URAL Motorcycles 2012 All Models User manual

Owners Manual 2012All Models
www.imz-ural.com

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2

3
Contents
Introduction..............................................................................................................................................................7
Warnings, Cautions, Notes.......................................................................................................................................9
Chapter 1 Speci cations
Speci cations
...............................................................
...............................................................
..........................
11
Torque Speci cations............................................................................................................................................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
3
Contents
Introduction..............................................................................................................................................................7
Warnings, Cautions, Notes.......................................................................................................................................9
Chapter 1 Speci cations
Speci cations
...............................................................
...............................................................
..........................
11
Torque Speci cations............................................................................................................................................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

4
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
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
4
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
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

5
Chapter 15 Warranty
Warranty.................................................................................................................................................................75
Chapter 16 Service Coupons
Service Coupons
...............................................................
...............................................................
.....................
85
New Address Form
...............................................................
...............................................................
.................
95
New Owner Form..................................................................................................................................................96
URAL Starting and Running Tips
...............................................................
..........................................................
97
5
Chapter 15 Warranty
Warranty.................................................................................................................................................................75
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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7
INTRODUCTION
Welcome to the URAL Motorcycling Family! Your Ural has been built by the Irbit Motorcycle Factory in Rus-
sia and distributed by Irbit Motorworks of America, the United States af liate of the Irbit Motorcycle Factory.
The Ural motorcycle conforms to all applicable US Federal Motor Vehicle Safety Standards and US Environ-
mental 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 motor-
cycle 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 out ts 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!
7
INTRODUCTION
Welcome to the URAL Motorcycling Family! Your Ural has been built by the Irbit Motorcycle Factory in Rus-
sia and distributed by Irbit Motorworks of America, the United States af liate of the Irbit Motorcycle Factory.
The Ural motorcycle conforms to all applicable US Federal Motor Vehicle Safety Standards and US Environ-
mental 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 motor-
cycle 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 out ts 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!

8
8

9
Important Notice!
Statements in this manual preceded by the following words are of special im por tance:
WARNING:
MEANS THERE IS THE POSSIBILITY OF
PERSONAL
INJURY TO
YOURSELF OR OTH ERS.
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 mecha-
nisms 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.” Fol-
lowing 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 extended or reduced following repeated checks of the lubricant
condition and general mechanical condition of the motorcycle.
Carefully study this Owner’s Manual before starting the motorcycle.
Speci cations and design are subject to change without notice.
9
Important Notice!
Statements in this manual preceded by the following words are of special im por tance:
WARNING:
MEANS THERE IS THE POSSIBILITY OF
PERSONAL
INJURY TO
YOURSELF OR OTH ERS.
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 mecha-
nisms 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.” Fol-
lowing 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 extended or reduced following repeated checks of the lubricant
condition and general mechanical condition of the motorcycle.
Carefully study this Owner’s Manual before starting the motorcycle.
Speci cations and design are subject to change without notice.

10
10

11
Chapter 1
SPECIFICATIONS
GENERAL
Patrol & Gear-Up
Tourist
Maximum speed of motorcycle
105 km/h 65 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
2580 mm / 8 ft 2580 mm / 8 ft
Width
1700 mm / 5 ft 6 in
Height
Height Height
1100 mm / 3 ft 6 in
Road Clearance
125 mm / 5 in
Seat height
Seat height Seat height
840 mm / 33 in
Wheel base
1470 mm / 58 in
ENGINE
Type
4 stroke, overhead valves, opposed twin-cylinder
Displacement
Displacement Displacement
749 cc
Cylinder bore
78 mm
Piston stroke
78 mm
Compression ratio
8.6 :1
Rated horsepower
Rated horsepower Rated horsepower
23 KW / 45 BHp
Rated rotational speed
Rated rotational speed Rated rotational speed
5600 RPM
Rated torque
52 N -M @ 3750 RPM
Lubrication system
Dual system of forced lubrication and splash ing
Lubricant
Lubricant Lubricant
SAE 20W/50
CARBURETOR
Carburetor type
32 CVK Keihin
Number of carburetors
2
Air cleaner
Air cleaner Air cleaner
Paper Filter Element
Fuel
91 octane premium unleaded gasoline
PCV Valve
Internal Breather
11
Chapter 1
SPECIFICATIONS
GENERAL
Patrol & Gear-Up
Tourist
Maximum speed of motorcycle
105 km/h 65 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
2580 mm / 8 ft 2580 mm / 8 ft
Width
1700 mm / 5 ft 6 in
Height
Height Height
1100 mm / 3 ft 6 in
Road Clearance
125 mm / 5 in
Seat height
Seat height Seat height
840 mm / 33 in
Wheel base
1470 mm / 58 in
ENGINE
Type
4 stroke, overhead valves, opposed twin-cylinder
Displacement
Displacement Displacement
749 cc
Cylinder bore
78 mm
Piston stroke
78 mm
Compression ratio
8.6 :1
Rated horsepower
Rated horsepower Rated horsepower
23 KW / 45 BHp
Rated rotational speed
Rated rotational speed Rated rotational speed
5600 RPM
Rated torque
52 N -M @ 3750 RPM
Lubrication system
Dual system of forced lubrication and splash ing
Lubricant
Lubricant Lubricant
SAE 20W/50
CARBURETOR
Carburetor type
32 CVK Keihin
Number of carburetors
2
Air cleaner
Air cleaner Air cleaner
Paper Filter Element
Fuel
91 octane premium unleaded gasoline
PCV Valve
Internal Breather

12
ELECTRICAL
Ignition system
Electronic Ignition
Spark plugs
NGK BP7HS or Equivalent
Ignition timing
Automatic advance
Alternator
Alternator Alternator
50 amp / 14 Volt
Battery
Interstate FAYTX-20HL or equivalent
Headlight
Headlight Headlight
Wagner, 7" round sealed beam
TRANSMISSION
Clutch
Dry double-disk clutch
Gearbox
4 speed gearbox with reverse
GEAR RATIOS
I gear
I gear I gear
3.6
II gear
II gear II gear
2.28
III gear
III gear III gear
1.56
IV gear
IV gear IV gear
1.19
Reverse gear
Reverse gear 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 / 105 ml 3.5 Oz / 135 ml
Shock Absorbers (shock oil) 105 ml / 3.5 oz 105 ml / 3.5 oz
Brake Reservoir
Brake Reservoir Brake Reservoir
DOT 3 or 4 brake  uid to upper line
12
ELECTRICAL
Ignition system
Electronic Ignition
Spark plugs
NGK BP7HS or Equivalent
Ignition timing
Automatic advance
Alternator
Alternator Alternator
50 amp / 14 Volt
Battery
Interstate FAYTX-20HL or equivalent
Headlight
Headlight Headlight
Wagner, 7" round sealed beam
TRANSMISSION
Clutch
Dry double-disk clutch
Gearbox
4 speed gearbox with reverse
GEAR RATIOS
I gear
I gear I gear
3.6
II gear
II gear II gear
2.28
III gear
III gear III gear
1.56
IV gear
IV gear IV gear
1.19
Reverse gear
Reverse gear 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 / 105 ml 3.5 Oz / 135 ml
Shock Absorbers (shock oil) 105 ml / 3.5 oz 105 ml / 3.5 oz
Brake Reservoir
Brake Reservoir Brake Reservoir
DOT 3 or 4 brake  uid to upper line

13
RUNNING GEAR
Frame
Tubular welded
Rear wheel suspension
Swing arms with
spring shock absorbers
Front fork
Leading link
Sidecar
Sidecar Sidecar
Cushioned body (on rubber
cushions) and wheel with
hydraulic spring shock absorber
Sidecar drive
Steel shaft driven by  nal drive. User Selectable for (Patrol
and Gear Up only)
engagement.
Brakes
Disc-type with hydraulic drive on front, Shoe type with
mechanical drive on rear and side car wheels
Tires
4” x 19”
Front 32 psi cold (1.5 Bar / 150 kPa)
Front 32 psi cold
Side 30 psi cold (1.5 Bar / 150 kPa)
Side 30 psi cold
Rear 40 psi cold (2.5 Bar / 250 kPa)
Rear 40 psi cold
CLEARANCES
mm
in
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  nal drive
0.1 - 0.3
0.004
FREE TRAVEL / ADJUSTMENTS
mm
in
Hand brake control lever
5 - 8
0.2 - 0.3
Clutch control lever
Clutch control lever Clutch control lever
5 - 8
0.2 - 0.3
Foot brake drive pedal
 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
13
RUNNING GEAR
Frame
Tubular welded
Rear wheel suspension
Swing arms with
spring shock absorbers
Front fork
Leading link
Sidecar
Sidecar Sidecar
Cushioned body (on rubber
cushions) and wheel with
hydraulic spring shock absorber
Sidecar drive
Steel shaft driven by  nal drive. User Selectable for (Patrol
and Gear Up only)
engagement.
Brakes
Disc-type with hydraulic drive on front, Shoe type with
mechanical drive on rear and side car wheels
Tires
4” x 19”
Front 32 psi cold (1.5 Bar / 150 kPa)
Front 32 psi cold
Side 30 psi cold (1.5 Bar / 150 kPa)
Side 30 psi cold
Rear 40 psi cold (2.5 Bar / 250 kPa)
Rear 40 psi cold
CLEARANCES
mm
in
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  nal drive
0.1 - 0.3
0.004
FREE TRAVEL / ADJUSTMENTS
mm
in
Hand brake control lever
5 - 8
0.2 - 0.3
Clutch control lever
Clutch control lever Clutch control lever
5 - 8
0.2 - 0.3
Foot brake drive pedal
 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

14
14

15
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
 y 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
 nal 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
en gine sump
14 to 19 Nm
10 ft/lb to 14 ft/lb
 nal drive case nuts
25 to 30 Nm
18 ft/lb to 22 ft/lb
nut fastening pinion bearing
(Patrol, Gear Up rear axle)
68 to 90 Nm
50 ft/lb to 66 ft/lb
nut fastening pinion bear ing
22 to 27 Nm
16 ft/lb to 20 ft/lb
re verse 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
15
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
 y 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
 nal 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
en gine sump
14 to 19 Nm
10 ft/lb to 14 ft/lb
 nal drive case nuts
25 to 30 Nm
18 ft/lb to 22 ft/lb
nut fastening pinion bearing
(Patrol, Gear Up rear axle)
68 to 90 Nm
50 ft/lb to 66 ft/lb
nut fastening pinion bear ing
22 to 27 Nm
16 ft/lb to 20 ft/lb
re verse 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

16
16

17
Chapter 2
MOTORCYCLE CONTROLS & INSTRUMENTATION
Fig ure 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 lamp
15 - “High-low” beam switch
5 - Front brake control lever
16 - Clutch control lever
6 - Throttle control twist grip
17 - Steering damper tightening bolt
7 - Ignition cutoff switch
18 - High-beam indicator lamp
8 - Electric Start Button
19 - Ignition Switch
9 - Rear brake pedal & sidecar wheel brake
20 - Battery discharge warning lamp
10 - Reverse gear lever
21 - Parking brake
11 - Kick start lever
1
2
3
4
5
6
7
7
8
9
9
10
10
11
12
13
14
15
16
16
17
17
18
19
19
20
21
17
Chapter 2
MOTORCYCLE CONTROLS & INSTRUMENTATION
Fig ure 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 lamp
15 - “High-low” beam switch
5 - Front brake control lever
16 - Clutch control lever
6 - Throttle control twist grip
17 - Steering damper tightening bolt
7 - Ignition cutoff switch
18 - High-beam indicator lamp
8 - Electric Start Button
19 - Ignition Switch
9 - Rear brake pedal & sidecar wheel brake
20 - Battery discharge warning lamp
10 - Reverse gear lever
21 - Parking brake
11 - Kick start lever
1
2
3
4
5
6
7
7
8
9
9
10
10
11
12
13
14
15
16
16
17
17
18
19
19
20
21

18
Clutch Control Lever
Clutch Control Lever Clutch Control Lever
Font Brake Control Lever
Clutch control lever:
When the clutch lever is squeezed, the engine is dis en gaged from the gear-
box. 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:
B
EFORE 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 dam-
age 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 ac tu at ed. The
front brake should be used together with rear brake. When the brake lever is squeezed, the stop signal
lights are switched on.
18
Clutch Control Lever
Clutch Control Lever Clutch Control Lever
Font Brake Control Lever
Clutch control lever:
When the clutch lever is squeezed, the engine is dis en gaged from the gear-
box. 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:
B
EFORE 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 dam-
age 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 ac tu at ed. The
front brake should be used together with rear brake. When the brake lever is squeezed, the stop signal
lights are switched on.

19
Kickstart lever
: Designed to start the engine. Upon kicking the lever the crankshaft is actuated
through the gearbox. The lever is returned to its initial position by the spring inside the gearbox.
Gear shift lever:
This is a heal shift type of lever. To shift up from a low gear to a high gear the
rear arm(heal shift) is pressed. To shift down from a high gear to a low gear the from arm is depressed.
Since the heel-toe shift lever is short-coupled, it is much easier to shift up using the heal shift, and to
shift down using the toe shift with the ball of your foot. The neu tral gear is be tween the 1
st
and 2
st and 2 st
nd
gears. It is important to shift smoothly with a constant force, and not to kick the gear shift pedal. Seri-
ous damage may result to the shifting mechanism if the gear shift pedal is kicked, rather than pressed.
NOTE: The neutral lamp will illuminate when the transmission is in neu tral. (see “Start-
ing the Engine”).
Gear Shift Foot Pedal
Kick Lever
Kick Lever
19
Kickstart lever
: Designed to start the engine. Upon kicking the lever the crankshaft is actuated
through the gearbox. The lever is returned to its initial position by the spring inside the gearbox.
Gear shift lever:
This is a heal shift type of lever. To shift up from a low gear to a high gear the
rear arm(heal shift) is pressed. To shift down from a high gear to a low gear the from arm is depressed.
Since the heel-toe shift lever is short-coupled, it is much easier to shift up using the heal shift, and to
shift down using the toe shift with the ball of your foot. The neu tral gear is be tween the 1
st
and 2
st and 2 st
nd
gears. It is important to shift smoothly with a constant force, and not to kick the gear shift pedal. Seri-
ous damage may result to the shifting mechanism if the gear shift pedal is kicked, rather than pressed.
NOTE: The neutral lamp will illuminate when the transmission is in neu tral. (see “Start-
ing the Engine”).
Gear Shift Foot Pedal
Kick Lever
Kick Lever

20
Parking Brake Sidecar Drive Lever
Parking Brake Sidecar Drive Lever Parking Brake Sidecar Drive Lever
Rear Brake Pedal
Parking Brake:
Used to hold the bike when parked. To engage, press the rear brake pedal, push
down and twist the parking brake lever counter clockwise.
Sidecar drive engagement lever:
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.
Rear brake lever:
Actuates the rear brakes on both the motorcycle and sidecar.
WARNING:
DO NOT 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:
AN IMPROPERLY ADJUSTED REAR BRAKE PEDAL COULD INTERFERE WITH PROPER REAR
BRAKE OPERATION RESULTING IN POOR BRAKE ACTION.
20
Parking Brake Sidecar Drive Lever
Parking Brake Sidecar Drive Lever Parking Brake Sidecar Drive Lever
Rear Brake Pedal
Parking Brake:
Used to hold the bike when parked. To engage, press the rear brake pedal, push
down and twist the parking brake lever counter clockwise.
Sidecar drive engagement lever:
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.
Rear brake lever:
Actuates the rear brakes on both the motorcycle and sidecar.
WARNING:
DO NOT 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:
AN IMPROPERLY ADJUSTED REAR BRAKE PEDAL COULD INTERFERE WITH PROPER REAR
BRAKE OPERATION RESULTING IN POOR BRAKE ACTION.