URAL Motorcycles 2000 TOURIST Operating instructions

Year 2000
Repair Manual

TABLE OF CONTENTS
Chapter 1: General Information
1.1 URAL Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .
.
1
1.2 Maintenance, Lubrication and Tune-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.5 General Dismantling and Repair Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Chapter 2: Chassis and Running Gear
2.1 Description and General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.2 Operating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.3 Front Fork and Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.4 Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.5 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.6 Wheels, Tires, Shock Absorbers and Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.7 Fenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . 62
2.8 Bench Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.9 Windshield and Fairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Chapter 3: Sidecar
3.1 Description and General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.2 Installation and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.3 Sidecar Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.4 Frame/Attachment . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.5 Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.6 Sidecar body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.7 Handling Differences Between Single & Dual Wheel Drive . . . . . . . . . . . . . . . . . . . 72
3.8 Driven Sidecar Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.9 Fender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.10 Upholstery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Chapter 4: Engine
4.1 Description and General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.2 Repair Information and Service Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.3 Cylinder Heads and Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.4 Cylinders and Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.5 Camshaft, Timing Gears, Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.6 Oil Pump and Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.7 Removing and Reinstalling the Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.8 Crankshaft and Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.9 Crankcase and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Chapter 5: Gearbox
5.1 Description and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.2 Gearbox (Solo Motorcycle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.3 Shift Mechanism Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
5.4 Gearbox Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
5.5 Gearbox Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
5.6 Repairing the Gearbox Assembly Units and Parts . . . . . . . . . . . . . . . . . . . . . . . . . 127
Chapter 6: Clutch
6.1 Description and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
6.2 Clutch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
6.3 Removing and Reinstalling the Clutch Release Mechanism . . . . . . . . . . . . . . . . . . 134
6.4 Clutch Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . 135
6.5 Clutch Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Chapter 7: Driveshaft and Final Drive
7.1 Description and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
7.2 Removal and Installation of Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
7.3 Removing and Reinstalling Propellor Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
7.4 Removing and Reinstalling the Rear Swing Arm . . . . . . . . . . . .. . . . . . . . . . . . . . . . 139
7.5 Driveshaft and Universal Joint Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
7.6 Final Drive Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
7.7 Repairing the Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
7.8 Final Drive with Driven Sidecar Wheel (Sportsman) . . . . . .. . . . . . . . . . . . . . . . . . . 145
Chapter 8: Electrical
8.1 Description and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
8.2 Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
8.3 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
8.4 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
8.5 Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
8.6 Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
8.7 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
8.8 Turn Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
8.9 Wiring, Switches, Fuses, Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Chapter 9: Fuel, Carburetion, Air Intake, Exhaust
9.1 Description and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
9.2 Fuel Tank, Fuel Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
9.3 Carburetors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
9.4 Air Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
9.5 Exhaust pipes & Mufflers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Chapter 10: Repair Supplies
10.1 URALSeals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
10.2 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

10.3 Substitute Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Chapter 11: Conversion Tables 168
Appendix
# 1 Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
# 2 Troubleshooting Guides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
169
179

This Repair Manual deals with maintenance and repair of all U.S. Specification
URALmotorcycles.
The Repair Manual provides information on setup, tune-ups, servicing, diagnosing
problems, removing and installing components (otherwise referred to as "assembly
units"), overhauling components, adjusting repaired components, and testing the
repaired motorcycle.
The increasing competition in the motorcycle market requires, more than ever, careful
attending to the customer in order to assure the owner satisfaction with one’s motorcycle and
to maintain customer confidence in the dealer and factory.
It is important to repair the client’s vehicles correctly in a well organized and clean repair shop
equipped with all necessary tools and parts. In such an environment, and having been trained
at the technical training course, a repair technician will prove to be competent and efficient.
Repairs on the engine and transmission especially, should be carried out in dust-free places.
During breaks, disassembled transmissions and openings leading to the inner engine parts or
lubrication holes should be protected from dust by clean rags.
Valves, valve springs, spring retainers, rockers, pushrods, tappets, pistons, connecting rods
and bearings should be put away in suitable boxes. Disassembled parts have to be cleaned
and thoroughly checked for the following:
Sliding and rolling surfaces for wear and freedom from scoring marks, all metal parts,
particularly castings, tempered parts and welded joints as well for cracks and corrosion,
and rubber parts for suitableness.
As a rule, all gaskets and tab washers are to replaced upon reassembling.
When disassembling parts, attention has to be paid to the arrangement of lock-washers on
screws and nuts, spacing washers, gaskets, rubber mounts and so on. If necessary, mark
mating parts in order to guarantee correct assembly.
As the reassembly has to be carried out precisely in the reverse order, it has not been
considered necessary to separately explain the assembly.
Proper service and repair is important for the safe, reliable operation of all mechanical
products. The service procedures recommended and described in this Service Manual are
effective methods for performing service operations. Some of these service operations
require the use of tools specially designed for the purpose. These special tools should be
used when and as recommended.
It is important to note that some warnings against the use of specific service methods, which
could damage the motorcycle or render it unsafe are stated in this Repair Manual. However,
please remember that these warnings are not all inclusive. Since Ural could not possibly
know, evaluate and advise the service trade of all possible ways in which service might be

done or of all the possible hazardous consequences of each way, we have not undertaken
any such broad evaluation. Accordingly, anyone who uses a service procedure or tool which
is not recommended must first thoroughly satisfy himself that neither his nor the operator’s
safety will be jeopardized by the service methods selected.
Wear eye protection while using any of these tools: hammers, arbor or hydraulic presses,
gear pullers, spring compressors, and slide hammers. Be especially cautious when using
pulling, pressing or compressing equipment. The forces involved can cause parts to “fly-out”
with considerable force and cause bodily injury.

GENERAL INFORMATION
1.1 SPECIFICATIONS
*Note: -10 Models are Deco Classics
GENERAL TOURIST / SPORTS
UTILITY/ *-10 Mdls
SOLO
Maximum speed of motorcycle 108 km/h / 65 mph
*119km/h / 74 mph
122 km/h / 77 mph
Reference fuel consumption at 85% of
maximum speed
12.5 km/l / 29 mpg
14 km/l / 32.5 mpg
16.7 km/l / 39 mpg
Dry mass of motorcycle 700 lb. / *680 lb. 460 lb.
Maximum load-carrying capacity 500 lb/485 lb/*400 lb 330 lb.
Noise level below 80db
OVERALL DIMENSIONS OF MOTORCYCLE
Length 2500 mm / 8 ft 2200 mm / 7 ft
Width 1700 mm / 5 ft 6 in 850 mm / 2 ft 8 in
Height 1100 mm / 3 ft 6 in 1060 mm / 3 ft 8 in
Road Clearance 125 mm / 5 in
Seat height 840 mm / 33 in 810 mm / 32 in
Wheel base 1470 mm / 55 in
ENGINE
Type 4 stroke, overhead valves, opposed twin-cylinder
Displacement 649 cc
Cylinder bore 78 mm / 3.07 in
Piston stroke 68 mm / 2.68 in
Compression ratio 8.5
Rated horsepower 35
Rated rotational speed 5600 RPM
Rated torque, Nm 45 Nm / 398.7 in-pound
Ignition system Contactless with electronic ignition timing
Lubrication system Dual system of forced lubrication and by splashing
Lubricant SAE 20W/50 (see Owner’s Manual Maintenance Section)
CARBURETOR
Carburetor type Keihin Seiki 32 CVK
Number of carburetors 2
Air cleaner Pleated Paper Filter
Fuel 91 octane premium unleaded gasoline
PCV Valve Internal Breather

ELECTRICAL EQUIPMENT
Ignition system 12 V
Ignition coil B204
Spark plugs NGK BP7HS or NDW20FP-1
Ignition timing Automatic spark timer
Power supplies Alternator
Storage battery (Russian supplied with new motorcycle)
Recommended replacement: Interstate #12N9-4B-1
Voltage regulator (electronic) Internal to Alternator
Horn C205B
Headlight URAL
 part no. UA-TB6014-017
Sylvania Incandescent 6014, 7" round sealed beam
TRANSMISSION
Clutch Dry double-disk clutch
Gearbox 4 speed box with reverse gear (no reverse for solo model) and gear
shifting foot pedal
GEAR RATIOS TOURIST / SPORTSMAN / UTILITY SOLO/CRUISER
I gear 3.6 3.6
II gear 2.28 2.28
III gear 1.7 1.7
IV gear 1.3 1.3
Reverse gear 4.2 N/A on Solo
4.2 on -10 mdls
Speedometer drive ratio 0.4 0.5
Final drive Pair of bevel gears with propeller shaft
Final drive ratio 4.62 3.89
FLUID CAPACITIES TOURIST &
-10 Models
Sportsman Solo
Gasoline tank 19 L / 5 Gal 19L / 5 Gal 18.5 L / 4.9 Gal
Reserve 2L / 0.5 gal 2L / 0.5 gal 2L- / 0.5 Gal
Engine crankcase 2 L / 2 qt. + 3.6 oz. 2.0L / 2.11 qt 2 L / 2 qt. + 3.6 oz.
Gearbox 0.9L / 1 qt 0.9L / 1 qt 0.9L / 1 qt
Final drive 110 ml / 3.85 oz. 150 ml / 5.25 oz. 110 ml / 3.85 oz.
Telescopic Forks
(-10 & solo models)
N/A on Tourist N/A on Sportsman 135 ml / 4.56 oz.
Shock Absorbers 105 ml / 3.55 105 ml / 3.55 oz 105 ml / 3.55 oz

RUNNING GEAR TOURIST / SPORTSMAN SOLO
Frame Tubular welded
Rear wheel suspension Swing arm with hydraulic spring
shock absorbers
Sidecar: same as -40
Solo: Lower spring rate
Front fork Leading link Telescopic spring
Sidecar Cushioned body (on rubber
cushions) and wheel on long-lever
suspension with hydraulic spring
shock absorber
N/A
Brakes Shoe-type with mechanical drive on front, rear and sidecar wheels,
front wheel has dual cams.
Tires 4” x 19”
Front & Side: 22 psi cold
Rear: 36 psi cold
3.5” x 18”
Solo:
Front 25 psi cold
Rear: 32 psi cold
-10’s: Front & side:
25 psi cold
Rear: 36 psi cold
CLEARANCES mm in
Valves with engine cold 0.05 0.002
Between spark plug electrodes 0.50 - 0.65 0.020 - 0.026
Between brake shoes and drum 0.3 - 0.70 0.012 - 0.028
Backlash between tooth faces of
bevel gears in final drive
0.1 - 0.3 0.004
Between rotor and ignition pickup 0.3 - 0.4 .012 - .016
FREE TRAVEL / ADJUSTMENTS mm in
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 throughout motorcycle center
distance (exception: Sportsman 0° toe-in)
10 N/A
Angle of motorcycle inclination to
vertical plane (camber angle of rear
wheel)
1° away from sidecar
N/A
Headlight installation (with motorcycle
laden) horizontal (high beam)

TORQUE SPECIFICATIONS
Metric (in repair manual) US Equivalent Location on Bike
29 to 33 Nm 22 ft/lb. to 30 ft/lb. cylinder heads
22 to 25 kgf-m 175 ft/lb. to 185 ft/lb. fly wheel tightening screws
3.8 to 4.2 kgf-m 30 ft/lb. to 40 ft/lb. cylinder
2.1 to 3.0 kgf-m top 14 ft/lb. to 22 ft/lb. shock absorber
3.6 to 5.0 kgf-m bottom 28 ft/lb. to 36 ft/lb. shock absorber
3.0 to 3.4 kgf-m 22 ft/lb. to 26 ft/lb. bearing nut
3.0 to 3-4 kgf-m 22 ft/lb. to 26 ft/lb. final drive to swing arm bolts
1.6 to 1.8 kgf-m 12 ft/lb. to 14 ft/lb. oil pump bolt
.8 to 1.0 kgf-m 5 ft/lb. to 8 ft/lb. engine sump
1.4 to 1.8 kgf-m 10 ft/lb. to 14 ft/lb. final drive case nuts
7 to 9 kgf-m 50 ft/lb. to 66 ft/lb. nut fastening the pinion bearing
2.2 to 2.8 kgf-m 16 ft/lb. to 20 ft/lb. reverse gear brake lever
1.8 to 2.0 kgf-m 14 ft/lb. to 16 ft/lb. generator gear nut
14.0 to 16.8 kgf-m 100 ft/lb to 120 ft/lb steering stem nut
CONVERSIONS
To convert from mm to in, divide by 25.4 (there are 25.4 mm per inch).
To convert from liters to gallons, divide by 3.785 (there are 3.78 liters per gallon).
To convert from liters to quarts, multiply by 1.056 (there are 1.056 quarts per liter).
To convert from liters to pints, multiply by 2.112 (there are 2.112 pints per liter).
To convert from km to miles, multiply by .62 (there is .62 mile per km).
To convert from km/hr to mph, multiply by .62.
To convert from Newton-meter (Nm) to inch-pound, multiply by 8.86.
To convert from cm3(cc) to pints, divide by 473 (there are 473 cc per pint).
To convert Celsius to Fahrenheit, F°= C°x 1.8 = 32°.
To convert Fahrenheit to Celsius,C °= (F°- 32°) divided by 1.8

CAUTION: During the initial 2,500 km of use a fundamental bedding-in of parts for all the
mechanisms of the motorcycle takes place. During this period do not overload the engine or race the
motorcycle in excess of the speeds specified in the section "Running-In of New Motorcycle." Doing
so will void the warranty.
Each URALmotorcycle is supplied with an individual tool kit, including documentation, as follows.
Tools Set of Spares
Wrench 7 x 8 mm Inner tube patch kit
Wrench 10 x 12 mm Oil filter element
Wrench 13 x 14 mm Kick starter pedal sleeve
Wrench 14 x 17 mm Fuses
Wrench 19 x 22 mm
Socket wrench 10 x 12 mm Documents
Socket wrench 10 x 13 mm Owner’s Manual
Socket wrench 19 x 21 mm Driving the URALSidecar Manual
Wrench 27 mm (except with Solo models)
Double head wrench Owner’s Video
Spanner wrench
Spanner wrench assembly Accessories
Screwdriver 150 mm Air Pump
Screwdriver 100 mm Air Pressure Gauge
Pliers 2 Ignition keys
Tool kit pouch

1.2 Maintenance, Lubrication, & Tune-up
Maintenance Intervals
Maintenance intervals recommended are based on operational experience under various climatic and
road conditions. However, these intervals may be extended or reduced following repeated checks of
the lubricant condition and general technical condition of the motorcycle.
In certain sections of this manual you will find references to more frequent maintenance intervals than
the "Light Duty" minimal maintenance intervals referred to in the Maintenance Schedule Summary. The
sidecar motorcycle requires adherence to the "Normal Duty" maintenance schedule.
Maintenance Schedule Summary
The following schedule is broken into two columns to indicate the type of usage and operating
environment to which the machine will be subject. The "Normal Duty" category includes operation in
dusty, hot climates, while pulling loads on hilly terrain for significant periods of time in the
maintenance cycle, operation primarily with the sidecar accessory attached or for owners who want to
take extra care to keep their machines in "tip top" condition.
The "Light Duty" schedule is the minimal maintenance that an owner should perform to keep the
factory warranty in place. It is acceptable when the machine is used primarily in ideal climates with
very little dust or contamination of fuel supply and with sidecar accessory unattached.
Maintenance Schedule Summary
1. Change motor oil, clean or replace oil filter element, clean air filter element and fuel filter,
check bearings play. Check electronic ignition pickup air gap. Adjust throttle, clutch and
brake cables, and check gearshift linkage for adjustment. Check battery fluid.
At 500km then every 2,500km
2. Change gearbox oil, replace oil filter, and rotate tires.
Every 5,000km
3. Lubricate drive axle/hub, replace final drive gear oil.
Check level every 2,500km,
Replace at 500km and every 10,000km
4. Replace spark plugs, torque cylinder head stud nuts, adjust valve lash, re-pack wheel
bearings, and check ignition timing.
Every 10,000km

Table 1.2-1 Lubrication Chart
Item Part To Be Lubricated Lubricant Schedule
1 Lever pin and interrupter felt
Pins and weight holes, automatic unit
cam bushing
Industrial oil or spindle
oil
Every 5,000 km
Every 5,000 km
2 Engine crankcase
Oil filter
20w/50 Det. oil and
URALOil Treatment
Every 2,500 km1
Every 5,000 km
3 Gearbox 20w/50 Det. oil and
URALOil Treatment
Every 2,500 km2
4 Air cleaner Spray WD-40 Wash and oil every 2,500 km
5 Shock absorbers of rear suspension and
sidecar wheel suspension
Industrial oil or spindle
oil
Change every 10,000 km
6 Final drive 80/90 wt. Gearlube and
URALOil Treatment
Top up every 2,500 km3,
change every 10,000 km
7 Hinges of sidecar collet joint Grease Every 10,000 km
8 Hinge joints of brake system Spindle oil/WD-40 Every 5,000 km
9 Brake pedal shaft Spindle oil/WD-40 Every 2,500 km
10 Universal joint of propeller shaft (grease
cup)
Grease Every 10,000 km
11 Lever pins and end pieces of clutch and
hand brake cables
Clutch, front brake and throttles control
cables
Grease
Spindle oil/WD-40
Every 5,000 km
Every 5,000 km
12 Pins and cams of brake shoes Grease Every 5,000 km
13 Wheel hub Grease Every 10,000 km
14 Front fork dampers (lubrication points) Spindle oil/WD-40 Change every 10,000 km
15 Carburetor throttle control twist grip Grease Every 5,000 km
16 Speedometer drive flexible shaft and
speedometer axle
Industrial oil or spindle oil Every 10,000 km
17 Steering column bearings Grease Every 20,000 km
18 Telescopic forks (-10 and Solo) 5 wt. -10 wt. Fork Oil As needed
1. After break-in, changes required at 500km, 2,500km, 3,500km and 5,000km.
2. During break-in, change at 500 km and then 2,500km.
3. During break-in, change at 500km.

Table 1.2-1 (cont’d) Lubrication diagram

Control Cable Maintenance
The daily preventive maintenance involves checking the functioning of the cables, the condition and
fastening of the tie rods and cables and braking action. Refer to the maintenance summary for
lubricating and schedule.
After every 5,000 km, check the condition of the brakes, clean the brake shoes and the active surface of
the brake drums, lubricate the hinge pins and the cams of the brake linings, the joints, the linkage of the
rear and sidecar wheel brakes, lever axles, the parking brake bearing, the throttle control twist grip, the
lever pins and ends of cables used in the clutch, the front brake control, the control cables used in the
clutch, the front brake and the throttles.
Motor Oil
The URALhas been certified for EPA with premium grade SAE 20W/50 petroleum based detergent
oil rated for air-cooled engines.
This oil can be used in both the engine and transmission. The Authorized URALDealer should be
prepared to make recommendations for all lubricants best suited to local conditions.
For operation below 32º F, SAE 10W/40 oil is recommended.
Tune-up
To help prolong the service life of the motorcycle, it is essential to inspect the machine frequently and
make repairs promptly as they are discovered. A machine that has had little or no periodic service may
be very difficult to diagnose and repair when a problem does occur.
In addition to the following, top off all lubricants and adjust running gear and sidecar alignment.
As a minimum, check and adjust:
•spark plug gaps •pick up and rotor gap
•valve clearances •carburetors
•throttle synchronization •brake controls
•clutch •drive housing
•adequate fuel quantity, condition, and flow •all switches and lights functioning
•acceptable quantity and condition of oil in
the engine crankcase, gearbox, and final drive
•battery condition and charge

1.3 Normal Operation
This section describes techniques and precautions for operating a URALmotorcycle, including break-
in procedures for new or rebuilt engines.
Pre-ride Preliminaries
Before each ride, attend to all the requirements of the everyday maintenance as outlined in this manual.
When filling the motorcycle with fuel and oil, take care to avoid spills that might damage the machine
or create safety or environmental hazards. The fuel tank should not be overfilled. Overfilling can
result in fuel leakage during operation. Always check engine oil level before starting the engine.
CAUTION: When checking or topping off lubricants use caution to prevent dirt and debris
from falling into the fill opening. When using funnels, tubes, pumps, etc., ensure they are not
contaminated with dust or dirt. When draining oil, use care to prevent oil from contacting
wheels, tires, or brakes, and avoid skin contact with used oil.
Starting The Engine
WARNING: Before starting the engine, make sure that the gear shift mechanism is in the neutral
position (between I and II gears) to prevent sudden accidental movement which could cause possible
damage to motorcycle and personal injury. For sidecar motorcycles equipped with a reverse gear,
make sure that reverse is not engaged.
If ignition is switched on, the green neutral light on the instrument panel should illuminate when the
transmission is in neutral, however, the neutral light will also be on if the motorcycle is in reverse gear.
Check to be sure that the reverse lever is in the forward position, or manually roll the motorcycle
forward and back to ensure that both transmission and reverse are in neutral before starting.
Open the fuel petcock by setting its handle to the down position.
NOTE: For URAL
 s manufactured earlier than mid-95, the down position is off. This type of valve
has a flatter / wider blade than the later valves. If in doubt, verify fuel flow by removing the fuel line at
the carburetors. (Reserve is up and off is horizontal.)
Getting a URALengine started is an art that must be mastered. Owners may need to be coached
through the process. The use of throttle and carburetor enrichment is critical for successful starting, as
is a fully-charged battery. Depending on the engine
and ambient temperatures, use the carburetor enricheners and starting procedure as follows.
Starting A Warm Engine
When the engine is hot, do not enrich the carburetors. To do so risks flooding the engine. Turn on the
ignition, check the cutoff switch in the run position, select neutral gear, and push down on the kick

lever just far enough to engage it; about 1/4 of its travel. The standard Russian position for starting the
sidecar motorcycle is standing on the passenger peg on the right foot, and stepping down on the
kickstarter with the ball of the left foot. Take up the slack in the throttle until you can feel some slight
resistance from the return springs in the carburetors. However, do not advance the throttle, since this
may flood the engine.
Step down swiftly on the kickstart lever and give it a full stroke to the bottom stop. If the engine starts,
tickle the throttle (rapidly twist part way towards full throttle and then back off) to keep the engine
running, but don't allow it to rev up.
WARNING: Once the engine starts, do not allow it to rev beyond 2,000 rpm while cold, which may
lead to seizure of the piston pin and pistons in the cylinders. Cold oil flows through the oil ducts
more slowly and cannot provide sufficient lubrication.
A correctly adjusted warm engine should run steadily at low speed with the throttle control twist grip
fully closed. Start driving the motorcycle only after having warmed up the engine, with the engine
running steadily at low speed. In cold seasons do not run the engine at high RPM during initial 3 km or
drive at a speed exceeding 30 mph until the engine is fully warmed up.
If the engine doesn't start on the first kick, kick it through aggressively, four or five times. A properly
adjusted warm engine should start within a few kicks. If the engine doesn't start, or coughs, that
indicates it is cold enough to require some enriching of the mixture. However, it may also be flooded.
Flooded Engine
To start an engine that is flooded pull out both enrichers, open the throttle fully, hold it there and kick
the engine through several times. It should fire. As soon as it fires, return the throttle to just above idle
to keep it running. If it still doesn't fire, take the spark plugs out to see if they are very wet with
gasoline. If they are wet, dry them, and clear excess gasoline from the cylinders by kicking the engine
over several times with the plugs out and the throttle closed. Then replace the plugs and repeat the
starting procedure using no enricheners.

Cold Engine, Warm Day
When the engine has been standing for several hours but the ambient temperature is high (60°F or
above), it will probably start without enrichment. If it doesn't fire, use one of the following procedures.
Cool Engine, Cool Day
When the engine is cool or cold and the ambient temperature is between 40-60 F, pull out both
enricheners. As soon as the engine starts, immediately push both enricheners back in. Run the engine at
moderate speed for 30-60 seconds. If it starts to die, tickle the twist grip throttle (rapidly twist part way
towards full throttle and then back off) to keep the engine running. After 1 to 3 minutes, depending on
ambient temperature, the engine should run smoothly.
Cold Weather Starting
If the engine is cold and ambient temperature is below 40 degrees F, first, give the engine 5-10
(depending on how cold it is) priming kicks with the ignition off. This will get some oil circulated to
key internal parts. Pull open the enricheners on both carburetors The engine should then soon fire,
depending on how cold it is. For example, when the ambient temperature is 0 degrees F, it typically
takes about 3 to 5 seconds to start the engine. As soon as the engine starts, push in both enricheners.
Then follow the running procedure described in Starting the Engine (also in section 1.3).
NOTE: It is very important to back off on the enricheners as soon as the engine will sustain itself
without sputtering. The URAL
 can foul plugs quickly (as soon as one minute) if the engine is run too
rich. If one plug fouls and the other doesn't, the engine will run very unevenly and have greatly
reduced power.
WARNING: Sustained operation on only one cylinder for even just a few minutes could overheat
the cylinder and cause irreversible damage to either the valves or piston. Thus it is critical to
immediately shut the engine down if it appears to be running on only one cylinder.
Operating Precautions
WARNING: Make sure that sidecar windshield is in the full back position and it doesn't interfere
with the right handlebar.
To move the motorcycle from rest, shift to the 1st gear only. Avoid releasing the clutch suddenly,
because the engine is liable to stall or the motorcycle will start with a jerk.
Do not drive the motorcycle at speeds below the recommended speeds with the 2nd, 3rd or 4th gears
engaged. It is not advisable to use the 1st and 2nd gears for a long time, unless so required by road
conditions.

WARNING: When shifting to lower gears with the motorcycle in motion, do not downshift at speeds
higher than those listed in the table. Shifting to lower gears when speed is too high may severely
damage the transmission or cause the rear wheel to lose traction.
Shift to neutral before shutting off the engine. The shifting mechanism can be damaged by attempting
to shift the transmission when the engine is not running. When engine speed decreases, as in climbing
a hill or running at a reduced speed, change from a higher gear to the next lower gear while partially
closing the throttle.
CAUTION: Do not run the engine at extremely high rpm with clutch disengaged or transmission
in neutral. Do not idle the engine unnecessarily for more than a few minutes with the motorcycle
standing still. Remember the URALengine is an air cooled engine which requires the movement
of air to keep the engine at normal operating temperatures and to avoid overheating the
cylinders.
An engine run long distances at high speed must be given close attention, to avoid overheating and
consequent damage. The engine should be checked regularly and kept well tuned. Valve seating and
good compression is particularly important, especially for a sidecar motorcycle equipped with
windshields, carrying heavy loads, or operating in hot weather.
WARNING: When riding on wet roads or under rainy conditions, braking efficiency is greatly
reduced and caution should be used when applying the brakes, accelerating and turning. This is
especially true immediately after the rain begins and the oil from the road surface combines with the
water.
When descending a long, steep grade, downshift and use engine compression together with intermittent
application of both brakes to slow the motorcycle. Drum-type brakes tend to overheat and fade if used
continuously.
Shutting Down an Overheated Engine
An overheated engine can backfire or detonate when being shut down. The engine jerking at low
speeds is hard on both the engine and the transmission. To avoid damage when shutting down an
overheated engine, reduce the engine speed to the minimum and completely close the choke without
switching off the ignition. This will make the engine stall without any knocks or backfire. After the
engine stops, switch off the ignition.
Running In a New Motorcycle
URALmotorcycles require a running-in period to allow new parts such as bearings to seat. The
running-in period also applies to new or overhauled components. Since the URALengine is an old
fashioned design it is critical to observe this running-in procedure. Failure to follow the running-in
procedure will void the Ural warranty.

During the running-in period, a new motorcycle requires the most careful attention. In the course of
this period, do not overload the machine, avoid traveling on freeways and climbing steep upgrades. Do
not race the engine or allow it to overheat at any time.
Pay special attention to lubrication of the engine. It is recommended that after the initial 500 km, the
break-in oil be drained, the crankcase flushed, and refilled with fresh oil to the correct level.
Transmission and final drive lubricants can be changed per the normal maintenance schedule summary.
The running-in period for the motorcycle is divided into two stages, up to 1,000 km and from 1,000 up
to 2,500 km. When running-in, keep the speeds within the limits stated in the following Table. Even
on a thoroughly run-in motorcycle, Ural advises not exceeding the listed maximum speeds:
Table 1.3-1 SPEEDS NOT TO EXCEED FOR RUNNING-IN
Gear Tourist (-40 ) & Patrol Solo & Cruiser ( -10 )
0 - 2,500 km After Run-In 0 - 2,500 km After Run-In
I 9 mph 12 mph 10 mph 15 mph
II 21 mph 27 mph 22 mph 31 mph
III 30 mph 39 mph 40 mph 74 mph
IV 42 mph 65 mph 50 mph 70 mph