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URAL Motorcycles Deco Classic 1998, Owner'S Manual

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URAL Motorcycles Deco Classic 1998 Owner'S Manual Download Page 19

Chapter 3

Engine Operation and Maintenance

Pre-Trip Preliminaries

Before each trip, attend to all the requirements of the everyday
maintenance as outlined in this manual. When priming the
motorcycle with fuel and oil, take all the precautions to keep
everything neat and clean.

Gasoline level in the tank fully primed should be 10 - 15 mm /½ -
¾ in. below the lower edge of the tank filler. Do not overfill the
tank. See that the oil level in the engine crankcase is not higher
than the top and not lower than the bottom marks on the dipstick
with the filler plug undone.

CAUTION: When draining and refilling the oil tank or
transmission, be careful that dirt and debris does not get into
case or oil tank. Do not allow draining oil to get on rear wheel,
tire, or brake components.

Summary of Contents for Deco Classic 1998

Page 1: ...Use the table of contents to the left to navigate that manual URAL MOTORCYCLES 1998 Models IMZ 8 103 10 Deco Classic Italia IMZ 8 103 40 Tourist IMZ 8 107 Sportsman IMZ 8 123 Solo IMZ 8 503 Utility ...

Page 2: ...becomes thoroughly familiar with the special operating characteristics of sidecar outfits before venturing out on the 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 tools and equipment Your Authorized URAL Dealer and URAL certified Service Center has the facilities experien...

Page 3: ...t can be found not only in BMWs but also in Porsches Hondas and others These are wondrous engines at wondrous prices But they still retain the basic soul of Max Friz s first engines And although it is not as evolved as the most modern boxers the IMZ650 cc is true to the earlier versions in looks but also has many modern internal components These parts like pistons rings valves valve guides seats a...

Page 4: ...merica UMOA which is an owner s club that we have formed to facilitate communication adventure and motorcycling experience for the new URAL owners across America We look forward to seeing you at a future rally or URAL Owner s Club Meeting Any suggestions or comments are welcome Write to us or post an e mail on the URAL CHAT bulletin board at www ural com ...

Page 5: ...anisms 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 c...

Page 6: ... 6 Figure 7 Figure 10 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 25 Figure 26 Figure 27 Figure 29 Figure 30 Figure 31 Figure 32 Figure 35 Figure 36 Figure 37 Figure 38 ...

Page 7: ...pg Dry mass of motorcycle 700 lb 680 lb 460 lb Maximum load carrying capacity 500 lb 485 lb 400 lb 330 lb Noise level below 80db OVERALL DIMENSIONS OF MOTORCYCLE TOURIST SPORTSMAN UTILITY 10 Models SOLO Length 2500 mm 8 ft 2200 mm 7 ft Width 1700 mm 5 ft 6 in 850 mm 2 ft 8 in Height 1100 mm 3 ft 6 in 1060 mm 3 ft 8 in Road Clearance 125 mm 5 in Seat height 840 mm 33 in 810 mm 32 in Wheel base 1470...

Page 8: ...r of carburetors 2 Air cleaner Inertial type with internal filter Fuel 91 octane premium unleaded gasoline PCV Valve Internal Breather ELECTRICAL EQUIPMENT Ignition system 12 V Ignition coil B204 Spark plugs NGK BP7HS or NDW20FP 1 Ignition timing Automatic spark timer Power supplies G424 generator 14 amp 150 watt 40mdls or 35 amp 300 watt 10 mdls and solo Storage battery Russian supplied with new ...

Page 9: ...or jetting is leaner and the rear axle gear ratio is always 4 62 not 3 89 This is necessary to accommodate the reduced air pressure and engine power at higher altitudes FLUID CAPACITIES Tourist 10 Models Sportsman Solo Gasoline tank 19 L 5 Gal 19L 5 Gal 18 5 L 4 9 Gal Reserve 2L 0 5 gal 2L 0 5 gal 2 L 0 5 Gal Engine crankcase 2 L 2 qt 3 6oz 2L 2 qt 3 6 oz 2 L 2 qt 3 6oz Gearbox 0 9L 1 qt 0 9L 1 qt...

Page 10: ...A on solo Brakes Shoe type with mechanical drive on front rear and sidecar wheels front wheel has dual cams Tires 4 x19 Rugged Cruiser Front Side 22 psi cold Rear 36 psi cold 3 5 x 18 Cruiser 10 Front Side 25 psi cold Rear 36 psi cold 3 5 x 18 SOLO Front 25 psi cold Rear 32 psi cold CLEARANCES mm in Valves with engine cold 0 05 0 002 Between spark plug electrodes 0 50 0 65 0 020 0 026 Between brak...

Page 11: ...brake drive pedal of full stroke of pedal 25 30 1 0 1 2 Toe in throughout motorcycle center distance exception Sportsman 0 toe in 10 mm 3 8 inch Angle of motorcycle inclination to vertical plane camber angle of rear wheel 1 away from sidecar Headlight installation with motorcycle laden horizontal high beam ...

Page 12: ...b to 36 ft lbs shock absorber 3 0 to 3 4 kgf m 22 ft lb to 26 ft lb bearing nut 3 0 to 3 4 kgf m 22 ft lb to 26 ft lbs final drive to swing arm bolts 1 6 to 1 8 kgf m 12 ft lb to 14 ft lb oil pump bolt 8 to 1 0 kgf m 5 ft lb to 8 ft lb engine sump 1 4 to 1 8 kgf m 10 ft lb to 14 ft lb final drive case nuts 7 to 9 kgf m 50 ft lb to 66 ft lb nut fastening the pinion bearing 2 2 to 2 8 kgf m 16 ft lb...

Page 13: ...rt from liters to pints multiply by 2 112 there are 2 112 pints per liter To convert from km to miles multiply by 62 there is 62 mile per km To convert from km hr to mph multiply by 62 To convert from Newton meter Nm to inch pound multiply by 8 86 To convert from Newton meter Nm to foot pound multiply by 7376 To convert from cm3 cc to pints divide by 473 there are 473 cc per pint To convert Celsiu...

Page 14: ...t knob 14 Horn push button 4 Neutral and reverse gear engagement pilot lamp 15 High low beam switch 5 Front brake control lever 16 Clutch control lever 6 Carburetor throttle control twist grip bolt 17 Steering damper tightening 7 Ignition kill switch 18 High beam indicator light 8 Electric Start Button optional 19 Ignition lock 9 Rear brake pedal sidecar wheel brake 20 Battery discharge warning ...

Page 15: ...e is actuated through the gearbox The lever is returned to its initial position by the spring inside the gearbox Gear shift foot pedal Fig 1 11 also see Fig 16 1 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 easi...

Page 16: ...nterrupter and head and tail lamps Note II position is not used for US import models due to DOT regulations Note Leaving the key in the 1 or II position will discharge the battery Always return the key to the 0 position before taking it out Speedometer is on the dash board with trip and total odometer The trip odometer is reset to zero by rotating push button Fig 1 3 counter clockwise Note that th...

Page 17: ...ist grip below the kill switch The steering damper absorbs lateral kicks on the front wheel Turning tightening bolt Fig 1 16 clockwise increases friction This can be used while driving fast over bad roads WARNING Do not tighten the damper to the point where the steering becomes stiff Doing so will adversely affect handling qualities This is particularly critical for the Solo model The air shutter ...

Page 18: ...n SIDE STAND SOLO MODEL ONLY WARNING Be sure the side stand is fully retracted before riding the motorcycle If the side stand is not fully retracted during vehicle operation it could contact the road surface with possible loss of vehicle control ...

Page 19: ...line level in the tank fully primed should be 10 15 mm in below the lower edge of the tank filler Do not overfill the tank See that the oil level in the engine crankcase is not higher than the top and not lower than the bottom marks on the dipstick with the filler plug undone CAUTION When draining and refilling the oil tank or transmission be careful that dirt and debris does not get into case or ...

Page 20: ...trol shutter carburetor enricheners and starting procedure as follows 1 When the engine is hot do not choke or enrichen the carburetors To do so risks flooding the engine Turn on the ignition and depress the kick lever see Fig 1 about 1 4 of its travel enough to firmly get the ball of your foot on the lever with either your left foot or right foot depending on what position is most comfortable wit...

Page 21: ...ine starts immediately retract the enricheners Run the engine at moderate speed for 30 60 seconds If it starts to die tickle the twist grip throttle rapidly twist part way towards full throttle and then back off to keep the engine running Close the choke about of its travel if needed As soon as the engine runs smoothly without sputtering at the backed off choke position fully open the choke and ke...

Page 22: ...is could cause abnormal wear of the parts and may lead to seizure of the piston pin and pistons in the cylinders since cold oil flows through the oil ducts with difficulty and fails to ensure sufficient lubrication A correctly adjusted warm engine should run steadily at low speed with the throttle control twist grip fully closed Start driving the motorcycle only after having warmed up the engine w...

Page 23: ...e speed decreases as in climbing a hill or running at a reduced speed change from a higher gear to the next lower gear while partially closing the throttle CAUTION Do not run the engine at extremely high rpms with clutch disengaged or transmission in neutral Do not idle the engine unnecessarily for more than a few minutes with motorcycle standing still An engine run long distances at high speed mu...

Page 24: ...hout switching off the ignition This will make the engine stall without any knocks or backfire Then switch off the ignition Do not stop an overheated engine by switching off the ignition The engine jerking at low speeds results in premature wear both to the engine and the transmission While using the motorcycle in summer pay special attention to the condition of the tires Keep them inflated up to ...

Page 25: ...y During the running in period a new motorcycle requires the most careful attention In the course of this period do not overload the machine avoid traveling on freeways and climbing steep upgrades Do not race the engine or overheat it at any time Throttle limiters may have been installed on the motorcycle to prevent excessive rpm s during the running in period There is a label on the gas tank that...

Page 26: ...ual should be followed because they may affect the safe operation of your motorcycle Note The performance of new motorcycle initial service is required to keep your new motorcycle warranty in force and to ensure proper emissions system operation WARNING Stop the engine and support the motorcycle securely before performing all service procedures Service should be performed in an adequately lighted ...

Page 27: ...vil punishment and fines This air oil cooled engine must always run on both cylinders as evenly as possible Whenever one cylinder is not firing stop the engine and determine the cause and correct it before proceeding ...

Page 28: ...ket is fitted between the cylinder and the crankcase When mounting the left hand cylinder see that the holes in the gasket are in line with those in the crankcase through which oil is fed for lubrication of the above mentioned cylinder and oil is drained from the valve box Piston piston rings and piston pins The engine piston has three milled grooves for fitting the piston rings When the piston is...

Page 29: ...d for ventilation Figure 4 Engine longitudinal section 1 Flywheel 12 Camshaft gear 23 Packing ring 2 Crankcase 13 Timing gear cover 24 Oil filter plug 3 Camshaft bushing 14 Front cover of crankcase 25 Sump bolt 4 Camshaft 15 Breather 26 Sump 5 Rear journal of crankshaft 16 Seal 27 Drain plug 6 Starter Generator 17 Breather tenon 28 Oil trap ...

Page 30: ... pin 11 Generator gear 22 Oil filter 33 Roller bearing 34 Rear bearing housing Figure 5 Engine cross section 1 Starter Generator 15 Adjusting bolt locknut 29 Roller bearing 2 Camshaft 16 Rocking arm 30 Crankpin 3 Tappet 17 Rockshaft 31 Crankcase 4 Tappet guide 18 Cylinder head cap 32 Sump 5 Sealing cap 19 Cylinder head stud 33 Oil pump 6 Push rod 20 Gasket 34 Crankshaft cheek 7 Push rod tube 21 Ig...

Page 31: ...ion As the pistons move up the vent duct is overlapped the crankcase interior is cut off from the atmosphere and vacuum is built up If the piston rings are in good condition the breather maintains permanent vacuum in the crankcase thus excluding any possibility of oil expelling though the seals The crankcase ventilation system is routed to the air cleaner When running the motorcycle in winter an i...

Page 32: ...cap and drain off accumulated oil Turn the crankshaft using the kick lever Just when the intake valve Fig 6 22 begins to close set the clearance for the exhaust valve Fig 6 10 and at the time the exhaust valve begins to open set the clearance for the intake valve Check the clearance between the larger end of the rocker arm and the valve stem If the clearance happens to be larger or smaller than 0 ...

Page 33: ...5 Camshaft gear 17 Valve block 6 Breather tenon 18 Rocker arm 7 Breather 19 Adjusting bolt 8 Seal 20 Adjusting bolt locknut 9 Camshaft 21 Rockshaft 10 Exhaust valve 22 Intake valve 11 Valve guide 23 Tappet guide 12 Exhaust branch 24 Tappet Completely follow all maintenance intervals specified in the Maintenance Schedule Summary and the mileage noted on the Service Coupons ...

Page 34: ...vel wipe the dipstick and insert it into the crankcase without screwing in the dipstick Change oil in the engine crankcase for the first time after 500 km then as outlined in the Maintenance Schedule Summary Before changing the filter wash the engine lubrication system To this end fill the crankcase with at least 1 lt 1 qt of fresh oil Warm up the engine before changing oil Drain used oil from the...

Page 35: ...for lubrication of friction parts in cylinder head 5 Crank shaft oil traps 19 Tube for lubrication of timing gears 6 Vertical duct for oil flow into rear bearing housing 20 Oil duct for lubrication of friction parts in cylinder head 7 Crankcase sump 21 Inner cavity of push rod tube for oil flow 8 Oil duct to oil filter 22 Oil drain duct out of cylinder head 9 By pass valve 23 Filler plug with dips...

Page 36: ...lower and the upper oil level limits In checking the oil level wipe the dipstick and insert it into the crankcase without screwing in the dipstick Change oil in the engine crankcase for the first time after 500 km then as outlined in the Maintenance Schedule Summary Before changing the filter wash the engine lubrication system To this end fill the crankcase with at least 1 lt 1 qt of fresh oil War...

Page 37: ... to dismantle the valve While screwing in the filter plug be careful so as not to damage the rubber gasket During motorcycle service keep oil level in the engine crankcase close to the top groove of the oil dipstick Stop the motorcycle as soon as oil level drops down to the lower mark groove of the dipstick ...

Page 38: ...c ignition timing is employed For the electric circuit diagram of the motorcycle with contactless ignition system refer to Fig 32 The system consists of moving coil pickup and the electronic commutator module Ignition coil The ignition coil has two high voltage terminals each supplying one of the cylinder spark plugs and operating in conjunction with the moving coil pickup Figure 12 Moving Coil Ig...

Page 39: ...er and carry them in the motorcycle at all times The lower portion of the plug shell is threaded M14 X 1 25 with an 11 mm length of thread Spark gap of 0 5 0 65 mm 0 020 0 026 is set between the side electrode and the bottom end of the central electrode Always use a crush washer when installing a spark plug preferably a new crush washer WARNING Do not over tighten the spark plug when mounting it o...

Page 40: ...run on both cylinders as evenly as possible Whenever one cylinder is not firing stop the engine and determine the cause and correct it before proceeding ...

Page 41: ...rottle valve 11 Needle jet 12 Starter plunger rubber cap 13 Starter plunger fitting 14 Starter lever 15 Starter lever spring plate 16 Starter plunger spring 17 Starter plunger 18 Mixing chamber body 19 Float bowl gasket 20 Float bowl baffle plate 21 Pilot jet 22 Float arm hinge pin 23 Float arm 24 Float 25 Float bowl 26 Main jet plug washer 27 Main jet plug 28 Air jet 29 Air adjusting screw 30 Air...

Page 42: ...adapter This manual is intended as a guide for users of Mikuni carburetors who want to learn the basic methods of tuning and adjusting to obtain top performance and fuel economy The arrows that appear in the drawings in this text show the direction in which air fuel and air fuel mixture flows Information herewith obtained from Mikuni engineering data and manuals 1 CARBURETOR FUNCTION The function ...

Page 43: ...re ratio shown in Fig 1 is required for ordinary engines In the high speed range the ratio of about 12 to 13 grams of air for 1 gram of fuel produces the maximum output However in the case of an engine with low cooling efficiency a somewhat richer mixture 10 to 12 grams of air against 1 gram of fuel may be required to prevent seizure of the engine 3 FUNCTION AND CONSTRUCTION Mikuni VM Type Carbure...

Page 44: ...wn into the pilot outlet to mix with air flowing through the main bore 7 The fuel mixed at this stage then goes into the engine When the throttle valve is opened slightly during low speed operation the pilot outlet alone cannot supply the required fuel and the shortage has to be made up with fuel injected from the bypass the adjustment of the mixture ratio during this stage is made by the pilot je...

Page 45: ...el the needle valve begins to close due to the lever action of the float arm rising as the float attains buoyancy thus shutting off the supply of fuel The fuel lever in the bowl controls the amount of fuel which is metered to make the optimum fuel mixture For example too high a level allows more fuel than necessary to leave the needle jet enriching the mixture Too low a level results in a leaner m...

Page 46: ...e is closed when starting the engine At temperatures above 60 F the enrichment lever 6 MAINTENANCE A carburetor consists of various precision machined parts such as jets needles valves etc Therefore care should be exercised when removing jets or disassembling the carburetor for cleaning 1 Proper tools should be used for disassembling and reassembling of jets Handle each part carefully to avoid scr...

Page 47: ...when the enrichment valve is opened c Engine performance grows worse when it gets hot d Removal of the air cleaner improves engine performance somewhat e The exhaust gases are heavy f The spark plug is fouled black wet deposit around electrode When air fuel mixture is too lean a The engine overheats b The performance improves when the starter choke is opened c Acceleration is poor d Spark plug bur...

Page 48: ......

Page 49: ...ons Clogged fuel filter Clean filter Clogged low speed fuel jets Disassemble carburetor and chemically clean Clogged vent in fuel tank cap Unclog vent or replace cap Float stuck Remove float bowl check float operation and correct or replace Float damaged or leaking Replace float Incorrect float level Set float height in accordance with shop manual specifications Intake air leak Check carburetor mo...

Page 50: ...under HARD STARTING IDLE MIXTURE ADJUSTMENT IS INEFFECTIVE CARBURETOR DOES NOT RESPOND TO MOVEMENT OF THE IDLE MIXTURE SCREW Idle speed set too high Adjust idle speed in accordance with specifications in Owner s Manual or shop manual Clogged low speed air bleeds Disassemble carburetor and chemically clean Damaged mixture adjustment needle Replace mixture adjustment needle Mixture adjustment needle...

Page 51: ...xture adjustment Low speed Low speed jet size change Intermediate jet needle height adjustment High speed Main jet size change ENGINE DOES NOT DEVELOP FULL POWER OR MISSED ON ACCELERATION Incorrect use of choke Correct use of choke Clogged air cleaner Clean or replace Incorrect air fuel mixture adjustment Low speed Low speed jet size change Intermediate jet needle height adjustment High speed Main...

Page 52: ... Incorrect float level Set float height in accordance with shop manual specifications Ignition problem Repair replace or adjust as necessary NOTE It may be necessary to change carburetor jets to correct the air fuel mixture rations under the following circumstances Exhaust system modifications Air cleaner alteration or removal Altitude changes Temperature and humidity changes ...

Page 53: ...the gearbox disengage the engine from the gearbox during shifting of the gears and during braking to a stop The clutch provides for smooth starting of the motorcycle from rest protects the power transmission parts against damage when the engine speed or drive wheel speed is suddenly changed The clutch is of dry double disk design Figure 13 Clutch 1 Release rod 6 Slider 11 Primary shaft 16 Flywheel...

Page 54: ...of the motorcycle Under conditions of heavy traffic when gears frequently have to be shifted do not to slip the clutch too much as this will cause heavy wear of the disks When stopped for any length of time e g a traffic light it is best to shift into neutral and release the clutch lever Holding the clutch in for long periods will cause excessive heating and wear Clutch adjustment The clutch contr...

Page 55: ...adial bores in the shaft The gear of the kick starter has an additional small rim The intermediate gear is installed on the neck of the bracket which travels in the longitudinal direction of the shaft Bronze bushings are pressed into the gear holes of the kick starter intermediate and I gear of the main shaft The kick starter Fig 15 consists of shaft Fig 15 4 with pawl Fig 15 7 the kick lever with...

Page 56: ...e rod 16 Kick start shaft busing 27 Main shaft bearing 6 Clutch shaft sleeve 17 Gear II of main shaft 28 Driven speedometer gear 7 Packing ring 18 Engagement sleeve of I II gears 29 Main Shaft seat 1 8 Front gearing cover washer 19 Intermediate gear bracket 30 Main shaft 9 Main shaft bearing 20 Kick starter spring 3l Flexible disk of propeller shaft sleeve 10 Engagement sleeve of III IV gears 21 K...

Page 57: ... neutral When the right hand lever is turned to one third of its travel the gear shift mechanism is set to neutral position The bracket with an intermediate gear will not move and the gear is set in neutral position When the reverse gear engagement quadrant is turned further the bracket with an intermediate gear travels along the shaft the reverse gear is engaged and simultaneously the gear shift ...

Page 58: ...uadrant spring 9 Reverse gear engagement lever 10 Reverse gear engagement quadrant 11 Gear shift quadrant 12 Intermediate gear bracket axle 13 Fork shaft 14 Shaft fork of III and IV gears 15 Shaft fork of I and II gears 16 Pawl crank lever fastening nut 17 Pawl crank lever 18 Bushing 19 Seal 20 End of quadrant shaft ...

Page 59: ...been loctited into proper position If you experience problems with the gearbox it usually means some internal problem like a broken tooth for example rather than misadjustment In case of a problem we encourage you to contact your dealer for their consultation instead of readjusting the gearbox which may only complicate the existing problem If you still feel that you need to make a gearbox adjustme...

Page 60: ...fter the click use your right arm to screw the lower adjusting screw slightly in After doing this move the wrench back to 2nd gear position and repeat the above test Keep testing and making adjustments by screwing the lower screw in until the wrench stops moving further after the click is felt If you feel no click at all you should screw out the lower adjusting screw still pressing the rear of the...

Page 61: ...stops immediately after the click is felt After adjustments tighten the locknuts on both adjusting screws and put the plastic cap back over the nut as described in number 5 ...

Page 62: ...cipal parts included in the gearbox Fig 18 are the split box with covers the clutch shaft and main shaft with gears and shift sleeves the gear shift mechanism and the kick starter Figure 18 Solo Gearbox section through shafts 1 Starter spring 11 Oil washer of main shaft 21 Gear shift quadrant 2 Gear IV of clutch spring 12 Gear IV of main shaft 22 Gear I of main shaft ...

Page 63: ...n shaft nut 9 Main shaft 19 Gears I and II shaft fork 29 Clutch release slider 10 Front bearing cap washer 20 Gear II of main shaft 30 Slider seal The kick starter Fig 19 consists of shaft Fig 19 4 with pawl Fig 19 7 secured thereon the kick lever with the pedal return spring 1 and kick starter gear Fig 19 3 The shaft is supported by the bushings provided in the gearbox Figure 19 Kick Starter 1 Re...

Page 64: ... not only shifting of the gears in succession but also in any versions for instance from the lowest gear directly to the highest one and vice versa The main application of the lever however is to set the gearbox sleeves into the neutral position The gear shift pedal is used to change gears in a definite succession The lower gears are engaged by depressing the front arm of the pedal while the rear ...

Page 65: ...l the gearbox with 400 cm 0 4 qt minimum of the oil used for the engine next start the engine install the motorcycle onto the stand shift in the III or IV gears for 2 or 3 min Then drain the oil and fill the gearbox with 19 5 oz of fresh oil and 12 oz of URAL Oil Treatment In winter fill the gearbox with warm oil CAUTION Severe damage due to insufficient lubrication of gears shafts and bearings ca...

Page 66: ...0 1 to 0 3 mm 0 004 to 012 in backlash is necessary between the active faces of gears CAUTION Bearing nut Fig 22 31 is left hand threaded Maintenance of propeller shaft and final drive The daily maintenance involves tightening the nuts which fasten the final drive to the swinging fork arm Failure to tighten the nuts in due time results in loose joints and destruction of the final drive cover Every...

Page 67: ...ersal joint The flexible joint is essentially a coupling sleeve fitted with plates and pins Propeller shaft Item 23 is aligned by means of the ball end of the main shaft which enters the socket in the front end of the propeller shaft 1 Driven gear fastening bolt 13 Oil drain duct 25 Hood 2 Driven gear rim 14 Needle bearing 26 Propeller shaft collar ...

Page 68: ...eal 29 Needle bearing 6 Casing seal 18 Protective washer 30 Wedge belt 7 Seal cover 19 Universal joint splined fork 31 Bearing nut 8 Rear wheel axle 20 Lock ring 32 Gasket 9 Seal spring 21 Universal joint cross 33 Driving gear 10 Distance bushing 22 Grease cup 34 Casing cover 11 Casing 23 Propeller shaft 35 Adjusting washer 12 Driven gear hub 24 Lock ring 36 Ball bearing ...

Page 69: ...he seat Figure 23 Motorcycle and Sidecar Frames 1 Rear suspension swinging arm 10 Collet clamp 20 Lever sidecar wheel 2 Rear mud shield 11 Collet clamp screw 21 Brake tie rod 3 Rear grab bar 12 Motorcycle stand 22 Brake drum cover 4 Spring loaded hydraulic shock absorber 13 Brake pedal 23 Sidecar wheel axle 5 Seat Saddle or Tractor 14 Sidecar wheel brake lever 24 Protective hood ...

Page 70: ...otorcyclel frame 16 Sidecar wheel brake rod 26 Sidecar fender 8 Sidecar adjusting strut 17 Rear collet clamp bracket 27 Rubber member of body suspension 9 Sidecar frame legs 19 Lever pins 18 Rear bracket fastening bolt 28 Parking brake 19 Lever pins ...

Page 71: ... the parking brake mechanism availability of the side leg and welded on brackets for fastening of the air pump The sidecar frame is coupled to the motorcycle frame through collet clamp Fig 23 10 and rear collet clamp bracket Fig 23 17 and two frame legs Fig 23 9 and Fig 23 15 The brackets welded to the frame at the rear are used for mounting the rubber members of the body suspension The swinging a...

Page 72: ...per position of moving cam Fig 24 11 corresponds to the maximum load When the motorcycle is used under the maximum load adjusting the spring in the sidecar wheel shock absorber simultaneously with adjusting the compression of the spring in the motorcycle shock absorbers Care of shock absorbers Fill the shock absorber with 105 cm of hydraulic fluid composed of industrial oil or spindle oil Change h...

Page 73: ...nder washer 19 Rebound valve throttle plate 30 Seal 9 Rod 20 Intake valve plate 31 Rubber seal of rod 10 Check ring 21 Bypass valve spring 32 Felt seal of rod 11 Moving cam 22 Bypass valve retainer 33 Pressure washer ...

Page 74: ...se extensive tire wear If the motorcycle is not stable on the road or is difficult to steer check alignment Checking and measuring the alignment should be carried out on level ground Check toe in of the motorcycle and the sidecar wheels with the aid of two straight bars applied to the side faces of the wheels just below the axles The toe in should be 10 mm or 3 8 in at the front wheel When adjusti...

Page 75: ...he two inclined legs by screwing the forks in or out Check the lean out angle while the motorcycle is running on the road With the lean out properly adjusted the motorcycle will not pull to either side while running at normal road speed If it pulls to the right increase the lean out to 2 or 3 If it pulls to the left decrease the lean out CAUTION Double check for correct toe in before making any ch...

Page 76: ...020 in clearance between the spring tip and the locknut of the nut tightening the fork leg tube so as to ensure free rotation of the tightening nut with the stem The leading link front fork used on the Tourist and Sportsman models use a front lever type fork with two interchangeable spring hydraulic shock absorbers Fig 27 The friction type steering damper is made up of two steel washers moving Fig...

Page 77: ...r handling of all models Figure 26 Front Fork 1 Safety washer 2 Seal 3 Fork cross piece 4 Steering column stem nut 5 Supporting washer 6 Spring washer 7 Tightening bolt 8 Steering column stem 9 Bearing nut 10 Top angular ball 11 Tightening nut 12 Top end of spring 13 Packing ring of cover 14 Fork leg cover with headlight bracket 15 Union bolt 16 Steering column bridge 17 Friction washers 18 Spring...

Page 78: ...damper washers by hand 3 While rocking the front fork up and down with the handle bar or with the fork leg tips determine if there is any play If play in bearings is evident unlock and slacken off nut Fig 27 4 of the steering column stem move up cross piece Fig 27 3 with the nut having first released tightening nuts Fig 27 11 of the fork legs Tighten bearing nut Fig 27 9 and release it 1 8 1 6 of ...

Page 79: ...ing hydraulic shock absorber 3 Fork crosspiece 11 Tightening nut 19 Brake drum cover tie rod 4 Nut of steering column stem 12 Washer 20 Wheel lever 5 Supporting washer 13 Leg housing with headlight 21 Moving washer 6 Spring washer bracket 14 Steering column bridge 22 Steering column bridge 7 Clamping bolt 15 Fender clip 23 Lower radial thrust ball 8 Steering column stem 16 Front fender bearing ...

Page 80: ...s and nipples Care should be taken to keep tires properly inflated See TIRE DATA chapter 13 for correct cold tire inflation pressures Check before riding when tires are cold Do not over inflate tires WARNING Improper tire inflation will cause abnormal tread wear and could result in unstable handling Under inflation could result in the tire slipping on the rim Check inflation pressure and inspect t...

Page 81: ...ycle Wheel 1 Tire 2 Tire flap 3 Spokes 4 Brake drum 5 Roller bearings 6 Thrust washer 7 Right hand distance bushing 8 Intermediate bushing 9 Left hand distance bushing 10 Seal 11 Seal nut 12 Locknut 13 Hub 14 Wheel rim ...

Page 82: ...nd extract the cable through the slots of the screw and the bracket Bring the hand brake cable end out of the hole in the brake lever making the cable match the lever slot 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 mo...

Page 83: ...has two studs that fit the two holes in the round nut holding the luggage rack down ...

Page 84: ...east every 2 500 km the tension and condition of the wheel spokes do this with wheels jacked up Every 5 000 km check the condition of the motorcycle toe in of the sidecar the lean out angle of the motorcycle and adjust the wheel bearings if necessary rotate the wheels including the spare proceeding in clockwise direction to keep tread wear even on all tires Every 10 000 km check and change if requ...

Page 85: ...are equalized To return the levers to their initial position a spring Fig 30 9 is installed on the bottom lever The brake shoes are provided with adjusting bolts Fig 30 5 to compensate for the 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 normal performance of the brake leave a gap between the shoes ...

Page 86: ... Figure 30 Fron Wheel Brake 1 Top brake lever 9 Brake lever spring 2 Inspection hole plug 10 Adjusting screw 3 Brake shoe 11 Tie rod 4 Adjusting bolt locknut 12 Locknut 5 Adjust bolt 13 Tie rod fork 6 Brake shoe springs 14 Pin 7 Front brake cam 15 Brake drum cover 8 Bottom brake lever Figure 31 Sidecar Wheel Brake ...

Page 87: ......

Page 88: ...s should be burnished in during the initial running in period Speeds during this period should not exceed 45 mph 70 kmh with sidecar attached 50 mph 90 kmh without sidecar see Speeds Recommended for Running in table Follow burnishing procedures carefully Make approximately 100 stops using 75 of full braking power This can be done over several periods and need not be done in one session Choose an a...

Page 89: ... brake malfunction and personal injury If you ride under adverse conditions steep hills heavy traffic etc more frequent inspection 1 000 km or less will be necessary We do not recommend using the rear brake only ...

Page 90: ... the rear brake pedal equal to about 25 30 mm 1 1 2 in of the full stroke of the pedal are required for the carburetors carburetor throttle synchronized With the control levers handles fully depressed for the clutch complete disengagement of the engine from the transmission noiseless shifting of gears means good adjustment of the clutch cable for the carburetors lift of throttles to the maximum an...

Page 91: ...nd schedule After every 5 000 km check the condition 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 bearing the throttle control twist grip the lever pins and ends of cables used in the clutch the front brake control ...

Page 92: ...nated with two lamps The speedometer is driven by the main shaft of the gearbox via a flexible shaft After every 10 000 km add five or six drips of oil into the union butt end to lubricate the speedometer axle Wash and lubricate the flexible shaft used in the speedometer drive ...

Page 93: ...start models the 9amp hour battery is replaced with a larger capacity battery with 270 cold cranking amps and 18 amp hours The generator with built in rectifier is driven by the engine camshaft driven gear The transmission ratio between the engine crankshaft and the generator shaft is 1 33 The generator is secured with two studs on the engine crankcase At the drive side the generator cover is so d...

Page 94: ... body Headlight A 7 diameter DOT approved sealed beam headlight is used on the US URAL Adjust it so that the high beam is horizontal when the motorcycle is in its normal loaded condition Figure 32 Electric Circuit Diagram ...

Page 95: ...Turn indicator interrupter 22 Braking signal bulb 33 Interrupter and commutator 11 Turn indicator bulb 23 Side bulb number 34 Spark plug 12 Motorcycle head lamp plate illumination bulb 35 Spark plug cap Deleted on electric start The stop light switch of the hand brake is screwed into the base of the hand brake lever and is fixed with a locknut The stop light switch is secured on the frame bracket ...

Page 96: ...parking The switch is located under the seat except on the electric start models where it has been removed ...

Page 97: ...generator bearings take place Every 10 000 km check for proper tightening of nuts of the binding post bolts the generator clamping screws the generator fastening nuts Every 20 000 km clean the cover cavity at the slip rings end from brush and copper dust Blow through the generator with compressed air At least once monthly or daily on electric start bikes when taking short trips check the charge of...

Page 98: ...ndicator bulb 15 Speedometer 26 Generator 4 Sidecar rear lamp 16 Speedometer illumination bulbs 27 Generator operation indicator bulb 5 Sidecar side and brake bulb 17 Fuse plate 28 Side and parking bulb in lamp 6 Adjustment relay 18 Horn 29 Highbeam ON indicator bulb of lamp 7 Contact neutral gear indicator switch 19 Induction coil 30 Left turn indicator ...

Page 99: ...ke lever and is fixed with a locknut The stop light switch is secured on the frame bracket by means of two screws The switch rod is connected via a spring to the top arm of the foot brake pedal When installing the stop light switch see that the spring coupling the switch rod and the brake pedal is not loose If the stop light either stays on or doesn t come on adjust the spring tension by moving th...

Page 100: ...is given in Fig 35 A summary of lubrication maintenance intervals is given in the lubrication chart Cosmetic Maintenance 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 oxi...

Page 101: ...orm to keep the factory warranty in place It is acceptable when the machine is used primarily in ideal climates with very little dust or contamination of fuel supply and with sidecar accessory unattached 1 Change motor and trans oil replace filter element clean and or replace air filter element and fuel filter Normal 500 1 500 2 500 3 500 5 000 then every 2 500 Light 4 500 10 000 15 000 20 000 25 ...

Page 102: ...Light Every 4 500 5 000 replace at 10 000 km Figure 35 Lubrication diagram ...

Page 103: ... 500 km 5 Shock absorbers of rear suspension and sidecar wheel suspension Industrial oil or spindle oil Change every 10 000 km 6 Final drive 80 90 Gear and URAL O T 4 Lube Top up every 2 500 km Change every 10 000 km 7 Hinges of sidecar collet joint Grease Every 10 000 km 8 Hinge joints of brake system Spindle oil WD 40 Every 5 000 km 9 Brake pedal shaft Spindle oil WD 40 Every 2 500 km 10 Univers...

Page 104: ...00 km 16 Speedometer drive flexible shaft and speedometer axle Industrial oil or spindle oil Every 10 000 km 17 Steering column bearings Grease Every 20 000 km 18 Telescopic forks 10 and solo 5wt 10wt Fork oil As needed Footnotes 1 During break in changes required at 500km 1 500km 2 500km 3 500km and 5 000km 2 During break in change at 500 km and then 2 500km 3 20W 50 Det oil and URAL Oil Treatmen...

Page 105: ...pared to liquid cooled engines a special oil treatment product has been developed and produced for URAL motorcycles by Hilton Oil Co This product URAL Oil Treatment has proven in tests to lower the engine s operating temperatures and reduce the friction and wear in the engine gearbox and final drive URAL Oil Treatment should be continually replaced whenever changing the oil in your URAL The follow...

Page 106: ...ed as follows check oil level topping off or changing oil altogether if required draw threaded joints lubricate the lubrication points check functioning of the instruments included in the electrical equipment and the ignition system attending to the jobs outlined in the manual check pressure in the tires bringing it to the specified values Note Since the URAL engine is an old fashioned design some...

Page 107: ...ollows clean the surface with turpentine rub the damaged spot with a waterproof abrasive cloth and water rub thoroughly thin the enamel with turpentine or acetone paint using a soft brush or a spray gun After patching let the surface dry in air 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 m...

Page 108: ...haft by depressing the kick lever pedal to distribute lubricant over the interior of the cylinders Lubricate the surfaces of chrome and zinc plated parts with a rust inhibitor Smear all the points provided with grease cups with commercial grease Seal the outlet holes of the mufflers Before starting a trip on the motorcycle that was under preservation proceed with the jobs listed in the section Pre...

Page 109: ...Seals Mounted on Motorcycle Fig 36 Part No Description Location 6204010 Clutch shaft seal assembly Gearbox Front Side 6204017 Gear case RH cover seal assy Gearbox cover RH Side 6204147 1 90 RH gearcase cover seal Gearbox cover LH Side 6204157 Main shaft Gearbox crankcase cover ...

Page 110: ...ase slide 7203213 20 Seals of clutch release rod Clutch release rod 7205039 Collar type seal spring assy Final drive case 7205113 b Collar seal drive gearcase Final drive case Z101 04122 Packing gland starting shaft Gearbox cover Z101 04131 Ring Gearbox front side Z101 08019 Collar with spring assy Fork leg Z101 08123 Seal collar Fork leg Z101 08159 Seal Steering column ...

Page 111: ...lls coat bolts nuts washers and tips with petroleum jelly or battery grease Use two wrenches for clamping or undoing the nuts to avoid breaking battery parts use a small floating charger which will keep the battery from losing its power while you are not using your bike This type of charger won t overcharge your battery but will keep it active so sulfating won t occur You will be able to find many...

Page 112: ...arter models as the battery drain from starting is significant WARNING Batteries produce explosive hydrogen gas at all times especially when being charged Keep cigarettes open flame and sparks away from battery at all times Ventilate 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 O...

Page 113: ...ge 1 3 Wrench 13 x 14 1 3 Ignition keys 2 4 Wrench 14 x 17 1 4 Theft proof lock keys 2 5 Wrench 19 x 22 1 6 Socket wrench 10 x 12 1 Set of Spares 7 Socket wrench 10 x 13 1 1 Inner tube patch kit 1 8 Socket wrench 19 x 21 1 2 Oil filter element 1 9 Wrench 27 mm 1 3 Fuses 2 10 Double head wrench 1 4 Touch up paint 1 11 Spanner wrench 1 12 Spanner wrench assembly 1 Documents 13 Screwdriver 150 mm 1 1...

Page 114: ...14 Screwdriver 100 mm 1 2 Driving the URAL Sidecar Motorcycle except with Solo models 1 15 Pliers 1 16 Tool kit pouch 1 3 Owner s Video 1 ...

Page 115: ...otorcycle main drive with a differential gear Fig 37 Fig 38 The following units that have been redesigned to produce the driven sidecar wheel are A Main drive B Rear wheel swing arm C Sidecar chassis fender and brake tie rod Additionally there are a number of new parts including the cross shaft to the sidecar wheel and two universal joints ...

Page 116: ... when decelerating The sidecar wheel receives its torque via a differential in the final drive About 30 of the power is transferred to the sidecar wheel during steady state operations with the sidecar wheel on the ground However if the sidecar wheel is lifted off of the ground when power is being applied most of the power will go to it If the sidecar wheel is kept in the air it will spin up and th...

Page 117: ...Grease the moveable slot joint of the propeller 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 maintenance After every 10 000 kilometers Change the grease in the universal joint bearing Chan...

Page 118: ...plines in the hub in the gear case Proceed further as described in the standard repair manual Assembling the main drive is effected in reversed order Before tightening the nut in the case cover the sun gear flange with seal and ball bearing should be installed The bronze ring should be positioned onto the sun gear neck next after the steel ring After putting the main drive together check and adjus...

Page 119: ...aring nut 14 Axle nut 24 Bolt 34 Spacer 5 Hub 15 Splint 25 Propeller shaft fork 35 Satellite gear 6 Propellor shaft 16 Ring 26 Seal rings 36 Satellite pin 7 Case seal 1 7 Spacer 27 Driving gear 37 Driven gear crown 8 Needle bearing 18 Nut 28 Bronze spacer 38 Screw 9 Double row bearing 19 Double row bearing 29 Spacer 39 Ring 10 Seal cap 20 Sun gear seal 30 Gasket 40 Bolt Figure 38 Sidecar Bearing U...

Page 120: ...g arm 6 Ball bearing 11 Bolt 2 Braking drum cover 7 Protective ring 12 Shock absorber silent block 3 Slotted hub 8 Spacer 13 Propeller shaft 4 Sidecar pin 9 Ring 14 Universal joint 5 Ball bearing 10 Spacer ring ...

Page 121: ...to beginners 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 ...

Page 122: ...r 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 Repeat 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 the point where you can keep it in the air for a full ci...

Page 123: ...special break in procedure see Running In The New Motorcycle Operate the motorcycle only at moderate speed and out of traffic until you have become thoroughly familiar with its operation and handling characteristics 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...

Page 124: ...ontact your dealer for repair of steering or suspension system wear or damage Do not tow a trailer At street intersections give the right of way to the vehicle on your right 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 s...

Page 125: ...ensure compliance with DOT requirements are available from your Authorized URAL Dealer The following tire data labels are mounted on the front frame of your URAL For motorcycle with sidecar accessory 19 tire IMZ 8 103 40 GVWR 137 LB 623 KG GAWRs Front 491 lb 223 kg with 4 00 x 19 tire 19 x 3 00 rim at 22 psi cold Side 304 lb 138 kg with 4 00 x 19 tire 19 x 3 00 rim at 22 psi cold Rear 577 lb 262 k...

Page 126: ... with 3 50 x 18 tire 18 x 3 00 rim at 32 psi cold WARNING Maximum inflation pressure must not exceed specification on tire sidewall WARNING When tires are worn to a tire center tread depths of 3 32 in they should be replaced ...

Page 127: ... carburetor s partially open the air control shutter under the air filter by moving the lever inch backwards Let the engine warm up for 3 5 minutes depending on the temperature 7 After the engine has warmed up completely open the air control shutter by moving the lever all the way down until it stops Trouble Shooting If engine does not start with above method the problem s may be one or more of th...

Page 128: ... the front of the engine 4 Not enough compression in the cylinders due to excessive wear or broken valve s 5 No spark to engine due to failure of electronic commutator or pick up assembly Items 4 5 above require the attention of a qualified mechanic at your URAL dealer WARNING Reverse Gear Damage WARNING Attempting to engage the reverse gear while the motorcycle is moving may cause SEVERE damage t...

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