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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