URAL Motorcycles Wolf 2004 Owner'S Manual Download Page 67 | Manualshive

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67

Appendix A

Warranty Claim Form

Irbit Motorworks of America, Inc.

Dealer_________________ ______Authorized #___________Date/__/__/__/

Motorcycle Information
VIN # /__/__/__/__/__/__/__/__/__/__/__/__/__/__/__/__/__/

Engine /__/__/__/__/__/__/

Gearbox /__/__/__/__/__/__/ Model ____________ Mileage (km)_________

Owner’s Name______________________ Date of Registration /___/___/___/
Complete
Address___________________________________________________________________________
Comments_________________________________________________________________________________

Service Information
Technician__________________Start Date /___/___/___/ Completion Date /___/___/___/
Diagnosis of Defect________________________________________________________
____________________________________________________________________________________________________________________________________________________________________________________
____________________________________________________________________________________________________________________________________________________________________________________
____________________________________________________________________________________________________________________________________________________________________________________
____________________________________________________________________________________________________________________________________________________________________________________

Part # Description Qty Dlr. Cost
____________________ ______________________ ______ _________
____________________ ______________________ ______ _________
____________________ ______________________ ______ _________
____________________ ______________________ ______ _________
____________________ ______________________ ______ _________
____________________ ______________________ ______ _________
____________________ ______________________ ______ _________

Parts Total $__________

All warranty parts are shipped using standard UPS ground only.

Flat Rate Schedule: Check the items that pertain to this claim.

1. Engine

2. Gearbox

3. Final Drive

4. Front Fork

5. Wheel & Tire

1.1 __ 1.4hr

1.7 __ 0.1hr

2.1 ___ 0.5hr

3.1 ___ 0.3hr

3.7 ___ 0.3hr

4.1 ___0.7hr

5.1 ___ 0.2hr

1.2 __ 1.5hr

1.8 __ 0.1hr

2.2 ___ 0.1hr

3.2 ___ 0.4hr

3.8 ___ 0.2hr

4.2 ___ 0.5hr

5.2 ___ 0.2hr

1.3 __ 2.0hr

1.9 __ 0.7hr

2.3 ___ 0.9hr

3.3 ___ 0.6hr

4.3 ___ 0.5hr

5.3 ___ 0.4hr

1.4 __ 1.5hr

1.10 __ 0.4hr

2.4 ___ 1.2hr

3.4 ___ 0.7hr

4.4 ___ 0.4hr

5.4 ___ 0.3hr

1.5 __ 0.2hr

1.11 __ 0.3hr

2.5 ___ 0.4hr

3.5 ___ 0.7hr

5.5 ___ 0.3hr

1.6 __ 0.1hr

1.12 __ 0.4hr

3.6 ___ 0.9hr

5.6 ___ 0.2hr

1.13 __ 0.3hr

6. Sidecar

7.Chassis

8. Electrical

6.1 ___0.3hr

6.5 ___ 0.2hr

7.1 ___ 0.3hr

7.5 ___ 0.2hr

8.1 ___ 0.6hr

8.5 ___ 0.2hr

8.9 ___ 0.3hr

6.2 ___ 0.1hr

6.6 ___ 0.2hr

7.2 ___ 0.5hr

7.6 ___ 0.2hr

8.2 ___ 0.4hr

8.6 ___ 0.3hr

8.10 ___ 0.1hr

6.3 ___ 0.3hr

6.7 ___ 0.4hr

7.3 ___ 0.4hr

7.7 ___ 0.4hr

8.3 ___ 1.2hr

8.7 ___ 0.2hr

8.11 ___ 0.2hr

6.4 ___0.4hr

7.4 ___ 0.3hr

7.8 ___ 0.2hr

8.4 ___ 0.6hr

8.8 ___ 0.1hr

Labor Information
Flat Rate Hours_______________ Shop Rate $_______________Total $_____________

Dealer Signature_________________________ Date_________

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Summary of Contents for Wolf 2004

Page 1: ...Irbit Motorcycle Factory Irbit Motorworks of America Owners Manual 2004 Model Wolf ...

Page 2: ......

Page 3: ...ngine Operation and Maintenance 21 Pre Trip Preliminaries 21 Starting the Engine 21 Operating Precautions 25 Running In the New Motorcycle 25 Chapter 4 Engine Design Brief Description of Design 27 Lubrication System 28 Fuel System 29 Ignition System 30 Chapter 5 Carburetors Carburetors 33 Carburetor Maintenance 34 Chapter 6 Power Transmission Power Transmission 35 Clutch 35 Gearbox 35 Final Drive ...

Page 4: ...rcycle 51 List of Recommended Lubricants 51 Lubrication Chart 52 Required Lubrication 52 Care of Motorcycle Paint 52 Preservation and Storage 53 Battery 53 List of Individual Tool Set Spare Parts Accessories Documents 55 Chapter 14 Learning to Ride the URAL Safe Operating Rules 57 Chapter 15 Warranty Warranty 59 Warranty Claim Form 67 Warranty Flat Rate Schedule 68 Chapter 16 Service Coupons Servi...

Page 5: ...ons or comments are welcome Write to us or post an e mail on the Ural Discussion bulle tin board at www imz ural com Happy Riding Important Notice Statements in this manual preceded by the following words are of special importance WARNING MEANS THERE IS THE POSSIBILITY OF PERSONAL INJURY TO YOURSELF OR OTHERS CAUTION Means there is the possibility of damage to the vehicle NOTE Other information of...

Page 6: ...6 ...

Page 7: ...lves opposed twin cylinder Displacement 745 cc Cylinder bore 78 mm Piston stroke 78 mm Compression ratio 8 6 1 Rated horsepower 29 KW 40 BHp Rated rotational speed 5600 RPM Rated torque 38 ft lbs 3750 RPM Lubrication system Dual system of forced lubrication and splashing Lubricant SAE 20W 50 CARBURETOR Carburetor type 32 CVK Keihin Number of carburetors 2 Air cleaner Paper Filter Element Fuel 91 o...

Page 8: ... 68 oz 2L Transmission oil 34 oz 1 L Final drive gear oil 4 5 oz 105 ml Shock Absorbers shock oil 105 ml 3 5 oz Brake Reservoir DOT 3 or 4 brake fluid to upper line RUNNING GEAR Frame Tubular welded Rear wheel suspension Swing arms with spring shock absorbers Front fork Telescopic Brakes Disc type with hydraulic drive on front disc type with hydraulic drive on rear Tires Front MC90 90 18 TIRE 18X2...

Page 9: ... top 14 ft lb to 22 ft lb shock absorber 38 to 49 NM bottom 28 ft lb to 36 ft lb shock absorber 30 to 35 NM 22 ft lb to 26 ft lb bearing nut 30 to 35 NM 22 ft lb to 26 ft lb final drive to swing arm bolts 16 to 19 NM 12 ft lb to 14 ft lb oil pump bolt 6 7 to 11 NM 5 ft lb to 8 ft lb engine sump 14 to 19 NM 10 ft lb to 14 ft lb final drive case nuts 68 to 90 NM 50 ft lb to 66 ft lb nut fastening th...

Page 10: ...10 ...

Page 11: ...l lever 2 Indicator lights 12 Electric start Button 3 Trip odometer reset knob 13 Engine kill switch 5 Clutch control lever 14 Throttle control twist grip 6 High low beam switch 15 Rear brake pedal 7 Turn signal switch 8 Horn push button 9 Gear shift foot pedal 10 Ignition switch 1 2 3 5 6 7 8 9 10 11 12 13 14 15 ...

Page 12: ...TRANSMISSION TO NEUTRAL TO PREVENT ACCIDENTAL MOVEMENT WHICH COULD CAUSE POSSIBLE DAMAGE TO MOTORCYCLE AND PERSONAL INJURY Caution Always engage the clutch release lever when shifting Serious internal damage may result to the transmission if the clutch release lever is not engaged Front brake control lever When the lever is squeezed the front wheel brake is actuated The front brake should be used ...

Page 13: ...e front arm is pressed shifting from higher to lower gear takes place When the rear arm is pressed shifting from lower to higher gear takes place The neutral position is fixed between the 1st and 2nd gears It is important to shift smoothly with a constant force and not to kick the gear shift pedal IMPORTANT The green pilot lamp will illuminate when the transmission is in neutral see Starting the E...

Page 14: ...Y ENOUGH TO LOCK THE WHEELS BECAUSE THIS MAY CAUSE POSSIBLE LOSS OF CONTROL OF THE MOTORCYCLE ALWAYS USE BOTH BRAKES NEVER STOP WITH FRONT OR REAR BRAKE ONLY Rear Brake Pedal WARNING DO NOT LET YOUR FOOT REST ON THE EXHAUST HEADER PIPE SERIOUS INJURY OR BURNS MAY RESULT FROM VERY HOT EXHAUST PIPES ...

Page 15: ...15 ...

Page 16: ...Voltage is supplied to running lights only Note Leaving the key in the Run or Parking position will discharge the battery Always return the key to the Off position before removing it Ignition Switch has three fixed positions of the key The positions of the ignition are shown above Ignition Switch ...

Page 17: ...me diate attention Neutral Indicator indicates that the gearbox is in neutral High Beam Indicator indicates that the headlight high beam is activated Speedometer is on the dash board with trip and total odometer The trip odometer is reset to zero by rotating knob counterclockwise Note that the odometer reads in kilometers not miles Alternator Fault Indicator Turn Signal Indicator Neutral Indicator...

Page 18: ...18 Electric Start Button Ignition Cutoff Switch Low High Beam Switch Horn Push Button Turn Signal Switch ...

Page 19: ... two positions ignition off up and ignition on down Electric Start Button is located on the right hand twist grip below the kill switch Low and High Beam Light Switch has two positions high beam up and low beam down Turn indicator switch is used for signaling a turn horn push button is used to activate the horn Trip odometer reset knob ...

Page 20: ...t the clutch lever end should be equal to 5 8 mm 0 2 0 3 in for the carburetors carburetor throttle cables 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 and equal height CONTROL CABLE MAIN...

Page 21: ...not higher than the top and not lower than the bottom marks on the dipstick with the filler plug undone See chapter 4 Lubrication System CAUTION When checking the engine oil level be careful that dirt and debris do not con taminate the oil STARTING THE ENGINE WARNING BEFORE STARTING THE ENGINE MAKE SURE THAT THE GEAR SHIFT MECHANISM IS IN THE NEUTRAL POSITION BETWEEN 1ST AND 2ND GEARS TO PREVENT A...

Page 22: ...starts stalling due to lack of fuel set the valve to the RES Reserve position and continue driving After refueling remember to set the valve back to ON to avoid running out of fuel completely IMPORTANT When parking the motorcycle for extended periods of time the valve should remain in the ON position WARNING Never leave the motorcycle with the engine turned off and the valve set to PRI as this may...

Page 23: ...hrottle since this may flood the engine 2 Give the kick lever a swift kick When the engine starts tickle the throttle quickly in crease and decrease it to keep the engine running but not too fast If the engine doesn t start repeat the kicking procedure Aproperly adjusted warm engine should start within a few kicks If the engine doesn t start try the procedure described below in item 3 If it still ...

Page 24: ...on as the engine will sustain itself without stalling Since the Ural is a carbureted air cooled engine the plugs will foul quickly as soon as one minute if the engine mixture is too rich If one plug fouls and the other doesn t the engine will run unevenly and may cause internal damage When the engine is hot do not choke or enrichen the carburetors To do so risks flooding the engine To start an eng...

Page 25: ...WHEN SPEED IS TOO HIGH MAY SEVERELY DAMAGE THE TRANSMIS SION OR CAUSE THE REAR WHEEL TO LOSE TRACTION CAUTION Do not run the engine at extremely high rpms with clutch disengaged or trans mission in neutral Do not idle the engine unnecessarily for more than a few minutes with themotorcyclestandingstill When operating the Ural motorcycle on the highway please try not to run continuously at speeds ab...

Page 26: ...26 ...

Page 27: ...tion of the engine power transmission units and the running gear mechanisms Under normal heating conditions of the engine the temperature of the cylinder heads should not be over 356 F 428 F 180 C 220 C During everyday preventive maintenance clean the engine of mud and dust paying special atten tion to the cooling fins as their fouling will impair the efficiency of the engine cooling Check en gine...

Page 28: ...oil filter at the intervals shown in the service coupons Set the rubber sealing bush ing into the filter and fit the filter with the bushing onto the adapter of plug then screw the latter into the front cover Now screw in the plug Fill the engine with 68 oz oil or until the top mark of the dipstick is reached Let the engine run for 3 5 min Check the oil level again adding oil up to the top groove ...

Page 29: ...When the engine is stopped and looses vacuum the petcock automatically shuts off WARNING FILL FUEL TANK SLOWLY TO PREVENT FUEL SPILLAGE DO NOT OVERFILL ABOVE THE BOTTOM OF FILLER NECK INSERT LEAVE AIR SPACE TO ALLOW FOR FUEL EXPANSION FUEL EXPANSION CAN CAUSE OVERFLOW THROUGH THE FILLER CAP VENT ONTO SURROUNDING AREAS AFTER REFUELING MAKE SURE FILLER CAP IS SECURELY TIGHTENED Fuel system maintenan...

Page 30: ... In certain situations spark plugs can quickly foul with carbon or soot The plugs can be cleaned but it is easier to put in a new set of plugs when on the road We recommend that you purchase an extra set of these plugs from yourAuthorized Ural Dealer and carry them in the mo torcycle at all times WARNING DO NOT OVERTIGHTEN THE SPARK PLUG WHEN MOUNTING IT ON THE ENGINE SINCE THIS COULD DAMAGE THE C...

Page 31: ...31 Ignition Module Coil ...

Page 32: ...32 ...

Page 33: ...he carburetor flanges are in need of replacement use only genuine Ural replacement or Ural recommended parts WARNING TO AVOID SEVERE ENGINE DAMAGE DO NOT MODIFY CARBURETOR SYNCHRONIZATION JETS OR THROTTLE LINKAGE THIS AIR 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 34: ...ns provided on the bottom of the float bowls The fuel filters should also be changed every 10 000 km or when they appear to be dirty or not flowing fuel correctly Changing the filters will ensure that clean fuel is provided to the carburetors and that there is no fuel starvation The carburetor to cylinder head adapters should be checked for leaks and cracks every trip Fail ure of the adapters will...

Page 35: ...x When the clutch lever is squeezed the engine is disengaged from the gearbox Use the clutch lever for starting from rest and for gear shifting Under conditions of heavy traffic when gears frequently have to be shifted do not slip the clutch too much as this will accelerate wear of the disks GEARBOX Shifting the gears is best accomplished by pushing down on the front toe plate for first gear and t...

Page 36: ...ch fasten the final drive to the swinging fork arm Failure to tighten the nuts may result in loose joints and the destruction of the final drive cover Change the final drive oil as determined by the service coupons Undo the filler and drain plugs and drain the used oil Reinsert the drain plug and fill the casing with fresh 20w 50 Castrol oil and flush the final drive by turning the rear wheel seve...

Page 37: ... adjustable allowing two positions The first lower position corresponds to the load due to the motorcycle s own weight and the driver s the second upper position of moving cam corresponds to the maxi mumload Care of shock absorbers Fill the shock absorber with 105 cm of hydraulic fluid Each time during maintenance check the bolts fixing the top and bottom ends of the shock absorbers for tightness ...

Page 38: ...justed periodically to avoid excessive play which might cause steering instability When properly adjusted the front fork should turn with just a hint of bearing drag but not free play or obvious resistance to turning The steering head bearings are of a roller bearing type and are designed for the lifetime of the motorcycle WARNING IMPROPER ADJUSTMENT OF THE STEERING HEAD E G TOO TIGHT WILL MAKE TH...

Page 39: ...motorcycle lift the motorcycle onto the center stand Undo the rear wheel axle nut and take it off together with the washer slacken off the nut on the union bolt of the left hand leg of the swinging arm pull out the rear wheel axle with the help of a wrench bar and removethewheel To reinstall the wheel on the motorcycle follow the reverse order of operations Prior to reassem bling wipe the axle and...

Page 40: ...OR FURTHER INFORMATION MISMATCHING TIRES TUBES AND RIMS MAY RESULT IN DAMAGE TO THE TIRE BEAD DURING MOUNTING OR MAY ALLOW THE TIRE TO SLIP ON THE RIM POSSIBLE CAUSING TIRE FAILURE IN ADDITION USING TIRES OTHER THAN THOSE SPECIFIED MAY AD VERSELY AFFECT MOTORCYCLE STABILITY PROTECTIVE RUBBER RIM STRIPS MUST BE USED TIRE SIZES ARE MOLDED ON THE TIRE SIDEWALL TUBE SIZES ARE PRINTED ON THE TUBE URAL ...

Page 41: ... drum or disc type may be used The adjustment of bearings is the same for both styles of wheel Adjustment of Wheel Bearings The life of wheel bearings is extended by proper adjustment Check the condition of bearings and adjust them every 5000 km To adjust the bearings proceed as follows Remove the wheel from the motorcycle Fit the rear wheel axle without protective cap tighten it by nut with the a...

Page 42: ...42 ...

Page 43: ...e done in one session Choose an area with clean dry pavement and no obstructions Travel in a straight line and apply both the hand front brake as well as the foot rear and sidecar brakes This procedure will ensure maximum braking performance during the running in period and is essential before raising your top speed after your Ural has been carefully run in after 1 500 km WARNING BECAUSE BRAKE PER...

Page 44: ...emaining on either pad The brake hose should be inspected periodically for leaks and cracks along the length of the hose as well as the banjo fittings on either end WARNING Never use any aftermarket brake hose for the front brake Use only genuine Ural brake hoses failure to do so could result in front brake failure and voiding the warranty INJURY IF YOU RIDE UNDER ADVERSE CONDITIONS STEEP HILLS HE...

Page 45: ...o spill brake fluid on the paint as damage to the paint may occur To check the brake fluid level in the reservoir remove the two top screws on the reservoir Remove the cover and the rubber gasket Fill the reservoir to within 1 4 inch of the top Squeeze the brake lever several times to ensure that any air that has been introduced is forced out of the system Replace the rubber gasket the cover and t...

Page 46: ...46 ...

Page 47: ...y supplies electric power to all the systems of the motorcycle when the engine and alterna tor have stopped An alternator with a built in rectifier is driven by the engine camshaft driven gear The alterna tor is secured with two studs on the engine crankcase At the drive side the alternator cover is so designed that by turning the alternator on the studs the backlash adjustment of the gear mesh ga...

Page 48: ... the circuit is said to be an open circuit The flow of electricity through a circuit always takes the path of least resistance If there is an accidental path of extremely low resistance created in a circuit the circuit is said to have a short circuit Ashort circuit will usually result in the melting of the fuse protecting that circuit ELECTRICAL EQUIPMENT MAINTENANCE During the daily preventive in...

Page 49: ...49 The fuse box is located under the front fork Theheadlightcontrolrelaysarelocatedunderthefueltank ...

Page 50: ...50 ...

Page 51: ...e special care must be taken to prevent rust from occurring and or to removed any rust or oxidation LIST OF RECOMMENDED LUBRICANTS LubricationArea Detergent Oil Quantity Engine 20w 50 Castrol 68 oz 2 0 L 1 Transmission 20w 50 Castrol 34 oz 1 0 L 2 Single Wheel Final Drive 80 90 wt Gearlube 3 5 oz 105 ml 1 68 oz is an approximate measure The exact oil quantity will be whatever is required to bring ...

Page 52: ...rcycle use a weak stream of cold or slightly heated water Never use a pressure washer Do not remove dust and mud by rubbing the surface with a dry cloth as sand particles will degrade the surface and the paint will rapidly lose its brilliance While washing do not use soda solution kerosene citric acids or mineral oils If the surface is stained with mineral oil degrease by wiping with a rag If afte...

Page 53: ...or to placing it in storage clean the bike thoroughly drain the carburetors or start the engine and let it run with the gasoline cock closed to remove gasoline in the float chambers of carburetors Then spray storage oil WD40 into each cylinder through the spark plug holes Turn the crank shaft by depressing the kick lever pedal to distribute lubricant over the interior of the cylinders Lubricate th...

Page 54: ...D BY MILK OF MAGNESIA VEGETABLE OIL OR BEATEN EGGS CALL DOCTOR IMMEDIATELY Caution When charging the battery disconnect the positive terminal from the battery to prevent damage to the electrical components Never jump start the motorcycle 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 V...

Page 55: ...keys 2 4 Wrench 14 x 17 1 5 Wrench 19 x 22 1 6 Socket wrench 10 x 12 1 7 Socket wrench 10 x 13 1 Set of Spares 8 Socket wrench 19 x 21 1 9 Wrench 27 mm 1 1 Oil filter element 1 10 Double head wrench 1 2 Fuses 2 11 Spanner wrench 1 3 Touch up paint 1 12 Spanner wrench assembly 1 13 Screwdriver 150 mm 1 Documents 14 Screwdriver 100 mm 1 1 Owner s Manual 1 15 Punch 1 16 Allen wrench 1 17 22mm Round w...

Page 56: ...56 ...

Page 57: ...cs under all conditions If you are an inexperienced rider we recommend that you obtain information and training in correct motorcycle riding technique Do not exceed the legal speed limit or drive too fast for existing conditions Always reduce speed when poor driving conditions exist High speed increases the influence of any other condition affecting stability and the possibility of loss of control...

Page 58: ...way the other driver may not know you have it Always signal when preparing to stop or turn All traffic signs including those used for the control of traffic at intersections should be obeyed promptly and to the letter SLOW DOWN signs near schools and CAUTION signs at railroad crossings should always be observed and your actions governed accordingly Never anticipate a traffic light When a change is...

Page 59: ...rom the time of purchase of the parts by a Dealer or retail customer 1 Engine 12 months 2 Gearbox 12 months 3 Final drive 12 months 4 Alternator 6 months 5 Electric starter 6 months 6 Ignition 6 months 7 The rest of the motorcycle parts and parts assemblies 30 days The above applies ONLY in cases when Dealer or retail customer identifies defects before using parts and or assemblies or these defect...

Page 60: ... of each coupon Failure to adhere to this requirement will void the warranty 4 All personnel who operates the motorcycle must sign a statement that they have studied the Owner s Manual and have gone through the sidecar motorcycle driving practice before taking the commercially outfitted URAL outfit on the public roads A copy of a signed and dated statement of completion by each driver and instruct...

Page 61: ...ailure to follow running in break in procedure 3 Replacement of expendable maintenance items beyond the first scheduled maintenance including but not limited to spark plugs filters lubricants compliance fittings tires see Owners Manual gaskets fuel line fuses bulbs 4 Paint and or decal fading peeling blistering chipping or rusting 5 Use for the following activities such use will VOID coverage Raci...

Page 62: ...pendix B applied to the Dealer s approved shop hourly rate 1 Dealer will fax a warranty parts request to IMWA Inc on a Warranty Claim Form Appendix A for all warranty parts 2 Irbit MotorWorks of America Inc will review and when approved will ship parts within 48 hrs and notify Dealer if repair will be covered under factory warranty 3 Dealer must submit claims for labor reimbursement within 10 busi...

Page 63: ...receipt of any motorcycle which may involve over 30 days of shop time including order and receipt time for parts service time and delivery time If Dealer fails to notify IMWA Inc in such a case Dealer will be solely responsible for any forced motorcycle repurchase that occurs and may be subject to termination of IMWA Inc Dealership IMWA Inc reserves the right to perform warranty work at its expens...

Page 64: ...be defective in material or factory workmanship under normal use for the applicable period Parts and Labor No charge for replacement of defective parts Your obligation To have required maintenance works performed in accordance with this manual and Service Coupons Failure to have required maintenance performed may result in losing warranty coverage Note The following items are not covered by the No...

Page 65: ...will meet applicable emission regulations within the time and mileage periods The obligation of Irbit Motorworks of America To repair or replace at its option any part or parts of the emission control systems which are proven to be defective in material or factory workmanship under normal use for the applicable period Parts Labor No charge to you Your obligation To have required maintenance perfor...

Page 66: ... street use 2 Removing or modifying the muffler internal baffles in any way 3 Replacing the air intake cleaner assembly with one not certified to be noise legal for street use 4 Modifying the air intake cleaner assembly in such a way as to make the vehicle no longer noise legal for street use IMPORTANT If you move from your present address or sell your motorcycle please fill out and mail the form ...

Page 67: ... _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Part Description Qty Dlr Cost ____________________ ______________...

Page 68: ...tem disconnection connection to cylinder heads 0 4 1 11 Valve gap adjustment 2 cylinders 0 3 1 12 Clutch disassembly assembly engine removed 0 4 1 13 Air filter assembly removal mount 0 3 2 0 Gear box 2 1 Gear box removal mount rear wheel and final drive removed 0 5 2 2 Gear box removal mount engine removed 0 1 2 3 Gear box disassembly 0 9 2 4 Gear box assembly 1 2 2 5 Gear box adjustment 0 4 3 0 ...

Page 69: ...2 Rear wheel removal mount 0 2 5 3 Wheel alignment and balancing 0 4 5 4 Wheel bearing adjustment 0 3 5 5 Tire removal mount on the rim 0 3 5 6 Brake adjustment per wheel 0 2 6 0 Sidecar 6 1 Sidecar removal mount 0 3 6 2 Sidecar wheel removal mount 0 1 6 3 Sidecar body removal mount 0 3 6 4 Sidecar fender removal mount 0 4 6 5 Shock absorber removal mount 0 2 6 6 Swing arm removal mount 0 2 6 7 Ru...

Page 70: ...0 Electrical 8 1 Wiring diagnosis for short circuit 0 6 8 2 Battery removal mount 0 4 8 3 Wire harness removal mount motorcycle 1 2 8 4 Wire harness removal mount sidecar 0 6 8 5 Alternator removal mount 0 2 8 6 Ignition system removal mount 0 3 8 7 Ignition coil removal mount 0 2 8 8 Horn removal mount 0 1 8 9 Ignition lock removal mount 0 3 8 10 Main switch RH or LH removal mount 0 1 8 11 Any li...

Page 71: ...motorcycle serviced regularly at the mileage indicated on the Service Coupons An owner who is qualified and capable of doing his or her own service work is allowed to do so without voiding the manufacturer s warranty PROVIDED that you sign the Service Coupon and date it after the work has been performed WARNING FOR YOUR PERSONAL WELFARE ALL THE LISTED SERVICE AND MAINTENANCE RECOMMENDA TIONS IN TH...

Page 72: ...olumn bearings 9 Check alternator bolts 10 Check brake fluid reservoir The maintenance above has been performed as described Owner s Signature Service Technician s Signature SERVICE COUPON NO 2 2 500 KM To be performed between 2 400 to 2 600 km Date Odometer reading km 1 Change engine oil and filter See Lubrication List chapter 11 2 Check final drive oil level 3 Inspect air filter element 4 Check ...

Page 73: ...B Hinges of the foot brake pedal shaft and linkage 9 Check condition and action of brakes 10 Check tires for tread depth greater than 3 32 11 Check fasteners for proper tightening 12 Check brake fluid reservoir The maintenance above has been performed as described Owner s Signature Service Technician s Signature SERVICE COUPON NO 4 7 500 KM To be performed between 7 400 to 7 600 km Date Odometer r...

Page 74: ...idling for synchronous operation B Check steering column bearings adjust if required C The condition and action of the brakes lubricate the brake shoe fulcrum pins and cams D The tension of wheel spokes Adjust if necessary E Electric wiring Tighten connections if required F Fasteners for proper tightening 11 Re pack the grease in wheel bearings adjust the bearings 12 Lubricate A Foot brake pedal s...

Page 75: ...etween 14 900 to 15 100 km Date Odometer reading km 1 Change engine oil and filter See lubrication chapter 11 2 Change transmission oil See lubrication chapter 11 3 Inspect air filter element 4 Check carburetors while idling for synchronous operation 5 Check adjustment of steering column bearings 6 Lubricate A Lever pins B Hinges of the foot brake pedal shaft and linkage 7 Check condition and acti...

Page 76: ... and blow out 4 Check carburetors while idling for synchronous operation 5 Check final drive gear oil level See Lubrication List chapter 11 6 Lubricate foot brake pedal shaft 7 Check fasteners for proper tightening 8 Adjust steering column bearings 9 Check battery electrolyte level and fluid level 10 Check air gap in electronic ignition between pickup and rotor 0 010 in The maintenance above has b...

Page 77: ...0 Check A Carburetors while idling for synchronous operation B Check steering column bearings adjust if required C The condition and action of the brakes D The tension of wheel spokes Adjust if necessary E Electric wiring Tighten connections if required F Fasteners for proper tightening 11 Repack the grease in wheel bearings adjust the bearings 12 Lubricate A Foot brake pedal shaft B Hinges of foo...

Page 78: ...med between 24 900 to 25 100 km Date Odometer reading km 1 Change engine oil and filter See Lubrication List chapter 11 2 Change transmission oil See Lubrication List chapter 11 3 Inspect air filter element 4 Check carburetors while idling for synchronous operation 5 Check A Adjustment of steering column bearings B Tension of wheel spokes 6 Lubricate A Lever pins B Foot brake pedal shaft C Hinges ...

Page 79: ...engine oil See Lubrication List chapter 11 2 Check final drive oil level 3 Inspect air filter element 4 Check fasteners for proper tightening 5 Check steering column bearings 6 Check adjustment of wheel bearings The maintenance above has been performed as described Owner s Signature Service Technician s Signature ...

Page 80: ...hile idling for synchronous operation B Check steering column bearings adjust if required C The condition and action of the brakes lubricate the brake shoe fulcrum pins and cams D The tension of wheel spokes Adjust if necessary E Electric wiring Tighten connections if required F Fasteners for proper tightening 11 Repack the grease in wheel bearings adjust the bearings 12 Lubricate A Foot brake ped...

Page 81: ...UMBER OWNER SNAME_____________________________________________ OLDADDRESS ______________________________APT NO _______ CITY________________ STATE ____________ ZIP CODE _________ MY NEWADDRESS IS NEWADDRESS ____________________________APT NO ________ CITY_______________ STATE _____________ ZIPCODE _________ Send this form to Irbit Motorworks of America 15411 NE 95th ST Redmond WA 98052 or fax to 42...

Page 82: ...ER NEWOWNER SNAME_____________________________________________ ADDRESS ______________________________APT NO _______ CITY ________________ STATE ____________ ZIP CODE _________ DATE OF SALE ________________ MO DAY YEAR PurchasedFrom___________________________________________________ City _____________________State ____________ Zip Code _______________ Send this form to Irbit Motorworks of America 1...

Page 83: ...hod the problem s may be one or more of the following 1 Engine is flooded i e the spark plugs have been fouled by too much throttle and fuel and will not spark Correction Flooding is corrected by removing the spark plugs and drying them 2 Too little fuel is getting to the engine due to low fuel in tank and or plugged fuel lines or fuel petcock Correction Clogged fuel lines or filter are corrected ...

Page 84: ...d proper alignment 5 Check the tire tread depth should be greater than 1 8 inch 6 Check the sidecar attachment mounts all mounts should be securely tightened Gasoline level in the fully filled tank 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 th...

Page 85: ...ning to Ride The Ural With SidecarAccessory Available through the Whitehorse Press www whitehorsepress com Available through Mike Weaver threeweavers earthlink net www molotovmotors com Weav s Useful Information and Technical Guide toAntique Russian Motorcycles and Sidecars ...

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