Related Manuals for URAL Motorcycles Ural Retro Solo 2004
Summary of Contents for URAL Motorcycles Ural Retro Solo 2004
- Page 1 URAL Motorcycles Owner’s Manual 2004 Model Retro Solo Irbit Motorworks of America Inc. 15411 NE 95th St Redmond WA 98052 www.imz-ural.com...
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Page 3: Table Of Contents
Contents Introduction ................................5 Warnings, Cautions, Notes ............................5 Chapter 1 Specifications Specifications ................................7 Torque Specifications ............................. 10 Conversions ................................10 Chapter 2 Motorcycle Controls & Instrumentation Motorcycle Controls & Instrumentation ........................11 Controls ................................12 Control Cable Adjustment ............................16 Control Cable Maintenance ........................... - Page 4 Chapter 7 Running Gear Running Gear ................................. 33 Spring-Loaded Hydrraulic Shock Absorber ......................33 Front Fork ................................34 Steering Head Bearings ............................34 Chapter 8 Wheel & Tires Wheels and Tires ..............................35 Tire Data ................................36 Wheel and Tire Maintenance ..........................37 Chapter 9 Brakes Brakes ..................................
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Page 5: Introduction
Welcome to the URAL Motorcycling Family! Your Ural has been built by the Irbit Motorcycle Factory in Russia and distributed by Irbit Motorworks of America, the United States affiliate of the Irbit Motorcycle Factory. The Ural motorcycle conforms to all applicable US Federal Motor Vehicle Safety Standards and US Environmental Protection Agency regulations effective on the date of manufacture. -
Page 7: Specifications
Chapter 1 SPECIFICATIONS GENERAL Retro Maximum speed of motorcycle 120 km/h 74 mph Reference fuel consumption at 85% of 14 km/L 33 mpg Dry mass of motorcycle 680 lb. Maximum load-carrying capacity 400 lb. Noise level below 80db OVERALL DIMENSIONS Length 2500 mm / 8 ft Width... - Page 8 ELECTRICAL Ignition system 135.3734.COM-2 (CDI) Ignition coil 135.3705-2 Spark plugs NGK BP7H Ignition timing Automatic spark timer Alternator 35 amp / 12 Volt Battery Interstate #YB18L-A or equivalent Headlight Sylvania Halogen 6024, 7" round sealed beam TRANSMISSION Clutch Dry double-disk clutch Gearbox 4 speed gearbox with reverse gear lever GEAR RATIOS...
- Page 9 CLEARANCES 0.006 to 0.004 Valves with engine cold 0.15 to 0.1 Between spark plug electrodes 1.016 0.040 Backlash between tooth faces of bevel gears in final drive 0.1 - 0.3 0.001 FREE TRAVEL / ADJUSTMENTS Hand brake control lever 5 - 8 0.2 - 0.3 Clutch control lever 5 - 8...
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Page 10: Torque Specifications
TORQUE SPECIFICATIONS Metric US Equivalent Location on Bike 54 to 61 Nm 40 ft/lb to 45 ft/lb cylinder heads 237 to 251 Nm 175 ft/lb to 185 ft/lb fly wheel tightening screws 19 to 30 Nm top 14 ft/lb to 22 ft/lb shock absorber 38 to 49 Nm bottom 28 ft/lb to 36 ft/lb... -
Page 11: Motorcycle Controls & Instrumentation
Chapter 2 MOTORCYCLE CONTROLS & INSTRUMENTATION Controls and Instrumentation 1 - Speedometer 12 - Gear shift (foot) pedal 2 - Turn indicator lamp 13 - Turn signal switch 3 - Trip odometer reset knob 14 - Horn push-button 4 - Neutral and reverse gear engagement 15 - “High-low”... - Page 12 Clutch Control Lever Clutch Control Lever Front Brake Control Lever Clutch control lever When the clutch lever is squeezed, the engine is disengaged from the gearbox. When the lever is released, the engine and gearbox are connected. WARNING: M AKE SURE FINGERS ARE NOT POSITIONED BETWEEN HAND CONTROL LEVERS AND HANDLEBAR GRIPS OR OPERATION OF VEHICLE COULD BE IMPAIRED WARNING: B EFORE STARTING ENGINE...
- Page 13 Kick starter is designed to start the engine. On pressing the lever, the crankshaft of the engine is rotated via the gearbox. The lever is returned to its initial position by a spring inside the gearbox. Gear shift lever Kick Starter Reverse Gear Selector Gear shift Lever.
- Page 14 CAUSE POSSIBLE LOSS OF CONTROL OF THE MOTORCYCLE LWAYS USE BOTH BRAKES EVER STOP WITH FRONT OR REAR BRAKE ONLY Ignition Switch has three fixed positions of the key. The positions of the ignition are shown above. All electrical systems are off. Voltage is supplied to all electrical systems.
- Page 15 Engine Cutoff Switch Electric Start Switch Headlight Hi / Low Beam Switch Turn Signal Switch Horn Switch...
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Page 16: Control Cable Adjustment
CONTROL CABLE ADJUSTMENT The control cables are adjusted by screw adjustments at the cable ends. With the control levers released: • for the clutch a play at the clutch lever end should be equal to 5 - 8 mm/0.2 - 0.3 in. •... -
Page 17: Chapter 3 Engine Operation
Chapter 3 ENGINE OPERATION PRE-TRIP PRELIMINARIES Pre-Trip Check List 1. Check all lights and the horn for proper operation. 2. Check the brake and clutch levers and/or pedals. 3. Make sure all wheels and the final drive assemblies are securely fastened . 4. - Page 18 Prime Position Reserve Fuel Fuel On Position Position 1. When starting the engine after the motorcycle has been parked for an extended period of time, or after the fuel tank and/or carburetors have been completely emptied of gasoline (e.g. due running out of fuel, evaporation, or installation of replacement parts), set the valve to the “PRI”...
- Page 19 Enrichener off Enrichener on Manual Starting (without electric starter) 1. Turn on the ignition and depress the kick lever 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 with your right hand on the throttle.
- Page 20 3. When the engine is cool or cold and the ambient temperature is between40°F-60°F/5°C- 15°C, engage both enricheners to start. As soon as the engine starts, immediately retract the enricheners. Run the engine at moderate speed for 30-60 seconds. If it starts to die, blip the twist grip throttle (rapidly twist part way towards full throttle and then back off) to keep the engine running.
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Page 21: Operating Precautions
OPERATING PRECAUTIONS WARNING: M ’ AKE SURE THAT SIDECAR WINDSHIELD IS IN THE FULL BACK POSITION SO IT DOESN INTERFERE WITH THE RIGHT HANDLEBAR To move the motorcycle from rest, shift to 1 gear only. Avoid releasing the clutch suddenly, because the engine is liable to stall or the motorcycle will start with a jerk. -
Page 23: Chapter 4 Engine Design
Chapter 4 ENGINE DESIGN The motorcycle is equipped with a two-cylinder four-stroke air-cooled engine. The opposed ar- rangement of cylinders in the horizontal plane is the outstanding feature of the motorcycle design which ensures proper cooling and balancing of the crank gear. The engine valves are located in the cylinder heads. -
Page 24: Lubrication System
LUBRICATION SYSTEM The motorcycle engine features a dual lubrication system, some parts are force-lubricated by pressure built up by the oil pump, while others by splashing . A full-flow paper oil filter is provided in the lubrication system to prolong the engine life. Maintenance of lubrication system. -
Page 25: Fuel System
FUEL SYSTEM The fuel system includes the gasoline tank, the three position fuel valve with filter and two carburetors. Petcock Location Petcock Fuel valve (petcock). The top threaded portion of the valve is screwed into the gasoline tank. The petcock is of an automatic shutoff design. Vacuum from the engine opens the valve when the engine is running. -
Page 26: Ignition System
IGNITION SYSTEM The ignition system incorporates the power supplies, ignition coil, Hall Effect pickup, electronic module, two spark plugs, a set of low and high voltage wires and the ignition switch. The ignition system will provide the spark to the spark plugs from 200 to 6000 RPM. With the engine at rest, the ignition system will draw 100 mA. - Page 27 3 / 8“ Ignition Module & Coil...
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Page 29: Chapter 5 Carburetors
Chapter 5 CARBURETORS 32mm CVK Keihin Seike carburetors are used on of the Ural motorcycle. They are preset with fixed mixture jetting and adjust automatically for altitude variations. This is due to the vacuum acti- vation mechanism of these constant velocity type carburetors. Be sure to check the condition of all carburetor adapters and air pipes every time before riding. -
Page 30: Carburetor Maintenance
CARBURETOR MAINTENANCE The carburetors will require the sediment in the float bowls be drained periodically. This will ensure that any contaminants that have accumulated in the float bowls do not enter the main or idle jets of the carburetors. The fuel can be drained by opening the drains provided on the bottom of the float bowls. -
Page 31: Power Transmission
Chapter 6 POWER TRANSMISSION The power transmission of the motorcycle is comprised of the clutch, gearbox, drive shaft and the final drive. CLUTCH The clutch transmits torque from the engine to the gearbox. Disengage the engine from the gear- box 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. - Page 32 Castrol oil and then refill the final drive with the specified lubricant. Reinsert the upper fill plug and wipe off any excess or spilled oil from the final drive. Filler Plug Universal Joint Splines Drain Plug Final Drive Assy Rear Universal Joint...
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Page 33: Chapter 7 Running Gear
Chapter 7 RUNNING GEAR SPRING LOADED HYDRAULIC SHOCK ABSORBER The suspension features cam-type adjusters used for varying the pretension of the supporting springs to suit the load and the road condition. The degree of tension of the springs is adjustable allowing two positions. -
Page 34: Front Fork
FRONT FORK The front fork used on the wolf model uses a telescopic design. To maintain the fork, change the fluid when it is called for in the service coupons and keep the forks free from dust and dirt. Consult your dealer for details on changing the front fork fluid. -
Page 35: Wheels And Tires
Chapter 8 WHEELS AND TIRES The Ural motorcycle is equipped with wheels that are easy to remove. Removing wheels. To remove the front wheel, set the motorcycle onto the center stand, lift it by the front wheel and put a rest under the front portion of the motorcycle frame. Slacken the nut of the union bolt at the end-piece base of the fork left-hand leg. -
Page 36: Tire Data
Front Rear tire pressure tire pressure or 150 kPa or 250 kPa WARNING: R IDING WITH EXCESSIVELY WORN UNBALANCED OR IMPROPERLY INFLATED TIRES IS HAZARDOUS AND WILL ADVERSELY AFFECT TRACTION STEERING AND HANDLING AME AS ORIGINAL EQUIPMENT TIRES MUST BE USED THER TIRES MAY NOT FIT CORRECTLY AND MAY BE HAZARDOUS TO USE ECAUSE TIRES TUBES AND WHEELS ARE CRITICAL SAFETY ITEMS AND SERVICING OF THESE ITEMS REQUIRES... -
Page 37: Wheel And Tire Maintenance
WHEEL AND TIRE MAINTENANCE During the pre-trip inspection, check air pressure in the tires. Check axle and spokes for safe fastening, be sure to tighten the spokes or fasteners and eliminate play as soon as they get loose or demonstrate excessive play. While lubricating, consult the Lubrication Chart. -
Page 39: Chapter 9 Brakes
Chapter 9 BRAKES The motorcycle is equipped with a hydraulic disc brake in front and hydraulic drum on the rear. The hydraulic disc brake consists of a caliper, brake pads and a wheel disc. The front brake is a hydraulic disc brake. Front Brake Reservoir The front brake hydraulic reservoir is located on the right handlebar. - Page 40 Differential Dipstick Brake Line The rear wheel brake is mounted in the rear hub, and is actuated via a hydraulic master cylinder linked to the brake pedal. Rear Brake Hydraulic Reservoir...
- Page 41 Brakes should be “burnished in” during the initial running in period. 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 area with clean, dry pavement and no obstructions.
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Page 43: Electrical Equipment
Chapter 10 ELECTRICAL EQUIPMENT The electrical equipment of the motorcycle includes power supplies, auxiliary instruments and electric wiring. Electric power supplies are a battery and an alternator with a built-in rectifier. A single wire system is used for wiring the electric circuits, i.e. a single wire carries power to the electrical devices and the frame and engine serve as the second wire (called the “ground”). -
Page 44: Electrical Equipment Maintenance
are allowed to flow from the battery without restriction, then the wires carrying the electricity will become hot enough to melt. The melting wires are extremely dangerous and can easily burn you. Most problems in automotive electrical circuits are caused by poor connections. Make sure that all connection points are clean and tight. - Page 45 Fuse box (Inside of headlight bucket) The headlight relays are located under the fuel tank...
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Page 46: Electrical Wiring Diagram
Wiring Diagram... -
Page 47: Maintenance Of Motorcycle
Chapter 11 MAINTENANCE OF MOTORCYCLE Maintenance should be performed after the specified total kilometers run irrespective of the techni- cal condition of the motorcycle. Different service duties and technical condition of the motorcycle may necessitate a change in the intervals. The Lubrication Chart indicating lubrication points of the motorcycle is given in Fig. -
Page 48: Lubrication Chart
LUBRICATION CHART PART TO BE LUBRICATED LUBRICANT Engine crankcase 20W/50 Detergent Oil Transmission 20W/50 Detergent Oil Air cleaner JR Filter Oil Telescopic forks 5wt-10wt Fork Oil Final Drive 80/90 Gear oil Brake pedal shaft Grease Drive shaft universal joint Grease Lever pins &... -
Page 49: Preservation And Storage
After patching, let the surface dry in air for 15 minutes. 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 mind that enamels are flammable. Color match may not be perfect due to humidity, fading, temperature and other variables. -
Page 50: Battery
BATTERY Storage batteries on the motorcycle should function at ambient air temperature from -40°C to plus 60°C/ 40°F to 140°F. As the battery is in service: • regularly check the voltage for 12.8 - 13.2 V • do not allow the battery to discharge. •... -
Page 51: List Of Individual Tool Set, Spare Parts, Accessories & Documents
LIST OF INDIVIDUAL TOOL SET, SPARE PARTS, ACCESSORIES & DOCUMENTS DESCRIPTION DESCRIPTION Tools Accessories 1. Wrench 7 x 8 1. Air Pump 2. Wrench 10 x 12 2. Air Pressure Gauge 3. Wrench 13 x 14 3. Ignition keys 4. Wrench 14 x 17 5. -
Page 53: Safe Operating Rules
Chapter 12 SAFE OPERATING RULES Before operating your Ural it is your responsibility to read and follow operating and maintenance instructions in this manual and follow these basic rules for your personal safety. • Know and respect the Rules of the Road in your state. •... - Page 54 • Do not allow others, under any circumstances to operate your motorcycle unless you are certain that they are experienced, licensed riders and are familiar with the operation of your particular motorcycle. • When leaving the motorcycle unattended, remove ignition key from switch. Protect your motorcycle against theft.
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Page 55: Chapter 13 Warranty
Chapter 13 WARRANTY AGREEMENT Irbit MotorWorks of America, Inc., (IMWA, Inc.) warrants to the first retail purchaser of the URAL® motorcycle from an Authorized IMWA Dealer and each subsequent owner that the motorcycle is free from defects in materials and workmanship for the period stated below. - Page 56 30 days of completion of training. Failure to adhere to this requirement will void the warranty. Warranty Disclaimers Limitations & Exclusions Disclaimer of Consequential Damage & Limitation of Implied Warranties Irbit MotorWorks of America, Inc. disclaims any responsibility for: • Loss of time due to warrantable issue •...
- Page 57 These Warranties Do Not Cover: 1. Failures or required services that are 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 •...
- Page 58 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.
- Page 59 After IMWA, Inc. inspection of engine or gearbox or final drive: 1. If engine/gearbox/final drive is found to be defective due to factory parts or assembly failure, the appropriate warranty order will be processed and the flat rate for removal and re-installation of the engine/gearbox/final drive will be authorized Failed engines/gearboxes/final drives will be warranted utilizing the following options at IMWA’s discretion...
- Page 60 This warranty applies to factory installed noise systems on URAL motorcycles manufactured on or after May 20, 2003. Irbit Motorworks of America warrants to the first retail purchaser and each subsequent purchaser that the motorcycle • was designed, built and equipped to conform at the time of first retail purchase, with all US EPA noise emission standards.
- Page 61 This warranty is given in addition to the Distributor’s Limited Warranty and is the only express emission control system warranty applicable to Ural motorcycles. Irbit Motorworks of America warrants to the first retail purchaser and each subsequent purchaser that • the motorcycle is designed, built and equipped to conform, at the time of sale, with all US EPA emission standards applicable at the time of manufacture.
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Page 62: Reporting Safety Defects
For this reason it is very important for you to notify Irbit Motorworks of America of any change of address or ownership. There is a form in the back of this manual. -
Page 63: Warranty Claim Form
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 /___/___/___/... -
Page 64: Flat Rate Schedule
Appendix B Flat Rate Schedule For warranty repair work on Ural motorcycles Code Unit or part Job description Allowed Time (in Hrs) for IMWA Authorized Dealers Engine Engine removal/mount with gear box Engine disassembly Engine assembly Engine running-in Cylinder head removal/mount Cylinder removal/mount Piston rings removal/mount (1 piston) Piston removal/mount... - Page 65 Code Unit or part Job description Allowed Time (in Hrs) for IMWA Authorized Dealers Final drive seal (7205039) replacement Drive shaft removal/mount (final drive removed) Front Fork Front fork removal/mount Front fork assy disassembly (total) Front fork assembly (total) Front fork bearings adjustment Wheel &...
- Page 66 Code Unit or part Job description Allowed Time (in Hrs) for IMWA Authorized Dealers Sidecar wind shield assy removal/mount Shock absorber removal/mount Swing arm removal/ mount Seat removal/mount Electrical Wiring diagnosis for short circuit Battery removal/mount Wire harness removal/mount (motorcycle) Wire harness removal/mount (sidecar) Alternator removal/mount Ignition system removal/mount...
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Page 67: Chapter 14 Service Coupons
Dependable performance may be anticipated if your motorcycle is entrusted for maintenance to an Authorized IMWA URAL Dealer. A current list of Authorized IMWA URAL dealers may be obtained from our web site www.imz-ural.com or by sending a self-addressed stamped envelope to: Irbit Motorworks of America 15411 NE 95th ST. Redmond, WA 98052 Authorized IMWA URAL Dealers carry spare parts, have special tools for disassembling the motor- cycle and employ experienced specialists to service and repair this motorcycle. - Page 68 SERVICE COUPON NO 1. 500 KM (To be performed between 400 to 600 km) Date_______________ Odometer reading____________ Change engine oil and filter. Change transmission oil. Change final drive oil. Check condition of the gasoline petcock, remove any contaminants, replace in-line fuel filters. Check carburetors while idling for synchronous operation.
- Page 69 SERVICE COUPON NO. 3. 5,000 KM (To be performed between 4,900 to 5,100 km) Date Odometer reading Change engine oil and filter. (See Lubrication List, chapter 11) Check transmission oil level. Check final drive oil level. Inspect air filter element. Check condition of the gasoline petcock, remove any contaminants, replace in-line fuel filters Check carburetors while idling for synchronous operation.
- Page 70 SERVICE COUPON NO. 5. 10,000 KM (To be performed between 9,900 to 10,100 km) Date Odometer reading Change engine oil and filter. (See Lubrication List, chapter 11) Change transmission oil. (See Lubrication List, chapter 11) Change final drive oil. (See Lubrication List, chapter 11) Inspect air filter element.
- Page 71 SERVICE COUPON NO. 6. 12,500 KM (To be performed between 12,400 to 12,600 km Date Odometer reading Change engine oil. (See Lubrication List, chapter 11) Check final drive oil level. Inspect air filter element. Check fasteners for proper tightening. Check adjustment of wheel bearings. The maintenance above has been performed as described.
- Page 72 SERVICE COUPON NO. 8. 17,500 KM (To be carried out within 17,400 to 17,600 km Date Odometer reading Clean the air filter, . Change oil in the engine and transmission. (See Lubrication List, chapter 11) Check condition of the gasoline petcock, remove any contaminants, clean and blow out. Check carburetors while idling for synchronous operation.
- Page 73 SERVICE COUPON NO. 9. 20,000 KM (To be performed between 19,900 to 20,100 km) Date Odometer reading Change engine oil and filter. (See Lubrication List, chapter 11) Change transmission oil. (See Lubrication List, chapter 11) Change final drive oil. (See Lubrication List, chapter 11) Inspect air filter element.
- Page 74 SERVICE COUPON NO. 10. 22,500 KM (To be performed between 22,400 to 22,600 km Date Odometer reading Change engine oil. (See Lubrication List, chapter 11) Check final drive oil level. Inspect air filter element. Check fasteners for proper tightening. Check steering column bearings. Check adjustment of wheel bearings.
- Page 75 SERVICE COUPON NO 12. 27,500 KM (To be performed between 27,400 to 27,600 km) Date Odometer reading Change engine oil. (See Lubrication List, chapter 11) Check final drive oil level. Inspect air filter element. Check fasteners for proper tightening. Check steering column bearings. Check adjustment of wheel bearings.
- Page 76 SERVICE COUPON NO. 13. 30,000 KM (To be performed between 29,900 to 30,100 km) Date Odometer reading Change engine oil and filter. (See Lubrication List, chapter 11) Change transmission oil. (See Lubrication List, chapter 11) Change final drive oil. (See Lubrication List, chapter 11) Inspect air filter element.
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Page 77: New Address Form
NEW ADDRESS FORM If you move, please fill out this form and mail to the address below. This will insure that you con- tinue to receive all correspondence from Irbit Motorworks of America. VEHICLE IDENTIFICATION NUMBER OWNER’S NAME _____________________________________________ OLD ADDRESS ______________________________ APT. NO. _______... -
Page 78: New Owner Form
DATE OF SALE ________________ MO / DAY / YEAR Purchased From ___________________________________________________ City _____________________State ____________ Zip Code _______________ Send this form to: Irbit Motorworks of America, 15411 NE 95th ST. Redmond, WA 98052 or fax to: (425) 696 - 0834... -
Page 79: Ural Starting And Running Tips
URAL - STARTING & RUNNING TIPS Starting the Engine 1. Open carburetor enricheners on both carburetors (pull lever out) if temperature is below 50 degrees. 2. Make sure fuel petcock is open “ON” or on reserve “RES.” Fuel petcock handle should be in 6 or 12 o’clock position. - Page 80 Pre-Trip Check List 1. Check all lights and the horn for proper operation. 2. Check the brake and clutch levers and/or pedals. 3. Make sure all wheels and the final drive assemblies are securely fastened . 4. Check the carburetor flanges and air filter ducts for integrity and proper alignment. 5.
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