URAL Motorcycles 2015 Gear Up User manual

INTRODUCTION
Welcome to the URAL Motorcycling Family! Your Ural has been built by the Irbit
Motorcycle Factory in Russia and distributed by Irbit Motorworks of America, the United
States affiliate of the Irbit Motorcycle Factory.
This Ural motorcycle conforms to all applicable US Federal Motor Vehicle Safety
Standards and US Environmental Protection Agency regulations effective on the date of
manufacture.
This manual covers the Gear-Up, Patrol, and T model and has been prepared to acquaint
you with the operation, care and maintenance of your motorcycle and to provide you
with important safety information. Follow these instructions carefully for maximum
motorcycle performance and for your personal motorcycling safety and pleasure. It is
critical that a beginning sidecar driver becomes thoroughly familiar with the special
operating characteristics of sidecar outfit 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!
Happy Uraling!

IMPORTANT SAFTEY INFORMATION
WE STRORLY SUGGEST THAT YOU READ THIS MANUAL COMPLETELY PRIOR TO RIDING
YOUR NEW URAL MOTORCYLE. THIS MANUAL CONTAINS INFORMATION AND ADVICE
THAT WILL HELP YOU PROPERLY OPERATE AND MAINTAIN YOUR MOTORCYCLE. PLEASE
PAY SPECIAL ATTENTION TO NOTICES IN THIS MANUAL MARKED AS FOLLOWS:
CAUTION
INDICATES POSSIBILITY OF EQUIPMENT FAILURE THAT MAY RESULT IN YOUR
MOTORCYLE BE UNSAFE TO OPERATE IF INSTRUCTIONS ARE NOT FOLLOWED
WARNING
INDICATES A VERY STRONG POSSIBLILITY OF INJURY TO YOURSELF AND OTHERS OR
LOSS OF LIFE IF INSTRUCTIONS ARE NOT FOLLOWED
NOTE
PROVIDES HELPFUL INFORMATION AND TIPS

Table of Contents
Section
General Information
1
Motorcycle Controls and Instrumentation
2
Motorcycle Operation
3
Service & Maintenance Sections
Lubrication
4
Engine & Chassis Maintenance
5
Electrical
6
EFI Troubleshooting
7
Consumer Information Sections
Warranty Information
8
Emission Control Information
9
Owner Documents
10
Schematics
11

1. General Information
Page
Service Rules
1-2
Model Identification
1-3
Model Specifications
1-4
Torque Chart
1-5
Clearance and Adjustment Specifications
1-6
Tire Data
1-6
Periodic Maintenance Chart
1-7
Motorcycle Storage and Care
1-8

SERVICE RULES
1. Always wear proper safety equipment including but not limited to safety glasses
and gloves.
2. Allow your motorcycle to cool down completely prior to servicing to avoid getting
burned.
3. Always use genuine Ural or Ural recommended parts, fluids and components
when servicing your motorcycle. Parts that do not meet these requirements may
result in damage.
4. Follow the service procedures as outlined in this manual.
5. Always follow the torque specifications when tightening nuts and bolts.
6. Clean all parts with non-flammable solvents prior to reassembly after servicing.
7. Always replace seals, O-rings, gaskets and cotter pins when reassembling.
8. If you remove self-locking nuts they should always be replaced with new ones.
9. Be responsible with solvents, cleaners and waste oils. Always dispose of them in
accordance with your local regulations.
WARNING
IF THE ENGINE MUST BE RUNNING TO PREFORM A PARTICULAR SERVICE
PROCEEDURE BE SURE YOU ARE IN A WELL VENTALATED AREA. EXHAUST
CONTAINS CARBON MONOXIDE GAS.
WARNING
GASOLINE IS VERY FLAMMABLE AND CAN BE EXPLOSIVE UNDER CERTAIN CONDITIONS.
IT IS ALSO VERY HARMFUL TO THE SKIN AND EYES. DO NOT SMOKE OR ALLOW SPARKS
IN OR NEAR YOUR WORK AREA.

MODEL IDENTIFICATION
VIN (Vehicle Identification Number)
The VIN label is located on the right hand
frame down tube and is also stamped on the
frame directly above the label.
List Your VIN Here
Engine Number
The engine number is stamped near the
crankcase breather, it is the second number.
List Your Engine Number Here
Gearbox Number
The gearbox number is stamped on the left
side of the gearbox directly above the shift
lever.
List Your Gearbox Number Here

MODEL SPECIFICATIONS
Model cT Patrol, Gear-Up
Engine and transmission
Displacement, cc 749 749
Engine type
OHV air cooled 2 cylinder 4 stroke "boxer"
(flat twin)
OHV air cooled 2 cylinder 4 stroke "boxer"
(flat twin)
Valve per cylinder 2 2
Bore and stroke (mm x mm) 78 x 78 78 x 78
Max output (hp) 41 @ 5500 rpm 41 @ 5500 rpm
Max torque (ft-lbs) 42 @ 4300 rpm 42 @ 4300 rpm
Compression 8.6:1 8.6:1
Fuel system Throttle body EFI Throttle body EFI
Starting Electric & Kick start Electric & Kick start
Clutch Double-disc dry Double-disc dry
Transmission type Manual Manual
Speeds 4 forward 1 reverse 4 forward 1 reverse
Primary drive (rear wheel) Driveshaft Driveshaft
Final drive ratio 4.62 4.62
Engagable sidecar wheel drive No Yes, driveshaft
Physical measures
Overall length, inch. 91.6 98.8
Overall heights, inch. 53.8 54.3
Overall width, inch. 63.6 63.6
Seat height, (unladen), inch. 31.0 32.0
Ground clearance (unladen), inch. 6.2 6.8
Dry weight, lbs 700 730
Chassis
Front suspension IMZ leading link fork IMZ leading link fork
Rear suspension
Double sided swing-arm with two Sachs
hydraulic spring shock absorbers, 5x
adjustable
Double sided swing-arm with two Sachs
hydraulic spring shock absorbers, 5x
adjustable
Sidecar suspension
Single sided swing-arm with Sachs
hydraulic spring shock absorber, 5x
adjustable
Single sided swing-arm with Sachs
hydraulic spring shock absorber, 5x
adjustable
Wheels 2.5X19 Aluminum rims with steel spokes 2.5X19 Aluminum rims with steel spokes
Tires Duro HF-308, 4.0x18" Duro HF-308, 4.0x19"
Front brake
4-piston fixed Brembo caliper with
295mm floating NG rotor
4-piston fixed Brembo caliper with
295mm floating NG rotor
Rear brake
HB big bore single piston integrated
floating caliper with 256mm fixed NG
rotor
HB big bore single piston integrated
floating caliper with 256mm fixed NG
rotor
Sidecar brake
2-piston fixed Brembo caliper with
245mm floating NG rotor
2-piston fixed Brembo caliper with
245mm floating NG rotor
Other
Fuel grade 91 Octane, unleaded 91 Octane, unleaded
Fuel tank capacity (gallons) 5.0 5.0
Reserve (gallons) app. 1 app. 1
Estimated fuel economy, mpg 31-37 31-37
Estimated range, miles 155-185 155-185
Recommended max cruising speed (mph)
70 70
Max permissible weight, lbs 1325 1325
Trunk volume, cubic ft. 2.9 2.9
Electrical
Alternator Denso, Peak Output 40 Amp @ 14vdc, 560 Wt Denso, Peak Output 40 Amp @ 14vdc, 560 Wt
Battery FAYTX20HL (12V, 20A) FAYTX20HL (12V, 20A)
Headlight H6024 (65/35) H6024 (65/35)
Spark plugs NGK BPR6HS NGK BPR6HS
Warranty 2-years parts and labor unlimited mileage 2-years parts and labor unlimited mileage

TORQUE SPECIFICATIONS
Chassis Newton Meters Foot Pounds
Fork Pinch Bolts (Upper and Lower Bridges) 50 36.9
Upper fork Nuts 30 22.1
Steering Head Nut 34 25.1
Front fork Upper Shock Bolts 49 36.1
Upper Shock Bolts 30 22.1
Lower Shock Bolts 49 36.1
Front and Rear Brake Caliper Bracket Bolts 50 36.9
Rear Caliper Mounting Bolts 50 36.9
Front Caliper Mounting Bolts 50 36.9
Sidecar Caliper Mounting Bolts 50 36.9
Front Brake Reaction Link 70 51.6
Brake Rotors 30 22.1
Rear Swing Arm Mounting Bolts 88 64.9
Sidecar Swing Arm Mounting Bolts 88 64.9
Front Fork to Pivot of Swing Arm Mounting Bolts 50 36.9
Lower Sidecar Frame Mounting Bolts 88 64.9
Sidecar Strut Mounting Bolts 88 64.9
Spoke Nipple 4 to 6 2.9 to 4.4
Drive Train
Engine. Gearbox. and Final Drive Drain Plugs 22 16.2
Cylinder Head Nuts 50 36.9
Valve Cover Nuts 24 17.7
Oil Pump Drive Gear Cap Bolt 10 7.4
Final Drive to Swing Arm Mounting Nuts 35 25.8
Final Drive Case Nuts 24 17.7
Engine Sump 10 7.4
Alternator Mounting Nuts 22 16.2
Intake Flange Mounting Bolts 20 14.8
Exhaust Header Pipe Nuts 24 17.7
Exhaust Mounting Clamp Bolts 16 11.8
Drive Wheel Splines (Spline Flanges) 30 22.1

CLEARANCES
Location
Millimeters
Inches
Intake Valves (Cold)
.1
.004
Exhaust Valves (Cold)
.1
.004
Spark Plug Electrode
1.00
0.04
Minimum Tread Depth
3.175
0.125
Minimum Brake Pad Thickness
1
0.04
FREE PLAY & ADJUSTMENTS
Location
Millimeters
Inches
Front Brake Lever
5 to 8
.2 to .3
Clutch Lever
5 to 8
.2 to .3
Rear Brake Lever
1/4 of Full Travel
1/4 of Full Travel
Toe-In (1wd)
8 to 12
.3 to .475
Toe-In (2wd)
3 to 8
.125 to .315
Lean Out
1 to 2 degrees
1 to 2 degrees
TIRE DATA
Location
Type
Recommended PSI
Front
Duro H-308 (4.0x19 or 4.0x18 cT)
32 PSI Cold
Rear
Duro H-308 (4.0x19 or 4.0x18 cT)
40 PSI Cold
Sidecar
Duro H-308 (4.0x19 or 4.0x18 cT)
32 PSI Cold
Spare (if equipped)
Duro H-308 (4.0x19 or 4.0x18 cT)
40 PSI Cold
Optional Knobby Tires
Duro H-308 (4.0x19 or 4.0x18 cT)
Per location on bike
WARNING
IMPROPER TIRE INFLATION WILL CAUSE ABNORMAL TREAD WEAR AND COULD
RESULT IN UNSTABLE HANDLING. UNDER-INFLATION COULD RESULT IN THE TIRE
SLIPPING ON THE RIM.

PERIODIC MAINTENANCE CHART
Description Odometer reading, km (miles)
New 1000 (625) 5000 (3125) 10000 (6250) 15000 (9375) 20000 (12500) 25000 (15625) 30000 (18750)
Check the painted and chromed surfaces for
dents, scratches and rust
I I I I
Engine oil* I R R R R R R R
Oil filter* R R R R R R R
Final drive and gearbox oil I R I R I R I R
Check valve clearance I I I I I I I
Check tightness of the cylinder stud nuts I I I I I I I
Spark plugs I I R I R I R
Fuel tank filter I I I I
In-line fuel filter R R R
Ignition timing I I I
Air filter* I I R I R I R
Check fuel hoses I I I I I I I
Compliance flanges (check for cracks and other
damage)
I I R I R I R
Throttle body synchronization I I I I I I I
Shock absorbers I I
Inspect wheels and tires (tire pressure , tire wear,
rims breakage and bents, wheel balancing)*
I I I I I I I I
Tightness of spokes I I I I I I I
Tightness of fasteners I I I I I I I I
Disc brake (pads, disc, hoses, calipers and
cylinders, lever travel)
I I I I I I I
Brake fluid level* I I I I I I I/R
Check operations of parking brake I I I I
Front fork oil R
Clutch, throttle and odometer cables, clutch lever
travel
I I I I I I I I
Bearings of the motorcycle and sidecar swing
arms. 2wd linkage on 2wd models, Retro reverse
linkage
I I I
Steering head bearings I I I
Wheel bearings I I I
Sidecar alignment I I I
Battery (charge level, contacts) * I I I I I I I
Electrical equipment I I I I I I I I
Headlight position I I I I I I I I
Lubrication of lever axels, cable ends, rear brakes
cams, splined parts of the drive shafts and hubs,
drive shaft U-joints*
I/L I/L I/L
Test drive P P P P P P P P
I - Inspect, if necessary – adjust, clean or replace R – Replace * - Also repeat after 1 year in use and after long storage
L – Lubricate P – Perform **- Also inspect when replacing tires

MOTORCYCLE STORAGE AND CARE
Storage
If you will be storing your motorcycle for the winter or long term, take the following
steps:
1. The motorcycle should be cleaned.
2. Check all fluid levels and add as necessary.
3. Check tire pressure.
4. Lubricate all shafts, splines, cables and joints.
5. Use a battery maintenance charger or disconnect battery.
6. Always store in a warm dry place to avoid rust and moisture build up.
7. Use a protective cover when needed.
After storage take the following steps prior to running your motorcycle:
1. Perform the pre-ride inspection.
2. Reconnect battery and/or disconnect charger.
3. Follow starting procedures.
4. Take the motorcycle for a short ride prior to any long trips.
CLEANING
It is important to maintain your motorcycle properly and clean on a regular basis. Use
the following guidelines when washing your motorcycle:
Make sure the engine is completely cool
Use warm soapy water and wash thoroughly
Avoid water from entering the air filter and electrical components
After washing dry the motorcycle with a cloth
Lubricate joints and cables as necessary
Run motorcycle to evaporate remaining water
WINTER CONSIDERATIONS
Motorists in many areas of the US experience the use of salt and other chemicals that
are applied to road surfaces in the winter. Salt and other caustic chemicals should
always be washed of you bike with fresh water as soon as possible to avoid rust and
corrosion.
NOTE
RUSTED OR CORRODED PARTS CAUSED BY SALT ARE NOT COVERED BY WARRANTY.

2. Motorcycle Controls & Instrumentation
Page
Hand Controls
2-2
Foot Controls
2-3
Ignition Switch
2-4
Speedometer
2-4
Indicator Lamps
2-5
Hydraulic Steering Damper
2-5
Parking Brake
2-6
Reverse Lever
2-6
Kick Starter
2-7
2wd Engagement Lever
2-7
Hydraulic Spring Shock Absorbers
2-8

HAND CONTROLS
Clutch Lever
Pulling the clutch lever will disengage the
clutch while releasing the lever will engage
the clutch.
High Beam Switch
Toggle the switch forward to turn on the
high beam and toggle back for “Flash to
Pass” feature.
Horn Button
Press the button to sound the horn.
Turn Signal Switch
Switch left or right to indicate turns and
push the button to cancel.
Left Hand Grip
Place you left hand on the grip to steer and
control the motorcycle.
Front Brake Lever
Pulling the lever will actuate the front
brakes.
WARNING
IF THE BRAKE LEVER FEELS SPONGY DO NOT
RIDE THE BIKE AND CONTACT YOUR
DEALER.
Starter Button
Press the button to engage the starter
motor.
CAUTION
DO NOT RUN STARTER FOR MORE THAN 5
SECONDS.
WARNING
WHEN USING THE STARTER ALWAYS BE
SURE THE GEARBOX IS IN NEUTRAL.
Engine “STOP” Switch
Toggle the switch forward to stop the
engine, toggle back to run.
Throttle Grip
Place your right hand on the grip to steer
and control the motorcycle. Rotate the grip
back to open the throttle.

FOOT CONTROLS
Shift Lever
This is a heel-toe type shifter, to upshift
use the heal portion of the shift lever, to
down shift use the toe portion of the
shifter.
Rear Brake Lever
Pressing the rear brake lever actuates the
rear and sidecar brakes.
WARNING
IF THE BRAKE LEVER FEELS SPONGY DO
NOT RIDE THE BIKE AND CONTACT YOUR
DEALER.

IGNITION SWITCH
SPEEDOMETER
Speedometer Indicator
Displays motorcycle speed in both miles per
hour and kilometers.
Odometer
The odometer displays total motorcycle
Kilometers.
Trip Meter
The trip meter displays the total trip
Kilometers and can be reset by twisting the
reset knob on the right hand fork cover.
(3 Position Switch)
In the “Off” position the engine cannot be
started.
In the “On” position the engine can be
started and all electrical functions can be
used.
In the “Park” position only the running
lamps (not including headlight) are
illuminated.

INDICATOR LAMPS
HYDRAULIC STEERING DAMPER
Low Fuel Level Indicator
While on Level ground lamp will flash when
fuel level is low and become solid when on
reserve level (app. 1 Gal.)
NOTE
FUEL LAMP CAN GIVE FALSE INDICATION
DUE TO SLOSHING WHILE RIDING. CHECK
LAMP ON LEVEL GROUND.
Gearbox Neutral Indicator
Lamp will illuminate when gearbox is in
neutral.
Charging System Failure Indicator
Lamp will illuminate if the alternator fails.
High Beam Indicator
Lamp will illuminate when high beam is on.
Turn Signal Indicator
Lamp flashes when signals are active.
Engine “MIL” Indicator
If lamp illuminates while engine is running
refer to “Troubleshooting” section of this
manual.
Adjustable Damper (16 Position)
The steering damper is fully adjustable to
accommodate different riding styles and
conditions.
Rotate the adjustment rod clockwise to
increase dampening and counter clockwise
to reduce dampening.
CAUTION
OVER ROTATION OF THE ADJUSTMENT ROD
CAN DAMAGE THE DAMPER AND/OR
CAUSE FLUID LEAKS.

PARKING BRAKE
REVERSE LEVER
Parking Brake Lever
The parking brake lever is located on the
right side of the motorcycle near the side
panel.
Pulling the handle up to the lock position
sets the parking brake.
Release the parking brake by lowering the
lever to the down position as shown.
CAUTION
OPERATING THE MOTORCYCLE WHILE
THE PARKING BRAKE IS ENGAGED CAN
DAMAGE THE BRAKE SYSTEM.
Reverse Engagement Lever
The reverse lever is located on the right
side of the gearbox near the foot peg.
Pulling the lever back while in Neutral will
engage the reverse gear.
Push the lever forward to put the gearbox
back into Neutral and use forward gears.
CAUTION
THE REVERSE LEVER MUST BE IN THE
FULL FORWARD POSITION FOR THE
GEARBOX TO SHIFT PROPERLY.

KICK START LEVER
2WD ENGAGEMENT LEVER
2wd Engagement Lever
Shifting the lever into the rear locked
position will engage 2wd.
Move the lever to the forward position to
dis-engage 2wd.
CAUTION
2WD SHOULD ONLY BE USED FOR LOOSE
ROAD CONDITIONS AND/OR OFF ROAD
PURPOSES.
WARNING
USE OF 2WD ON THE STREET CAN MAKE
THE MOTORCYLE DIFFICULT TO STEER
POSSIBLY RESULTING IN LOSS OF
CONTROL.
Kick Start Lever
To use the kick start lever rapidly press the
lever downward with you right foot as
shown.
WARNING
WHEN USING THE KICK STARTER ALWAYS
BE SURE THE GEARBOX IS IN NEUTRAL.

HYDRAULIC SPRING SHOCK ABSORBERS
Adjustable Shock Absorbers
The shock absorbers have 5 preload
adjustments.
Rotate the adjustment ring counter
clockwise as shown to increase spring
preload using the supplied wrench in your
tool kit.