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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 

 

 

 

 

 

 

Содержание 2015 cT

Страница 1: ......

Страница 2: ...motorcycle and to provide you with important safety information Follow these instructions 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 instru...

Страница 3: ...D MAINTAIN YOUR MOTORCYCLE PLEASE PAY SPECIAL ATTENTION TO NOTICES IN THIS MANUAL MARKED AS FOLLOWS CAUTION INDICATES POSSIBILITY OF EQUIPMENT FAILURE THAT MAY RESULT IN YOUR MOTORCYLE 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 ...

Страница 4: ... 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 ...

Страница 5: ...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 ...

Страница 6: ...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...

Страница 7: ... 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 ...

Страница 8: ...x 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 5X19 Aluminum rims with steel spokes 2 5X19 Aluminum rims with steel spokes Tires Duro HF 308 4 0x18 Duro HF 308 4 0x19 Front brake 4 piston fixed Brembo caliper with 295mm floating NG rotor 4 piston...

Страница 9: ...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...

Страница 10: ...to 12 3 to 475 Toe In 2wd 3 to 8 125 to 315 Lean Out 1 to 2 degrees 1 to 2 degrees TIRE DATA Location Type Recommended PSI Front Duro H 308 4 0x19 or 4 0x18 cT 32 PSI Cold Rear Duro H 308 4 0x19 or 4 0x18 cT 40 PSI Cold Sidecar Duro H 308 4 0x19 or 4 0x18 cT 32 PSI Cold Spare if equipped Duro H 308 4 0x19 or 4 0x18 cT 40 PSI Cold Optional Knobby Tires Duro H 308 4 0x19 or 4 0x18 cT Per location on...

Страница 11: ...s wheel balancing I I 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 2...

Страница 12: ... 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...

Страница 13: ...age Hand Controls 2 2 Foot Controls 2 3 Ignition Switch 2 4 Speedometer 2 4 Indicator Lamps 2 5 Hydraulic Steering Damper 2 5 Parking Brake 2 6 Reverse Lever 2 6 Kick Starter 2 7 2wd Engagement Lever 2 7 Hydraulic Spring Shock Absorbers 2 8 ...

Страница 14: ...eft hand on the 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 CAUTION DO NOT RUN STARTER FOR MORE THAN 5 SECONDS WARNING WHEN USING THE STARTER ALWAYS BE SURE THE GEARBOX IS IN NEUTRAL Engine ST...

Страница 15: ...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 ...

Страница 16: ...s Trip Meter The trip meter displays the total trip Kilometers and can be reset by twisting the reset knob on the right hand fork cover 3 Position Switch In the Off position the engine cannot be started In the On position the engine can be started and all electrical functions can be used In the Park position only the running lamps not including headlight are illuminated ...

Страница 17: ...will illuminate if the alternator fails High Beam Indicator Lamp will illuminate when high beam is on Turn Signal Indicator Lamp flashes when signals are active Engine MIL Indicator If lamp illuminates while engine is running refer to Troubleshooting section of this manual Adjustable Damper 16 Position The steering damper is fully adjustable to accommodate different riding styles and conditions Ro...

Страница 18: ...position as shown 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...

Страница 19: ...d 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 ...

Страница 20: ...NG SHOCK ABSORBERS Adjustable Shock Absorbers The shock absorbers have 5 preload adjustments Rotate the adjustment ring counter clockwise as shown to increase spring preload using the supplied wrench in your tool kit ...

Страница 21: ...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 ...

Страница 22: ... 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...

Страница 23: ...B 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 IMWA 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 o...

Страница 24: ...air 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 is em...

Страница 25: ...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...

Страница 26: ...he following guidelines during the first 1000 kilometers prior to the initial break in service 1 Do not overload or lug the engine 2 Do not exceed a top speed beyond 60mph 3 Do not ride at a constant rpm for long periods of time 4 Try to vary speed and load when riding 5 Shift smoothly between gears and do not down shift at high rpm 6 Always be sure the engine is warmed up before riding 7 Follow t...

Страница 27: ...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 ...

Страница 28: ... DOT 4 Drive Shaft Joints N A General Purpose Lithium Grease Drive Shaft Spines N A Moly EP Grease Clutch Shaft Splines N A Moly EP Grease Drive Wheel Splines Spline Flanges N A Moly EP Grease Wheel Axles N A General Purpose Lithium Grease Brake Linkage and Pivots N A General Purpose Lithium Grease Cables N A WD 40 ENGINE OIL VISCOSITY GRADES 20w 50 5w 40 Cold Weather F 0 10 20 32 60 80 100 F C 18...

Страница 29: ...LUBRICATION DIAGRAM ...

Страница 30: ...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...

Страница 31: ...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 ...

Страница 32: ... 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 ...

Страница 33: ...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 ...

Страница 34: ...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 ...

Страница 35: ...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 ...

Страница 36: ...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 ...

Страница 37: ...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 ...

Страница 38: ... 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 FIL...

Страница 39: ...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...

Страница 40: ...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 ...

Страница 41: ...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 center 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 ...

Страница 42: ... 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...

Страница 43: ... 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 ...

Страница 44: ...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...

Страница 45: ...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 ...

Страница 46: ...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 ...

Страница 47: ...ted to the parking brake handle and be sure the parking brake is in the off position Step 2 Adjust the cable to remove excess free play Step 3 With the parking brake set you will have approximately 12mm between the caliper stop bracket and the brake arm with spring ...

Страница 48: ...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 ...

Страница 49: ...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...

Страница 50: ...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 ...

Страница 51: ...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 ...

Страница 52: ...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 ...

Страница 53: ...REAR WHEEL REMOVAL INSTALLATION Step 1 Place the motorcycle on the center stand Step 2 Carefully remove the caliper retaining bolt safety clips Step 3 Remove the caliper retaining bolts and brake pads ...

Страница 54: ...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 ...

Страница 55: ...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 ...

Страница 56: ...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 ...

Страница 57: ...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 ...

Страница 58: ...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...

Страница 59: ...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...

Страница 60: ...tool kit carefully remove one side of the tire from the rim Step 3 Remove the tube from the tire Step 4 Remove the tire from the rim Step 5 Re install the tire in reverse order be careful not to pinch the tube during installation NOTE WHEN INFLATING THE TIRE BE SURE THE TIRE BEAD IS FULLY SEATED AND EVEN AROUND THE RIM ...

Страница 61: ...e loosen the bolt clamping the lower rear bracket and adjust the position of the bracket relative to the rear tube of the side car frame to obtain necessary toe in of the wheels Tighten up the bolt fastening the bracket adjust the length of the strut legs and secure them with bolts Check the lean out of the motorcycle using a level gauge or protractor with a plumb bob and a ruler standard lean out...

Страница 62: ...SIDECAR ALIGNMENT DIAGRAM ...

Страница 63: ...6 Electrical Page Lamp Bulb Replacement 6 2 Battery Maintenance Replacement 6 6 Fuse Locations 6 9 Relay Locations 6 10 Starter 6 11 Alternator 6 11 ECU Data Port 6 11 ...

Страница 64: ...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 ...

Страница 65: ...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 ...

Страница 66: ... 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 ...

Страница 67: ...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 ...

Страница 68: ... 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...

Страница 69: ...ve 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 BATERY TERMINALS COULD RESULT IN A FIRE ...

Страница 70: ... 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 ...

Страница 71: ...he steering neck This diagram shows the position and function for each fuse Fuse Box 2 if equipped The sidecar on all models except T has a separate fuse box This fuse box is located inside the sidecar nose on the right upper corner This diagram shows the position and function of each fuse ...

Страница 72: ...is located behind the headlight bucket To access this relay you must first remove the headlight bucket assembly EFI and Starter Relays To access the EFI and starter relays you must first remove the seat The relays are mounted to the frame base plate as shown ...

Страница 73: ...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...

Страница 74: ...7 EFI Troubleshooting Page Engine Management MIL Blink Codes 7 2 Service Notes 7 4 ...

Страница 75: ...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...

Страница 76: ...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 ...

Страница 77: ...SERVICE NOTES ...

Страница 78: ...8 Warranty Information Page Warranty Agreement 8 2 Warranty Disclaimers 8 3 California Emissions Statement 8 5 Limited Emissions Warranty 8 6 Reporting Safety Defects 8 8 ...

Страница 79: ...d to be defective in material or workmanship under normal use for the applicable time period In cases when warranty repair takes longer than 14 days the warranty time period see Warranty Time Period is extended for the time period of repair during which the motorcycle could not been ridden due to failures IMWA Inc provides warranty for spare parts for the following period of time starting from the...

Страница 80: ...ng 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 installa...

Страница 81: ...n 3 business days of the sale of Motorcycle Accept all eligible motorcycles for warranty service regardless of selling Dealer Keep records of all warranty work Attend service schools as provided by IMWA Inc Submit warranty claims to IMWA Inc IN WRITING within 10 business days of the repair date Obtain authorizations for warranty repairs from IMWA Inc when estimated cost will exceed 100 00 see Adva...

Страница 82: ... or 30 000 kilometers 18 641 miles whichever first occurs If an emission related part on your motorcycle is defective the part will be repaired or replaced by IMWA This is your emission control system DEFECTS WARRANTY OWNER S WARRANTY RESPONSIBILITIES As the owner of Ural motorcycle you are responsible for the performance of the required maintenance listed in your owner s manual IMWA recommends th...

Страница 83: ...e specifically defined by the state s Emission Warranty Parts List These warranted parts are injectors electronic valves air box air cleaner element spark plug ignition coil ignition control valve module catalyst carbon absorber In the State of California only Emission Control System emergency repairs as provided for in the California Administrative Code may be performed by other than an authorize...

Страница 84: ...YSTEM WARRANTY IMPLIED BY LAW INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE IS LIMITED TO THE EXPRESS EMISSION CONTROL SYSTEM WARRANTY TERMS STATED IN THIS WARRANTY THE FOREGOING STATEMENT OF WARRANTY ARE EXCLUSIVE AND IN LIEU OF ALL OTHER REMEDIES SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YO...

Страница 85: ...ar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in any individual problems between you your dealer or Irbit Motorworks of America Inc To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 366 0123 in Washington DC area Or wr...

Страница 86: ...9 Emission Control Information Page Crankcase Emission Diagram 9 2 California Emission Control Diagram 9 3 Vehicle Emission Control Label 9 4 ...

Страница 87: ...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 ...

Страница 88: ...being discharged directly into the ambient atmosphere throughout the useful life Evaporative emission are routed from the fuel tank through a carbon canister to the air box and controlled by an electrical valve The evaporative emissions are 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...

Страница 89: ...ment 749cc EIMFC 750A02 EIMFPMETALU1 Please Read Owner s Manual for Details Idle Speed 800 RPM at normal temp Max RPM 5 600 Ignition Timing Factory Preset Idle Mixture factory preset Plug type NGK BPR6HS Lubricant SAE 20W50 Plug Gap 0 040 1 0 1 02mm Fuel 91 Octane min Valve Clearance cold 0 05 0 10 mm 002 004in exhaust and intake Exhaust Emission Control System 3TWC This vehicle conforms to all US...

Страница 90: ...10 Owner s Documents Page New Owner Form 10 2 New Address Form 10 3 ...

Страница 91: ..._____________________________________APT NO _______________ CITY _________________________________ STATE _________ ZIP CODE ____________ __________ PHONE NUMBER _______ ______________________ E MAIL optional ____________________________________________________________________ DATE OF SALE ______ _____ ________ MO DAY YEAR ODOMETER READING AT THE TIME OF TRANSFER ___________________ Purchased From ...

Страница 92: ...ADDRESS__________________________________________________________APT NO __________ CITY___________________________STATE___________________________ZIP CODE________________ MY NEW ADDRESS IS NEW ADDRESS_________________________________________________________APT NO __________ CITY___________________________STATE___________________________ZIP CODE________________ Mail this form to Irbit Motorworks of...

Страница 93: ...11 Schematics Page Wiring Diagram 11 2 ...

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