Irbit Motorcycle Factory Gear up 2005 User manual

Irbit Motorcycle Factory
Irbit Motorworks of America
Owners Manual
2005 Model
Gear Up, Patrol, Tourist, Troyka

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Contents
Introduction...............................................................................................................................................................7
Warnings,Cautions, Notes.........................................................................................................................................9
Chapter 1 Specifications
Specifications .........................................................................................................................................................11
TorqueSpecifications............................................................................................................................................. 15
Chapter 2 Motorcycle Controls and Instruments
MotorcycleControls&Instrumentation.................................................................................................................. 17
Controls ................................................................................................................................................................ 17
Control and Instrument maintenance ....................................................................................................................... 25
Chapter 3 Engine Operation
EngineOperationandMaintenance ........................................................................................................................ 27
Pre-TripPreliminaries ............................................................................................................................................ 27
StartingtheEngine ................................................................................................................................................. 27
OperatingPrecautions............................................................................................................................................ 31
Running-IntheNewMotorcycle ............................................................................................................................ 32
Chapter 4 Engine Design
Brief Descriptionof Design .................................................................................................................................. 33
LubricationSystem ................................................................................................................................................ 34
FuelSystem........................................................................................................................................................... 35
IgnitionSystem ...................................................................................................................................................... 37
Chapter 5 Carburetors
Carburetors ........................................................................................................................................................... 39
Carburetor Maintenance ........................................................................................................................................ 40
Chapter 6 Power Transmission
PowerTransmission ............................................................................................................................................... 41
Clutch ................................................................................................................................................................... 41
Gearbox ................................................................................................................................................................ 41
FinalDrive............................................................................................................................................................. 42

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Chapter 7 Running Gear
RunningGear......................................................................................................................................................... 43
MotorcycleandSidecar Frames ............................................................................................................................ 43
Spring-LoadedHydraulicShockAbsorber............................................................................................................. 44
AdjustmentofSidecarInstallation ........................................................................................................................ ..45
FrontFork ............................................................................................................................................................ 46
Steering Head Bearings............................................................................................................................................48
Chapter 8 Wheel & Tires
WheelsandTires ................................................................................................................................................... 49
Tire Data ................................................................................................................................................................50
RunningGearMaintenance .................................................................................................................................... 51
Chapter 9 Brakes
Brakes .................................................................................................................................................................. 53
BrakeAdjustment .................................................................................................................................................. 53
Chapter 11 Electrical
ElectricalEquipment .............................................................................................................................................. 57
Electrical Circuits.....................................................................................................................................................59
ElectricalEquipmentMaintenance .......................................................................................................................... 59
WiringDiagram...................................................................................................................................................... 60
Chapter 12 Maintenance
MaintenanceofMotorcycle ................................................................................................................................... 61
ListofRecommendedLubricants ........................................................................................................................... 61
LubricationChart................................................................................................................................................... 63
RequiredLubrication ............................................................................................................................................. 64
CareofMotorcyclePaint....................................................................................................................................... 64
PreservationandStorage ....................................................................................................................................... 65
Battery .................................................................................................................................................................. 65
ListofIndividualToolSet,SpareParts,Accessories&Documents......................................................................... 66
Chapter 13 Gear-Up & Patrol Motorcycle With Engageable Sidecar Drive
Patrol MotorcyclewithEngageableSidecarDrive ................................................................................................. 69
Description ............................................................................................................................................................ 69
HandlingDifferencesfromtheSingleWheelDrive .................................................................................................. 69
SidecarMaintenance ............................................................................................................................................. 70
Chapter 14 Learning to Ride the URAL
Learningto RidetheUralMotorcyclewithSidecarAccessory ................................................................................ 71
SafeOperatingRules ............................................................................................................................................. 73

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Chapter 15 Warranty
Warranty............................................................................................................................................................... 75
Chapter 16 Service Coupons
ServiceCoupons ................................................................................................................................................... 82
NewAddressForm ............................................................................................................................................... 92
New OwnerForm ................................................................................................................................................. 93
URALStartingandRunningTips ............................................................................................................................ 94

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INTRODUCTION
Welcometothe URALMotorcycling Family! YourUralhas beenbuilt bythe IrbitMotorcycle Factoryin
Russiaand distributedbyIrbit MotorworksofAmerica,the United Statesaffiliateof theIrbit Motorcycle
Factory. TheUral motorcycleconformsto allapplicableUS FederalMotorVehicle SafetyStandards and
USEnvironmentalProtectionAgencyregulationseffectiveonthe dateof manufacture.Thismanual
coversthe Gear-Up,Patrol, andTouristmodels.
Thismanual hasbeen preparedtoacquaint youwith theoperation, careandmaintenance ofyour
motorcycle,and toprovideyouwithimportantsafetyinformation. Followtheseinstructions carefullyfor
maximummotorcycle performanceand foryour personalmotorcycling safetyand pleasure. Pleasepay
particularattention to thesection “Learning toRide theUralMotorcycle withSidecar”. Itis criticalthata
beginningsidecar driver becomesthoroughly familiar withthe special operatingcharacteristics of
sidecaroutfits beforeventuring outon thebusy roads.
Your Owner’s Manualcontains instructionsfor operation,maintenanceand minorrepairs. Majorrepairs
requirethe attentionofa skilledmechanic and theuse ofspecial tools andequipment.YourAuthorized
IMWA Ural Dealerhas thefacilities,experience andgenuineUral partsnecessaryto properlyrender this
valuableservice.
Anysuggestions or comments arewelcome! Writeto us orpostan e-mail on theUral Discussion
bulletinboard atwww.imz-ural.com.
Happy Riding!

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Important Notice!
Statementsinthis manual precededby the followingwords are ofspecial importance:
WARNING: MEANS THERE IS THE POSSIBILITY OF PERSONAL INJURY TO
YOURSELF OR OTHERS.
CAUTION: Meansthere isthepossibilityofdamage tothevehicle.
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.
Maintenanceintervals recommendedarebased onoperational experience undervarious climaticand
roadconditions. However, these intervalsmay be modifiedfollowing repeatedchecksof thelubricant
conditionand generalmechanical conditionof themotorcycle.
CarefullystudythisOwner’sManual beforestartingthemotorcycle.
Specificationsanddesign are subject tochange without notice.

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Chapter 1
SPECIFICATIONS
GENERAL
Patrol&Gear-Up Tourist
Maximumspeed ofmotorcycle 95 km/h 59 mph 105km/h 65mph
Drymass of motorcycle 736lb 736lb.
MaximumGrossVehicleWeight 1344lb. 1344lb.
Noiselevel below80db below80db
Fuelconsumption 31.3mpg 31.3mpg
OVERALL DIMENSIONS
Length 2580mm /8ft
Width 1700 mm / 5 ft 6 in
Height 1100 mm / 3 ft 6 in
RoadClearance 125 mm / 5 in
Seatheight 840 mm / 33 in
Wheel base 1470mm/ 58 in
ENGINE
Type 4stroke,overheadvalves,opposedtwin-cylinder
Displacement 745 cc
Cylinder bore 78mm
Pistonstroke 78mm
Compressionratio 8.6:1
Ratedhorsepower 23 KW / 45 BHp
Ratedrotationalspeed 5600RPM
Ratedtorque 52N-M @3750RPM
Lubricationsystem Dualsystemof forcedlubricationandsplashing
Lubricant SAE20W/50
CARBURETOR
Carburetor type 32CVKKeihin
Numberof carburetors 2
Air cleaner PaperFilterElement
Fuel 91octanepremiumunleadedgasoline
PCVValve InternalBreather

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ELECTRICAL
Ignitionsystem Electronic Ignition
Sparkplugs NGKBP7HSorEquivalent
Ignitiontiming Automatic advance
Alternator 35 amp / 12 Volt
Battery VARTAYB18L-Aorequivalent
Headlight Hela,7"roundsealedbeam
TRANSMISSION
Clutch Drydouble-disk clutch
Gearbox 4 speedgearboxwithreverse
GEARRATIOS
Igear 3.6
II gear 2.28
III gear 1.56
IVgear 1.19
Reversegear 4.36
Speedometerdriveratio 0.4
Finaldriveratio 4.62
FLUIDCAPACITIES Patrol,GearUp Tourist
Fueltank(gasoline) 5 Gal / 19L 5 Gal / 19L
Reserve (gasoline) .5 Gal / 2L .5 Gal /2L
Engine (oil) 68Oz / 2L 68Oz / 2L
Transmission(oil) 34 Oz / 1 L 34 Oz / 1 L
Finaldrive(gearoil) 4.5 Oz / 105 ml 3.5 Oz / 135 ml
ShockAbsorbers (shock oil) 105 ml / 3.5 oz 105 ml / 3.5 oz
BrakeReservoir DOT 3 or 4 brake fluid to upper line

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RUNNINGGEAR
Frame Tubularwelded
Rearwheelsuspension Swingarmswith
spring shockabsorbers
Frontfork Leadinglink
Sidecar Cushionedbody(onrubber
cushions)andwheelwith
hydraulicspringshockabsorber
Sidecardrive Steelshaftdrivenbyfinaldrive. Userselectableforengage
(PatrolandGearUp only) ment.
Brakes Disc-typewithhydraulicdriveonfront,Shoetype with
mechanicaldriveon rearandsidecarwheels
Tires 4” x 19”
Front 22 psi cold (1.5 Bar / 150 kPa) Front 22psi cold
Side 22 psi cold (1.5 Bar / 150 kPa) Side 22 psicold
Rear 36 psi cold (2.5 Bar / 250 kPa) Rear 36 psi cold
CLEARANCES mm in
Valveswithenginecold 0.05to0.1 0.002to0.004
Betweensparkplugelectrodes 1.016 0.040
Backlashbetweentoothfacesof
bevel gears infinaldrive 0.1 - 0.3 0.004
FREETRAVEL/ADJUSTMENTS mm in
Handbrakecontrollever 5 - 8 0.2 - 0.3
Clutchcontrollever 5 - 8 0.2 - 0.3
Footbrake drive pedal ¼ offullstrokeofpedal,
25 - 30 1.0 - 1.2
Toe-in distance 10mm 3/8inch
Lean-out 1°awayfrom sidecar

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TORQUESPECIFICATIONS
Metric USEquivalent Location on Bike
54 to 61 Nm 40 ft/lb to 45 ft/lb cylinderheads
237 to251 Nm 175ft/lb to185 ft/lb flywheeltighteningscrews
19 to 30 Nm top 14 ft/lb to 22 ft/lb shockabsorber
38 to 49 Nm bottom 28 ft/lb to 36 ft/lb shockabsorber
30 to 35 Nm 22 ft/lb to 26 ft/lb bearingnut
30 to 35 Nm 22 ft/lb to 26 ft/lb finaldrivetoswingarmbolts
16 to 19 Nm 12 ft/lb to 14 ft/lb oilpumpbolt
6.7 to 11 Nm 5 ft/lb to 8 ft/lb enginesump
14 to 19 Nm 10 ft/lb to 14 ft/lb finaldrivecasenuts
25 to 30 Nm 18 ft/lb to 22 ft/lb nutfasteningthepinionbearing
(Patrol, Gear Up rear axle only)
68 to 90 Nm 50 ft/lb to 66 ft/lb nutfastening thepinionbearing
22 to 27 Nm 16 ft/lb to 20 ft/lb reversegearlevernut
19 to 22 Nm 14 ft/lb to 16 ft/lb alternatorgearnut
136 to 163 Nm 100ft/lb to 120 ft/lb steeringstemnut

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Chapter 2
MOTORCYCLE CONTROLS & INSTRUMENTATION
Figure1. ControlsandInstrumentation
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” beamswitch
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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ClutchControlLever FontBrakeControl Lever
Clutch control lever . Whentheclutch lever issqueezed, theengineisdisengagedfromthe
gearbox. Whentheleveris released,theengineandgearboxareengaged.
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:Alwaysengagetheclutchrelease lever whenshifting. Seriousinternaldamagemay
result to the transmission if the clutch release lever is not engaged.
Front brake control lever Whentheleverissqueezed, the front wheel brakeisactuated. The
frontbrakeshouldbeused together withrearbrake.
Whenthebrakelever is squeezed,thestopsignallightsareswitchedon.

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Kick lever Isdesignedtostarttheengine. Onpressingtheleverthecrankshaftoftheengineis
actuatedthroughthegearbox. Theleverisreturnedtoitsinitialpositionbythespringinsidethe
gearbox.
Gear shift foot pedal Isatwo-armtype. When the frontarmisdepressed, shifting fromhigherto
lowergeartakesplace. Whenthereararmis depressed, shifting fromlowertohighergeartakes
place. Sincetheheel-toeshift lever isshort-coupled,youwillfindit easier toshiftintoahigher
gearifyou do notuseyour heel toshift,ratherthe ballofyourfoot. The neutral positionisfixed
betweenthe1st and2nd gears.Itisimportanttoshift smoothly with aconstant forceand notto kick
thegearshiftpedal. Seriousdamagemayresulttotheshiftingmechanismifthegear shift pedal is
kicked,ratherthan pushed.
IMPORTANT! Thegreen pilot lampwillilluminate when either thetransmissionis in neutral
or when the reverse gear is engaged (see “Starting the Engine”).
GearShiftFootPedal Kick Lever

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ParkingBrake SidecarDrive Lever ReverseGearLever RearBrake Pedal
Parking Brake isusedtoholdthebikewhenparked. Toengage,depresstherearbrakepedal
andpushdownthentwisttheparkingbrakelevercounterclockwise.
Sidecar drive engagement lever isusedtoengagethedriveaxletothesidecarwheelonthe
PatrolandGearUpmodelmotorcycles.
WARNING: Never engagesidecardriveon concrete orhardsurface. Severedamage to
drivetrainwill result ifthe sidecar driveisengaged onpavement.
Reverse gear lever isusedtomovethemotorcycleinreverse. Thetransmissionmustbein
neutralor1stgearforreversegeartobeengaged.
Rear brake lever isusedtoactuatetherear 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.