Page 58: ...REAR WHEEL cT_LH 1WD REMOVAL INSTALLATION CONT Step 4 Loosen both brake caliper mounting bolts using a 17mm wrench Step 5 Remove the axle nut Step 6 Loosen the axle pinch bolt Remove the axle 5 16 ...

Page 59: ...liper mounting plate back and remove caliper bolts Step 8 Remove brake mounting plate Step 9 Remove the rear wheel by tilting it outwards towards you and rolling it back as shown NOTE Re install the rear wheel in reverse order Torque all fasteners to specification 5 17 ...

Page 60: ...Step 1 Put the motorcycle on the central stand Remove final drive cover allowing access to wheel axle bolts Step 2 Remove two bolts from wheel axle Step 3 Remove sidecar drive shaft from rear swing arm hub allowing access to the wheel axle nut 5 18 ...

Page 61: ...AL INSTALLATION CONT Step 4 Remove tie wrap from the central pipe and release parking brake cable and rear brake hose Step 5 Remove two bolts from parking brake caliper and remove parking brake caliper Step 6 Remove the axle nut 5 19 ...

Page 62: ...REAR WHEEL GEAR UP_LH 2WD REMOVAL INSTALLATION CONT Step 7 Remove the axle Step 8 Remove rear brake caliper with bracket 5 20 ...

Page 63: ...EAR UP_LH 2WD REMOVAL INSTALLATION CONT Step 9 Remove the rear wheel by tilting it outwards towards you and rolling it back NOTE Re install the rear wheel in reverse order Torque all fasteners to specification 5 21 ...

Page 64: ...ATION Step 1 Remove the sidecar brake caliper Step 2 Carefully remove the sidecar hub cap Remove the cover by hand or pry bar Step 3 Remove the axle cotter pin and axle nut Step 4 Re install the sidecar wheel in reverse order 5 22 ...

Page 65: ...e rear wheel and rear brake rotor Step 2 Install the brake rotor on the spare wheel and torque to specification Step 3 Install the spare wheel on the motorcycle In order to install spare wheel as a front wheel or sidecar wheel it is required to reinstall brake disc brake disc adapter splined flange fittings and another parts from replacement wheel 5 23 ...

Page 66: ...me location as they were removed Take note of shim and or spacer placement DO NOT DISCARD Fitting Spare to Front and Sidecar Wheel Position Supplied Long and Short Spacers for Use of Spare Wheel in Front and Sidecar Position Recommended for temporary use until flat tyre can be repaired and fitted back to original position on bike Follow Instructions for Removal of Wheel as per Owner s Manual Instr...

Page 67: ...Remove the spacer and retaining ring Remove spacer and disk holder from opposite side of spare wheel 5 25 ...

Page 68: ...ecar Wheel to Spare and Insert Supplied Long Spacer Fit the supplied short spacer and retaining ring to opposite side Refit splined flange Follow Instructions to Refit Wheel to Front or Sidecar Position as per Owner s Manual Instructions 5 26 ...

Page 69: ...ke tension by lightly tapping each spoke and listening to the ring Loose spokes will make a low flat sound Step 1 Tap each spoke and compare the sound from one to another Step 2 Tighten spokes as needed If spokes require more than turn to tighten you may need to remove the tire and have the wheel professionally trued 5 27 ...

Page 70: ...ve the bearings out of the hub and replace Step 4 Re install in reverse order replacing the collars as needed NOTE WHEEL BEARINGS SHOULD BE INSPECTED AND REPLACED MORE FREQUENTLY THAN OUTLINED IN THE MAINTENANCE SCHEDULE WHEN THE MOTORCYCLE IS USED OFF ROAD OR IN ADVERSE WEATHER ON A REGULAR BASIS CAUTION FAILURE TO REPLACE THE WHEEL BEARINGS WHEN NEEDED CAN DAMAGE THE WHEEL HUB AND AXLE WARNING D...

Page 71: ...l kit carefully remove one side of the tyre from the rim Step 3 Remove the tube from the tyre Step 4 Remove the tyre from the rim Step 5 Re install the tyre in reverse order be careful not to pinch the tube during installation NOTE WHEN INFLATING THE TYRE BE SURE THE TYRE BEAD IS FULLY SEATED AND EVEN AROUND THE RIM 5 29 ...

Page 72: ...oosen the bolt clamping the lower rear bracket and adjust the position of the bracket relative to the rear tube of the side car frame to obtain necessary toe in of the wheels Tighten up the bolt fastening the bracket adjust the length of the strut 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 standard lean out is...

Page 73: ...SIDECAR ALIGNMENT DIAGRAM 5 31 ...

Page 74: ...6 Electrical Page Lamp Bulb Replacement 6 2 Battery Maintenance Replacement 6 6 Fuse Relay Locations 6 9 Sidecar Fuse Relay Locations 6 10 Starter 6 11 Alternator 6 11 ECU Data Port 6 11 6 1 ...

Page 75: ...the lamp out of the bucket Step 2 Disconnect the lamp Step 3 Carefully remove the lamp retaining clips and replace lamp Step 4 Re install in reverse order WARNING ALWAYS WEAR EYE PROTECTION WHEN REMOVING LAMP RETAINING CLIPS WARNING IT IS UNSAFE TO OPERATE YOUR MOTORCYCLE WITHOUT A FUNCTIONING HEADLIGHT 6 2 ...

Page 76: ...ulbs as needed The upper bulb in the running brake lamp and the lower is the license plate lamp Step 3 To remove the bulb twist and pull Step 4 Re install the bulbs in reverse order NOTE TO HELP PREVENT CORODED CONTACTS USE DIELECTRIC GREASE WARNING IT IS UNSAFE TO OPERATE YOUR MOTORCYCLE WITHOUT A FUNCTIONING TAIL AND BRAKE LIGHT 6 3 ...

Page 77: ...lens retaining screws Step 2 Inspect and replace bulbs as needed Step 3 To remove the bulb twist and pull Step 4 Re install the bulbs in reverse order NOTE TO HELP PREVENT CORODED CONTACTS USE DIELECTRIC GREASE WARNING IT IS UNSAFE TO OPERATE YOUR MOTORCYCLE WITHOUT FUNCTIONING TURN SIGNALS 6 4 ...

Page 78: ...ded Step 3 To remove the bulb twist and pull Step 4 Be sure to re install the lens gasket Step 5 Re install the bulbs in reverse order NOTE TAIL LIGHT BRAKE ON LEFT AND SIGNAL ON RIGHT NOTE TO HELP PREVENT CORODED CONTACTS USE DIELECTRIC GREASE WARNING IT IS UNSAFE TO OPERATE YOUR MOTORCYCLE WITHOUT FUNCTIONING SIDECAR LAMPS 6 5 ...

Page 79: ... dirt WARNING BATTERIES CONTAIN SULFURIC ACID WHICH CAN CAUSE SEVERE BURNS AVOID CONTACT WITH SKIN EYS OR CLOTHING ANTIDOTE EXTERNAL FLUSH WITH WATER 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 NEGATIVE TERMINAL FROM THE BATTERY TO PREVENT DAMAGE TO ELECTRICAL COMPONENTS ...

Page 80: ...battery cable Step 3 Remove the battery hold down straps Step 4 Loosen both the upper and lower starter bolts to allow clearance for battery removal CAUTION ALWAYS DISCONNECT THE NEGATIVE BATTERY CABLE FIRST TO AVOID SHORTING THE BATTERY WARNING SHORTING THE BATTERY TERMINALS COULD RESULT IN A FIRE 6 7 ...

Page 81: ... Re install in reverse order by sliding the battery back into place and reconnecting all straps and cables Step 7 Be sure to re tighten the starter bolts CAUTION ALWAYS RECONNECT THE POSITIVE BATTERY CABLE FIRST TO AVOID SPARKS NOTE USE DIELECTRIC GREASE ON THE BATTERY CONNECTIONS TO PREVENT CORROSION 6 8 ...

Page 82: ...This diagram shows the position and function for each fuse and relay in the fuse box 1 ECU Power 10a 2 ECU Relay Power 15a 3 Ignition Starter Signals 15a 4 Brake Lights Horn EVAP 15a 5 Lights High Beam 15a 6 Parking Lights 15a 7 Headlight Relay 8 ECU Relay 9 Starter Lock out Relay 10 Lighting Relay 11 Starter Relay 6 9 ...

Page 83: ...y you must first remove the headlight bucket assembly Fuse Box Sidecar The sidecar fuse box is located on the right hand interior body panel of the sidecar Fuse Box Diagram This diagram shows the position and function for each fuse and relay in the fuse box 1 Power Outlet 15a 2 Accessory Switch 15a 3 Accessory 15a 4 Spotlight 15a 5 Spotlight Relay 6 10 ...

Page 84: ...ilable check the output of the alternator with the engine running Connect the voltmeter to positive and negative terminals of the storage battery Start the engine While starting the voltage will drop to as low as 9 5 V At 3500 4000 rpm output voltage should be 13 5 14 5 VDC In the course of daily inspection check the fastening of wires to the alternator terminals and fastening of the alternator on...

Page 85: ...7 EFI Troubleshooting Page Engine Management MIL Blink Codes 7 2 Service Notes 7 4 7 1 ...

Page 86: ...lating to the fault Operation When the MIL is continuously lit with the key on an EMS fault has occurred Activate the blink code by turning the key on and toggling the key switch 3 times Off On Off On Off On within 10 seconds MIL will blink the code 02 indicating the ECU is in blink mode Once in blink mode the ECU will blink the code 02 first and then blink a unique code for each possible system f...

Page 87: ...al miss counted while the engine is running 35 P0298 Engine over heat Temperature measured above 170 36 P1352 Cyl2 Ignition Coil open or short to GND Detected circuit open 38 P0352 Cyl2 Ignition Coil short to battery Detected circuit short to battery 47 P0264 Cyl2 Injector open or short to GND Detected circuit open 48 P0265 Cyl2 Injector short to battery Detected circuit short to battery 12 P1335 ...

Page 88: ...SERVICE NOTES 7 4 ...

Page 89: ...8 Warranty Information Page Warranty Agreement 8 2 Warranty Disclaimers 8 3 Extended Warranty Spare Parts and Accessories Warranty 8 5 8 5 8 1 ...

Page 90: ...this limited warranty will be transferred to subsequent owners upon the resale of the motorcycle during the limited warranty period Warranty Coverage To obtain warranty service return your motorcycle at your expense within the limited warranty period to an authorised Ural dealer The authorised Ural dealer should be able to provide warranty service during normal business hours depending upon the wo...

Page 91: ...ong an implied warranty lasts Some states may not allow exclusion or limitation of incidental or consequential damages These Warranties Do Not Cover 1 Failures or required services that is not due to a defect in material or factory workmanship 2 Parts or accessories affected or damaged by Lack of required maintenance Owner abuse Accident and or collision Misuse Normal wear Neglect Improper install...

Page 92: ...l Motorcycles within 3 three business days upon Ural Motorcycle s request at Ural Motorcycles shipping expense Provide digital pictures of failed and or defective parts and assemblies with all claims Owner s Warranty Responsibilities As the owner of Ural motorcycle you are responsible for the performance of the required maintenance listed in your owner s manual URAL recommends that you retain all ...

Page 93: ...rent existing Manufactures Warranty There is no mileage limitation SPARE PARTS AND ACCESSORIES WARRANTY Ural Motorcycles provides limited warranty for spare parts and accessories for the following period of time starting from the time of purchase of the parts by a dealer or retail customer Engine 12 months Gearbox 12 months Final drive 12 months Alternator 6 months Starter 6 months EFI Components ...

Page 94: ...9 Emission Control Information Page Crankcase Emission Diagram 9 2 9 1 ...

Page 95: ...vehicle to be covered by EPA Certification Crankcase exhaust emitted by the timed breather is routed to the air filter box and ends prior to the filter The crankcase exhaust is recycled through the air filter and inducted back into the engine Please see the diagram below NOTE IT IS AGAINST FEDERAL LAW TO TAMPER WITH OR REMOVE EMISSION RELATED COMPONENTS 9 2 ...

Page 96: ...10 Owner s Documents New Owner Form New Address Form ...

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Page 98: ... ____________________________________________________________________ _______________ CITY _________________________________ STATE _________ POSTCODE _____________________ PHONE NUMBER _______ ______________________ E MAIL _______________________________________________________________________ DATE OF SALE ______ _____ ________ DAY MO YEAR ODOMETER READING AT THE TIME OF TRANSFER _________________...

Page 99: ...Intentionally left blank ...

Page 100: ..._______________________________ OLD ADDRESS_____________________________________________________________________ CITY___________________________STATE________________________POSTCODE____________ MY NEW ADDRESS IS NEW ADDRESS__________________________________________________________________ CITY___________________________STATE______________________POSTCODE____________ Mail this form to Ural Australi...

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Page 102: ...11 Schematics Wiring Diagram ...

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