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URAL Motorcycles CT, Owner'S Manual

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URAL Motorcycles CT Owner'S Manual Download Page 43

 

 

 

5.  Engine & Chassis Maintenance 

  

 

 

  

Page 

Air filter Inspection & Replacement 

5-2 

Fuel System Maintenance 

5-3 

Valve Train Inspection & Adjustment 

5-5 

Front Brake System Maintenance 

5-7 

Rear Brake System Maintenance  

5-9 

Parking Brake Adjustment 

5-11 

Sidecar Brake System Maintenance 

5-12 

Wheel Removal & Installation 

5-14 

Using the Spare Wheel 

5-22 

Spoke Maintenance 

5-22 

Wheel Bearing Replacement & Diagrams 

5-23 

Tire & Tube Replacement 

5-24 

Sidecar Alignment 

5-25 

Sidecar Alignment Diagram 

5-26 

 

 

 

 

 

 

Summary of Contents for CT

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Page 3: ...s carefully for maximum motorcycle performance 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 sidecar outfit before venturing out on the busy roads Your Owner s Manual contains instructions for operation maintenance and minor repairs Major repairs require the attention o...

Page 4: ...ND 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 BE 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 INFORMATION...

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: ...mation 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 ...

Page 7: ...ts 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 PR...

Page 8: ... stamped on the frame directly above the label List Your VIN Here Engine Number The engine number is stamped near the crankcase breather it 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 ...

Page 9: ... 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 Aluminum rims with steel spokes 2 15X19 Aluminum rims with steel spokes Tires Heidenau K28 4 0x18 Duro HF 308 4 0x19 Front brake 4 piston fixed Brembo caliper with 295mm floating NG rotor 4 pist...

Page 10: ...wing Arm Mounting Bolts 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 4 to 6 2 9 to 4 4 Drive Train Engine Gearbox and Final Drive Drain Plugs 22 16 2 Cylinder Head Nuts 50 36 9 Valve Cover Nuts 24 17 7 Oil Pump Drive Gear Cap Bolt 10 7 4 Final Dri...

Page 11: ...d 3 to 8 125 to 315 Lean Out 1 to 2 degrees 1 to 2 degrees TYRE DATA Location Type Recommended PSI Front Duro H 308 4 0x19 Heidenau K28 4 0x18 cT only 32 PSI Cold Rear Duro H 308 4 0x19 Heidenau K28 4 0x18 cT only 36 PSI Cold Sidecar Duro H 308 4 0x19 Heidenau K28 4 0x18 cT only 32 PSI Cold Spare if equipped Duro H 308 4 0x19 Heidenau K28 4 0x18 cT only 36 PSI Cold Optional Knobby Tires Duro H 308...

Page 12: ...I 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 Front fork oil R 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 mode...

Page 13: ... motorcycle for a short ride prior to any long trips CLEANING It is important to maintain your motorcycle properly and clean 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 from entering the air filter and electrical components After washing dry the motorcycle with a cloth Lubr...

Page 14: ...2 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 Lever 2 7 Kick Starter 2 8 2wd Engagement Lever 2 8 Hydraulic Spring Shock Absorbers 2 9 Hydraulic Steering Damper 2 9 ...

Page 15: ...e grip to steer 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 bac...

Page 16: ...pshift use the heal 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 ...

Page 17: ...l Indicator 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 app 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 eng...

Page 18: ...s bike 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 12 24 hour Cloc...

Page 19: ...ton 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 Prog...

Page 20: ...wn 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...

Page 21: ...to dis engage 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 you right foot as shown WARNING WHEN USING THE KICK STARTER ALWAYS BE SURE THE GEARBOX IS IN NEUTRAL ...

Page 22: ...n 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 ...

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 ...

Page 24: ... do 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 and during your first ride 1 Read the entire owner s manu...

Page 25: ... 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 Ural Dealer to find out your particular state s sidecar driver s license requirements When you accelerate the Ural will pull slightly to the right due to the inertia and drag of...

Page 26: ...he chair to the point where you can keep it in the air for a full circle you will have a good feel for the speed and turn radius that will lift the sidecar If after gaining proficiency with the Ural you plan to drive on the street with an empty sidecar go back to the parking lot and practice the above maneuvers with an empty sidecar You ll find that the sidecar will lift much more readily when it ...

Page 27: ...WEIGHT 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 to be sure you have enough fuel 2 Switch ignition on 3 Be sure the transmission is in neutral 4 Switch t...

Page 28: ...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 temperate Will I have a passenger or additional payload What is the best route for the speed I will be able to maintain Exter...

Page 29: ...s If traveling in warm temperatures reduce 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 be...

Page 30: ...nse particularly if you re planning to go off road Shock preload should be appropriate for the terrain and payload Tyre pressure should be in accordance with the specifications in the owner s manual Clutch cable free play should 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 continu...

Page 31: ...rgo in any location of the outfit that will act as a sail increase wind drag and increase stain on the drive train Unbalance loads will change the handling characteristics in turns while cornering and while braking Optimise loading of cargo for better handling and safer operation Sidecar Loading Balance Percentage Trunk area 20 Passenger Area 70 Front of Sidecar 10 Accessory Location Do s and Don ...

Page 32: ...he pitch of the engine has changed or valve train is making excessive noise this could be a sign to take a break and let the engine cool If the sound continues further diagnosis will be required Do you smell burnt oil smoking clutch rubber fuel Any smell that stands out while riding or while stopped should be investigated to determine the source and assess the situation Have you felt a loss of pow...

Page 33: ...d 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 ...

Page 34: ...A Motul Nautic Grease Clutch Shaft Splines N A Motul Nautic Grease Drive Wheel Splines Spline Flanges N A Motul Nautic 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 SERVI...

Page 35: ...LUBRICATION DIAGRAM ...

Page 36: ...Shaft Splines 2wd Moly EP Grease 7 Axles General Purpose Lithium Grease 8 Sidecar Mounting Pivots General Purpose Lithium Grease 9 Sidecar Brake Linkage Bushing General Purpose Lithium Grease 10 Clutch Shaft Splines Moly EP Grease 11 U Joints General Purpose Lithium Grease 12 Speedometer Cable WD 40 13 Clutch Cable WD 40 14 Front Brake Lever Pivot Bolt WD 40 15 Throttle Cables WD 40 16 Parking Bra...

Page 37: ...n 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 ...

Page 38: ... turn after seat of seal CAUTION DO NOT OVER TIGHTEN THE OIL FILTER Step 6 Fill engine with 2 1L 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 NOTE ALWAYS DISPOSE OF MOTOR OIL PROPERLY ...

Page 39: ...Be sure the clean any metal contaminates 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 gearbox with 9L of recommended motor oil Step 5 Re install fill plug and torque to specification NOTE ALWAYS DISPOSE OF MOTOR OIL PROPERLY ...

Page 40: ...ates 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 135ml 2wd or 105ml 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 ...

Page 41: ...se 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 ...

Page 42: ...lube or WD 40 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 ...

Page 43: ...Front Brake System Maintenance 5 7 Rear Brake System Maintenance 5 9 Parking Brake Adjustment 5 11 Sidecar Brake System Maintenance 5 12 Wheel Removal Installation 5 14 Using the Spare Wheel 5 22 Spoke Maintenance 5 22 Wheel Bearing Replacement Diagrams 5 23 Tire Tube Replacement 5 24 Sidecar Alignment 5 25 Sidecar Alignment Diagram 5 26 ...

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 to the air box housing and the lid is properly installed prior to tightening the retaining bolts CAUTION A DIRTY OR CLOGGED AIR FILT...

Page 45: ...rn the ignition key on and switch the run switch to the on position so the pump can cycle all fuel from the tank into the canister This can take a few moments Be sure not to run the pump dry after all fuel has been drained from the tank Step 4 Re install the return fuel line to the pump Step 5 Carefully remove the one time use clamps from both sides of the in line fuel filter WARNING THE FUEL SYST...

Page 46: ...ll debris for the intake filter and re install in the tank Step 8 Install the new in line fuel filter and replace all one time use clamps NOTE INSTALL IN LINE FILTER WITH DIRECTIONAL ARROW POINTED FORWARD WARNING THE FUEL SYSTEM IS UNDER PRESSURE WARNING GASOLINE IS EXTREMELY FLAMABLE ...

Page 47: ...op 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 centre mark located on the flywheel is centered in the window Step 3 Using a feeler gage check the free play on both valves to confirm they are within specifications ...

Page 48: ... clearance is within specifications Step 6 Replace the valve cover gasket if needed and re install the valve cover 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 POSSIBL...

Page 49: ... MAINTENANCE 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 ...

Page 50: ...fety 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...

Page 51: ...REAR BRAKE SYSTEM MAINTENANCE Step 1 Remove the caliper retaining bolt safety clips Step 2 Remove the caliper retaining bolts Step 3 Remove the brake pads by pulling to the rear of the motorcycle ...

Page 52: ...p 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 53: ...IF INCREMENTAL ADJUSTMENTS USING THE TOP ADJUSTMENT NUT DO NOT RETURN THE PARKING BRAKE TO NORMAL PERFORMANCE RETURN THE TOP ADJUSTMENT NUT TO A FULLY SEATED ZERO FREE PLAY POSITION AND MAKE ADJUSTMENTS ON THE LOWER CABLE ADJUSTER TO REGAIN NORMAL OPERATION OF THE PARKING BRAKE NOTE WITH THE PARKING BRAKE SET YOU WILL HAVE APPROXIMATELY 12MM BETWEEN THE CALIPER STOP BRACKET AND THE BRAKE ARM WITH ...

Page 54: ...MAINTENANCE 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 ...

Page 55: ...der 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 M...

Page 56: ...FRONT WHEEL REMOVAL INSTALLATION Step 1 Remove the lower caliper mounting bracket bolts Step 2 Carefully support the brake caliper using a strap Step 3 Loosen the axle pinch bolt ...

Page 57: ...p 4 Loosen the axle by rotating clockwise and remove from the wheel Step 5 To re install the wheel first place the caliper mount into the wheel Step 6 Position the wheel back on the bike and install the axle DO NOT tighten fully at this point ...

Page 58: ...REMOVAL INSTALLATION CONT Step 7 Re attach the caliper with mounting brackets and tighten to specification Step 8 Tighten the axle by rotating counter clockwise Step 9 Tighten the axle pinch bolts to specification ...

Page 59: ...REAR WHEEL REMOVAL INSTALLATION Step 1 Place the motorcycle on the centre stand Step 2 Carefully remove the caliper retaining bolt safety clips Step 3 Remove the caliper retaining bolts and brake pads ...

Page 60: ...AR WHEEL REMOVAL INSTALLATION CONT Step 4 Support the brake caliper using a strap Step 5 Remove the brake caliper mounting bracket bolts Swing the support brace bracket up Step 6 Remove the rear axle nut ...

Page 61: ...h bolt and remove the axle Step 8 Remove the rear wheel by tilting the outwards towards you and rolling it back as shown Step 9 To re install the rear wheel place the wheel back on the bike and push the axle through both the wheel and brake mounting bracket as shown ...

Page 62: ...CONT Step 10 Torque the caliper mounting bracket bolts to specification Step 11 Re install the brake caliper and brake pads Torque the caliper retaining bolts to specification Step 12 Re install the caliper retaining bolt safety clips ...

Page 63: ...WHEEL REMOVAL INSTALLATION Step 1 Remove the sidecar brake caliper Step 2 Carefully remove the sidecar hub cap Step 3 Remove the axle cotter pin and axle nut Step 4 Re install the sidecar wheel in reverse order ...

Page 64: ...all the spare wheel on the motorcycle The wheel spokes should be checked on a regular basis and per the maintenance intervals You check spoke 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 t...

Page 65: ...rive the bearings out of the hub and replace Step 4 Re install in reverse order replacing the dust seals 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 WARN...

Page 66: ...tool 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 ...

Page 67: ...loosen the bolt clamping the lower rear bracket and 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 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 68: ...SIDECAR ALIGNMENT DIAGRAM ...

Page 69: ...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 ...

Page 70: ...l 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 ...

Page 71: ...e bulbs 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 ...

Page 72: ... lenses 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 ...

Page 73: ...eeded Step 3 To remove the bulb twist and pull Step 4 Be sure to re install the lenses 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 ...

Page 74: ... of 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 COMPONEN...

Page 75: ...e 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 ...

Page 76: ... 6 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 ...

Page 77: ...ram 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 CA EVAP Emissions 10a 7 Headlight Relay 8 ECU Relay 9 Starter Lock out Relay 10 Lighting Relay 11 Starter Relay ...

Page 78: ...elay you must first remove the headlight bucket assembly Fuse Box Sidecar The sidecar fuse box is located on the left 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 ...

Page 79: ...ailable 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 o...

Page 80: ...7 EFI Troubleshooting Page Engine Management MIL Blink Codes 7 2 Service Notes 7 4 ...

Page 81: ...igits while a long pause between repeating the code or displaying the next code depending on the number of fault events To identify the fault initiate the blink sequence and count out blinks for each of the three digits Writing down the pattern helps The light will blink on half second intervals for each digit Between each digit a one second pause will occur Between each blink code or the repetiti...

Page 82: ...t to battery Check wires to ignition coil 141 241 Cylinder 1 2 O2 or O2 Heater O2 Sensor Circuit Failed Low Check O2 sensor 142 242 Cylinder 1 2 O2 or O2 Heater O2 Sensor Circuit Failed High Check O2 sensor 143 243 Cylinder 1 2 O2 or O2 Heater O2 Heater open or short to ground Check wires to O2 sensor 144 244 Cylinder 1 2 O2 or O2 Heater O2 Heater short to battery Check wires to O2 sensor 151 251 ...

Page 83: ...SERVICE NOTES ...

Page 84: ...8 Warranty Information Page Warranty Agreement 8 2 Warranty Disclaimers 8 3 ...

Page 85: ...ranty 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 workload of the au...

Page 86: ...long 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 instal...

Page 87: ...ted in your owner s manual URAL recommends that you retain all receipts covering maintenance on your motorcycle but URAL cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance You are responsible for presenting your motorcycle to an URAL dealer as soon as a problem exists The warranty repairs should be completed in a reasonab...

Page 88: ...9 Emission Control Information Page Crankcase Emission Diagram 9 2 ...

Page 89: ...y 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 ...

Page 90: ...10 Owner s Documents New Owner Form New Address Form Training Rebate Form ...

Page 91: ...Intentionally left blank ...

Page 92: ..._______________________________________________________ _______________ CITY _________________________________ STATE _________ POSTCODE _____________________ PHONE NUMBER _______ ______________________ E MAIL optional ____________________________________________________________________ DATE OF SALE ______ _____ ________ DAY MO YEAR ODOMETER READING AT THE TIME OF TRANSFER ___________________ Purch...

Page 93: ...Intentionally left blank ...

Page 94: ...__ OLD ADDRESS____________________________________________________________________ CITY___________________________STATE___________________________POSTCODE________________ MY NEW ADDRESS IS NEW ADDRESS__________________________________________________________________________ CITY___________________________STATE___________________________POSTCODE________________ Mail this form to Ural Australia Pty ...

Page 95: ...Intentionally left blank ...

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Page 97: ...For current wiring schematics please visit Ural Motorcycles website at www imz ural com ...

Page 98: ......

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