Irbit Motorcycle Factory Gear Up 2003 User manual

Irbit Motorcycle Factory
Irbit Motorworks of America
Owners Manual
2003 Model
Gear Up, Patrol, Tourist
www.imz-ural.com

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Contents
Introduction ...............................................................................................................................................................7
Warnings, Cautions, Notes.........................................................................................................................................9
Chapter 1 Specifications
Specifications ......................................................................................................................................................... 11
Torque Specifications ............................................................................................................................................. 15
Chapter 2 Motorcycle Controls and Instruments
Motorcycle Controls & Instrumentation .................................................................................................................. 17
Controls ................................................................................................................................................................ 17
Control and Instrument maintenance ....................................................................................................................... 25
Chapter 3 Engine Operation
Engine Operation and Maintenance ........................................................................................................................ 27
Pre-Trip Preliminaries ............................................................................................................................................ 27
Starting the Engine ................................................................................................................................................. 27
Operating Precautions ............................................................................................................................................ 31
Running-In the New Motorcycle ............................................................................................................................ 32
Chapter 4 Engine Design
Brief Description of Design .................................................................................................................................. 33
Lubrication System ................................................................................................................................................ 34
Fuel System ........................................................................................................................................................... 35
Ignition System ...................................................................................................................................................... 37
Chapter 5 Carburetors
Carburetors ........................................................................................................................................................... 39
Carburetor Maintenance ........................................................................................................................................ 40
Chapter 6 Power Transmission
Power Transmission ............................................................................................................................................... 41
Clutch ................................................................................................................................................................... 41
Gearbox ................................................................................................................................................................ 41
Final Drive ............................................................................................................................................................. 42

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Chapter 7 Running Gear
Running Gear ......................................................................................................................................................... 43
Motorcycle and Sidecar Frames ............................................................................................................................ 43
Spring-Loaded Hydraulic Shock Absorber ............................................................................................................. 44
Adjustment of Sidecar Installation ........................................................................................................................ ..45
Front Fork ............................................................................................................................................................ 46
Steering Head Bearings............................................................................................................................................48
Chapter 8 Wheel & Tires
Wheels and Tires ................................................................................................................................................... 49
Tire Data ................................................................................................................................................................50
Running Gear Maintenance .................................................................................................................................... 51
Chapter 9 Brakes
Brakes .................................................................................................................................................................. 53
Brake Adjustment .................................................................................................................................................. 53
Chapter 11 Electrical
Electrical Equipment .............................................................................................................................................. 57
Electrical Circuits.....................................................................................................................................................59
Electrical Equipment Maintenance .......................................................................................................................... 59
Wiring Diagram ...................................................................................................................................................... 60
Chapter 12 Maintenance
Maintenance of Motorcycle ................................................................................................................................... 61
List of Recommended Lubricants ........................................................................................................................... 61
Lubrication Chart ................................................................................................................................................... 63
Required Lubrication ............................................................................................................................................. 64
Care of Motorcycle Paint ....................................................................................................................................... 64
Preservation and Storage ....................................................................................................................................... 65
Battery .................................................................................................................................................................. 65
List of Individual Tool Set, Spare Parts, Accessories & Documents ......................................................................... 66
Chapter 13 Gear-Up & Patrol Motorcycle With Engageable Sidecar Drive
Patrol Motorcycle with Engageable Sidecar Drive ................................................................................................. 69
Description ............................................................................................................................................................ 69
Handling Differences from the Single Wheel Drive .................................................................................................. 69
Sidecar Maintenance ............................................................................................................................................. 70
Chapter 14 Learning to Ride the URAL
Learning to Ride the Ural Motorcycle with Sidecar Accessory ................................................................................ 71
Safe Operating Rules ............................................................................................................................................. 73

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Chapter 15 Warranty
Warranty ............................................................................................................................................................... 75
Warranty Claim Form ........................................................................................................................................... 81
Flat Rate Schedule ............................................................................................................................................... 82
Chapter 16 Service Coupons
Service Coupons ................................................................................................................................................... 85
New Address Form ............................................................................................................................................... 95
New Owner Form ................................................................................................................................................. 96
URAL Starting and Running Tips ............................................................................................................................ 97

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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. This manual
covers the Gear-Up, Patrol, and Tourist models.
This manual has been prepared to acquaint you with the operation, care and maintenance of your
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. Please pay
particular attention to the section “Learning to Ride the Ural Motorcycle with Sidecar”. It is critical that a
beginning sidecar driver becomes thoroughly familiar with the special operating characteristics of
sidecar outfits before venturing out on the busy 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
IMWA Ural Dealer has the facilities, experience and genuine Ural parts necessary to properly render this
valuable service.
Any suggestions or comments are welcome! Write to us or post an e-mail on the Ural Discussion
bulletin board at www.imz-ural.com.
Happy Riding!

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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 particular importance has been placed in
italic type.
CAUTION! During the initial 1,500 km, a fundamental bedding-in of parts for all the
mechanisms of the motorcycle takes place. During this period do not race, overload, or lug the
engine.
Note the riding procedures described in the section “Running-In of New Motorcycle.”
Following those procedures will ensure that you have the most powerful & smoothly operating
engine after break-in.
Maintenance intervals recommended are based on operational experience under various climatic and
road conditions. However, these intervals may be modified following repeated checks of the lubricant
condition and general mechanical condition of the motorcycle.
Carefully study this Owner’s Manual before starting the motorcycle.
Specifications and design are subject to change without notice.

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Chapter 1
SPECIFICATIONS
GENERAL
Patrol & Gear-Up Tourist
Maximum speed of motorcycle 95 km/h 59 mph 105 km/h 65 mph
Dry mass of motorcycle 736 lb 736 lb.
Maximum Gross Vehicle Weight 1344lb. 1344 lb.
Noise level below 80db below 80db
Fuel consumption 31.3 mpg 31.3mpg
OVERALL DIMENSIONS
Length 2580 mm / 8 ft
Width 1700 mm / 5 ft 6 in
Height 1100 mm / 3 ft 6 in
Road Clearance 125 mm / 5 in
Seat height 840 mm / 33 in
Wheel base 1470 mm / 58 in
ENGINE
Type 4 stroke, overhead valves, opposed twin-cylinder
Displacement 745 cc
Cylinder bore 78 mm
Piston stroke 78 mm
Compression ratio 8.6 :1
Rated horsepower 23 KW / 45 BHp
Rated rotational speed 5600 RPM
Rated torque 52 N -M @ 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 octane premium unleaded gasoline
PCV Valve Internal Breather

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ELECTRICAL
Ignition system Electronic Ignition
Spark plugs NGK BP7HS or Equivalent
Ignition timing Automatic advance
Alternator 35 amp / 12 Volt
Battery VARTA YB18L-A or equivalent
Headlight Hela, 7" round sealed beam
TRANSMISSION
Clutch Dry double-disk clutch
Gearbox 4 speed gearbox with reverse
GEAR RATIOS
I gear 3.6
II gear 2.28
III gear 1.56
IV gear 1.19
Reverse gear 4.36
Speedometer drive ratio 0.4
Final drive ratio 4.62
FLUID CAPACITIES
Patrol, Gear Up Tourist
Fuel tank (gasoline) 5 Gal / 19L 5 Gal / 19L
Reserve (gasoline) .5 Gal / 2L .5 Gal / 2L
Engine (oil) 68 Oz / 2L 68 Oz / 2L
Transmission (oil) 34 Oz / 1 L 34 Oz / 1 L
Final drive (gear oil) 4.5 Oz / 135 ml 3.5 Oz / 105 ml
Shock Absorbers (shock oil) 3.5 Oz / 105 ml 3.5 Oz / 105 ml
Brake Reservoir DOT 3 or 4 brake fluid to upper line

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RUNNING GEAR
Frame Tubular welded
Rear wheel suspension Swing arms with
spring shock absorbers
Front fork Leading link
Sidecar Cushioned body (on rubber
cushions) and wheel with
hydraulic spring shock absorber
Sidecar drive Steel shaft driven by final drive. User selectable for engage
(Patrol and Gear Up only) ment.
Brakes Disc-type with hydraulic drive on front, Shoe type with
mechanical drive on rear and sidecar wheels
Tires 4” x 19”
Front 22 psi cold (1.5 Bar / 150 kPa) Front 22 psi cold
Side 22 psi cold (1.5 Bar / 150 kPa) Side 22 psi cold
Rear 36 psi cold (2.5 Bar / 250 kPa) Rear 36 psi cold
CLEARANCES
mm i n
Valves with engine cold 0.05 to 0.1 0.002 to 0.004
Between spark plug electrodes 1.016 0.040
Backlash between tooth faces of
bevel gears in final drive 0.1 - 0.3 0.004
FREE TRAVEL / ADJUSTMENTS
mm i n
Hand brake control lever 5 - 8 0.2 - 0.3
Clutch control lever 5 - 8 0.2 - 0.3
Foot brake drive pedal ¼ of full stroke of pedal,
25 - 30 1.0 - 1.2
Toe-in distance 10 mm 3/8 inch
Lean-out 1° away from sidecar

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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 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
25 to 30 Nm 18 ft/lb to 22 ft/lb nut fastening the pinion bearing
(Patrol, Gear Up rear axle only)
68 to 90 Nm 50 ft/lb to 66 ft/lb nut fastening the pinion bearing
22 to 27 Nm 16 ft/lb to 20 ft/lb reverse gear lever nut
19 to 22 Nm 14 ft/lb to 16 ft/lb alternator gear nut
136 to 163 Nm 100 ft/lb to 120 ft/lb steering stem nut

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Chapter 2
MOTORCYCLE CONTROLS & INSTRUMENTATION
Figure 1. 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” beam switch
indicator lamp 16 - Clutch control lever
5 - Front brake control lever 17 - Steering damper tightening bolt
6 - Throttle control twist grip 18 - High-beam indicator lamp
7 - Ignition cutoff switch 19 - Ignition Switch
8 - Electric Start Button 20 - Battery discharge warning lamp
9 - Rear brake pedal & sidecar wheel brake 21 - Parking brake
10 - Reverse gear lever
11 - Kick start lever

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Clutch Control Lever Font 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 engaged.
WARNING: MAKE SURE FINGERS ARE NOT POSITIONED BETWEEN HAND CONTROL LEVERS AND HANDLEBAR
GRIPS OR OPERATION OF VEHICLE COULD BE IMPAIRED.
WARNING: BEFORE STARTING ENGINE, ALWAYS SHIFT 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 together with rear brake.
When the brake lever is squeezed, the stop signal lights are switched on.

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Kick lever Is designed to start the engine. On pressing the lever the crankshaft of the engine is
actuated through the gearbox. The lever is returned to its initial position by the spring inside the
gearbox.
Gear shift foot pedal Is a two-arm type. When the front arm is depressed, shifting from higher to
lower gear takes place. When the rear arm is depressed, shifting from lower to higher gear takes
place. Since the heel-toe shift lever is short-coupled, you will find it easier to shift into a higher
gear if you do not use your heel to shift, rather the ball of your foot. 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. Serious damage may result to the shifting mechanism if the gear shift pedal is
kicked, rather than pushed.
IMPORTANT! The green pilot lamp will illuminate when either the transmission is in neutral
or when the reverse gear is engaged (see “Starting the Engine”).
Gear Shift Foot Pedal Kick Lever

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Parking Brake Sidecar Drive Lever Reverse Gear Lever Rear Brake Pedal
Parking Brake is used to hold the bike when parked. To engage, depress the rear brake pedal
and push down then twist the parking brake lever counter clockwise.
Sidecar drive engagement lever is used to engage the drive axle to the sidecar wheel on the
Patrol and Gear Up model motorcycles.
WARNING: Never engage sidecar drive on concrete or hard surface. Severe damage to
drivetrain will result if the sidecar drive is engaged on pavement.
Reverse gear lever is used to move the motorcycle in reverse. The transmission must be in
neutral or 1st gear for reverse gear to be engaged.
Rear brake lever is used to actuate the rear brakes.
WARNING: DONOT APPLY EITHER BRAKE STRONGLY 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.
WARNING: ANIMPROPERLY ADJUSTED REAR BRAKE PEDAL COULD INTERFERE WITH PROPER REAR BRAKE
OPERATION RESULTING IN POOR BRAKE ACTION.
This manual suits for next models
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