URAL Motorcycles BC-75 (BAVARIAN CLASSIC) User manual

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URAL Classic Motorcycles
Owner’s Manual
2002 Models (All States)
BC-75 (Bavarian Classic)
LC-75 (Luxury Cruiser)
Tourist, Adirondac & Patrol
Classic Motorcycles & Sidecars, Inc.
P.O. Box 969
Preston, WA98050
www.ural.com

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Contents
Introduction ............................................................................................................................................................. 7
Warnings,Cautions,Notes....................................................................................................................................... 9
Chapter 1 Specifications
Specifications .........................................................................................................................................................11
TorqueSpecifications............................................................................................................................................. 14
Conversions .......................................................................................................................................................... 14
Chapter 2 Motorcycle Controls & Instrumentation
MotorcycleControls&Instrumentation.................................................................................................................. 15
Controls ................................................................................................................................................................ 16
Chapter 3 Engine Operation & Maintenance
EngineOperationandMaintenance ........................................................................................................................ 19
Pre-TripPreliminaries ............................................................................................................................................ 19
StartingtheEngine ................................................................................................................................................. 19
OperatingPrecautions............................................................................................................................................ 21
Running-IntheNewMotorcycle ............................................................................................................................ 22
Chapter 4 Design & Maintenance
Brief Descriptionof Design& Maintenance .......................................................................................................... 23
Engine ................................................................................................................................................................... 23
LubricationSystem ................................................................................................................................................ 23
FuelSystem........................................................................................................................................................... 24
IgnitionSystem ...................................................................................................................................................... 25
Chapter 5 Carburetors
Carburetors ........................................................................................................................................................... 25
Chapter 6 Power Transmission
PowerTransmission ............................................................................................................................................... 27
Clutch ................................................................................................................................................................... 27
Gearbox ................................................................................................................................................................ 27
FinalDrive............................................................................................................................................................. 27
Chapter 7 Running Gear
RunningGear......................................................................................................................................................... 29

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Motorcycleand Sidecar Frames ............................................................................................................................ 29
Spring-LoadedHydraulic ShockAbsorber............................................................................................................. 29
AdjustmentofSidecarInstallation ........................................................................................................................ ..30
FrontFork ............................................................................................................................................................ 31
SteeringHeadBearings.......................................................................................................................................... 31
Chapter 8 Wheel & Tires
WheelsandTires ................................................................................................................................................... 33
Tire Data ................................................................................................................................................................34
RunningGearMaintenance .................................................................................................................................... 35
Chapter 9 Controls & Instruments
HandleBar andControls ....................................................................................................................................... 37
Brakes .................................................................................................................................................................. 37
BrakeAdjustment .................................................................................................................................................. 37
ControlCableAdjustment...................................................................................................................................... 38
ControlCableMaintenance ................................................................................................................................... 39
Speedometer ......................................................................................................................................................... 39
Chapter 10 Electrical
ElectricalEquipment .............................................................................................................................................. 41
ElectricalSymbols ................................................................................................................................................. 42
Electrical Circuits.....................................................................................................................................................42
ElectricalEquipmentMaintenance .......................................................................................................................... 43
ElectronicIgnition .................................................................................................................................................. 43
IgnitionTiming ....................................................................................................................................................... 44
ElectronicIgnitionComponents .............................................................................................................................. 45
ElectricalWiringDiagram ....................................................................................................................................... 47
Chapter 11 Maintenance
MaintenanceofMotorcycle ................................................................................................................................... 49
ListofRecommendedLubricants ........................................................................................................................... 49
LubricationChart................................................................................................................................................... 50
RequiredLubrication ............................................................................................................................................. 52
Careof MotorcyclePaint....................................................................................................................................... 52
Preservationand Storage ....................................................................................................................................... 53
Battery .................................................................................................................................................................. 53
Listof IndividualToolSet, SpareParts,Accessories&Documents......................................................................... 54
Chapter 12 Patrol Motorcycle With Engageable Sidecar Drive
Patrol Motorcyclewith EngageableSidecar Drive ................................................................................................. 57
Description ............................................................................................................................................................ 57
HandlingDifferencesfromtheSingleWheelDrive .................................................................................................. 57
SidecarMaintenance ............................................................................................................................................. 58

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Chapter 13 Learning to Ride the URAL
LearningtoRidetheUralMotorcyclewithSidecarAccessory ................................................................................ 59
SafeOperatingRules ............................................................................................................................................. 60
Chapter 14 Warranty
Warranty............................................................................................................................................................... 63
Terms Used in thisWarranty Section .................................................................................................................. 63
Warranty Responsibilities ..................................................................................................................................... 63
Warranty Disclaimers, Limitations& Exclusions .................................................................................................. 65
Distributors Limited Warranties - New Motorcycle ............................................................................................. 66
Warranty Time Period .......................................................................................................................................... 67
Distributor’s Limited Warranties - MotorcycleTires............................................................................................ 67
Distributor’s LimitedWarranties Emission Control System.................................................................................. 69
Distributor’s Limited Warranties - Noise Control Systems .................................................................................. 70
Distributor’s Limited Warranties - Replacement Parts ......................................................................................... 71
Distributor’s Limited Warranties - UralAccessories ............................................................................................ 71
EPANoise Regulations......................................................................................................................................... 72
Classic Motorcycles Emission Control System Waranty ...................................................................................... 73
Classic Motorcycles Noise Control SystemWarranty ........................................................................................ 75
Reporting Safety Defects...................................................................................................................................... 75
ManufacturersWarranty Coverage ...................................................................................................................... 75
Chapter 15 Service Coupons
ServiceCoupons ................................................................................................................................................... 79
NewAddress Form ............................................................................................................................................... 89
New OwnerForm ................................................................................................................................................. 91
URALStartingandRunningTips .................................................................................................... InsideBack Cover

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INTRODUCTION
WelcometotheURALMotorcycling Family! Your new Uralmotorcycleconformsto all applicable US
FederalMotor VehicleSafetyStandardsand USEnvironmentalProtectionAgencyregulations effective
onthedate of manufacture. This manual covers theTourist, BC-75LC-75Adirondac,and Patrol.
Thismanual has been prepared toacquaintyouwith the operation, care andmaintenanceofyourmotor-
cycle,and to provideyouwith important safetyinformation. Followthese instructions carefullyformaxi-
mummotorcycle performance and foryourpersonalmotorcycling safety andpleasure. Pleasepay
particularattentionto the section “Learning to Ride the UralMotorcycle with Sidecar” andtheseparate
manual“DrivingtheUralSidecarMotorcycle.” Itiscriticalthatabeginningsidecardriverbecomes
thoroughlyfamiliar with the special operatingcharacteristicsofsidecaroutfits before venturing out onthe
roads.
YourOwner’sManual containsinstructionsforoperation, maintenance and minor repairs. Majorrepairs
requiretheattention of a skilled mechanic and the use of specialtoolsandequipment. YourAuthorized
UralDealerandUralcertifiedServiceCenterhasthefacilities,experienceandgenuineUralpartsneces-
saryto properly renderthisvaluableservice.
TheUralrepresentsanimportant piece of GermanandRussianhistory since it hasbeencontinually
manufacturedwith the same general arrangementandoutwardappearancefor the past 60yearsafter
Russianengineersinitially copied the BMW’s of 1939. It truly is an“instantantique”asmanyofour
ownershave said.
SincetheUralweighs700 lb. empty with the attachedsidecar, has a large frontalareaandis powered by
an old fashioned 745cc engine, itis not afast motorcycle. The UralTourists’topspeedis 65 mph with a
cruisingspeedsof55 mph butonlyafterfaithful adherence to the break-in period.
Ifyouarea vintageenthusiast, collector,localcommuter,hunter,fisherman,have children,grandchildren
or a dog that likes to ride, or you just like to be noticed on a rig that draws a crowd wherever you park,
welcome aboard!
TheclassicboxertwinhasaGermanheritage. Soeffective,simpleandpowerfulisthisdesignthat
Porsche,Volkswagen, andevenHarley(duringthewarwith the XAmodel)madethisdesigntheirchoice.
Thereliabilityandtorque of this elegant motor is due to its original designin1912byMaxFriz, a brilliant
Germanaircraft-enginebuilder. Hedevisedacompactand rugged engine that delivered significant
torquefor its displacement, atlowandconstantrpms, without the gyroeffectsofother twins. The military
andcivilianusesbecamelegendary.The German motorbike builder BMW, began sing the design in their
motorcyclesin1922.
Becauseofits opposed cylinder layout the “Boxer” as itwasdubbed,turnsthecrankshaft in line with the
motorcycle(or airplane!). Thisallowsfora straight-throughshaftconnection from theengine,through the

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gearboxandthrough a stainless steel driveshaft toarearwheelfinaldrive gear in the wheel hub. This
drivetraindesignis exactly like the millions of rear wheel drive automobiles builtoverthepasteighty
years! Itisatimetested,provendrive system made elegantly simple by the “Boxer” opposed cylinder
engine.
Todaythe “Boxer” enginehasevolvedintothe high tech and electronicallysophisticatedandcomplicated
versionsthatcan be found not only inBMWsbutalsoin Porsches, Hondas and others. These are won-
drous engines at wondrousprices! Buttheystillretainthe basic “soul” of Max Friz’sfirst engines. And
althoughitis not as evolved as the most modern “boxers”, the IMZ 750ccistruetotheearlierversionsin
looks,but also hasmanymoderninternal components. These parts,likepistons,rings, valves, valve
seatsandoilseals are modern and western made. The carburetors are made inJapan. Theseparts
maketheenginemorereliable and cleaner.
However, the “boxer” isstillanair cooledpower plant. As suchitmustbecarefullymonitoredduring
operationtoprevent overheating. As the gear making and other machine tools intheUralplantare
“vintage”ones,a careful break-in of the engine is veryimportant. Neglectingtofollowtheprescribed
speedsduringbreak-inor the frequent oil changes will cause this wonderful engine to rebel against its
“abusing”owner. However,bytreatingthe“boxer”with respect and raising it well,youwillberewarded!
Soitstruethat sometimes simple is better, andold fashioned ideas and designshave strong reasons for
theabilityto continue for a long time. It is themainreasonwhyovermillions of Urals have been sold
aroundtheworld.
Anysuggestionsorcommentsarewelcome! Write to us or post an e-mail on the Ural Discussion bulle-
tinboard atwww.ural.com.
Happy Riding!

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Important Notice!
Statementsinthismanualprecededby the following words are of special importance:
WARNING: MEANS THERE IS THE POSSIBILITY OF PERSONAL INJURY TO
YOURSELF OR OTHERS.
CAUTION: Meansthereis the possibility of damagetothevehicle.
NOTE: Other information of particular importance has been placed in
italic type.
CAUTION! During the initial 2,500 km, a fundamental bedding-in of parts for all the mecha-
nisms 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.
Maintenanceintervalsrecommended are based on operational experience under variousclimaticand
roadconditions. However, these intervals may be extended or reduced followingrepeatedchecksofthe
lubricantcondition and generaltechnicalconditionof the motorcycle.
Carefullystudy thisOwner’sManualbefore startingthemotorcycle.
Specificationsanddesignaresubjecttochangewithout notice.

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Chapter 1
SPECIFICATIONS
GENERAL Tourist,Patrol BC-75 & LC-75
&Adirondac
Maximumspeed ofmotorcycle 120km/h 74 mph 120km/h 74 mph
Referencefuelconsumptionat85%of 12.5km/L 29mpg 14 km/L 33 mpg
maximumspeed
Drymass of motorcycle 700lb 680lb.
Maximumload-carryingcapacity 500 lb. /485lb. 400lb.
Noiselevel below80db
OVERALLDIMENSIONS
Length 2500mm/ 8ft
Width 1700 mm / 5 ft 6 in
Height 1100 mm / 3 ft 6 in
RoadClearance 125 mm / 5 in
Seatheight 840 mm / 33 in
Wheel base 1470mm/ 58in
ENGINE
Type 4stroke,overheadvalves,opposedtwin-cylinder
Displacement 745 cc
Cylinder bore 78mm
Pistonstroke 78mm
Compressionratio 8.6 :1
Ratedhorsepower 26 KW / 35 BHp
Ratedrotationalspeed 5600RPM
Ratedtorque 35ft.-lbs@3750RPM
Lubricationsystem Dualsystem offorcedlubricationand splashing
Lubricant SAE 20W/50
CARBURETOR
Carburetor type 32CVKKeihin
Numberofcarburetors 2
Air cleaner PaperFilterElement
Fuel 91octanepremiumunleadedgasoline
PCVValve InternalBreather

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ELECTRICAL
Ignitionsystem 135.3734.COM-2 (CDI)
Ignitioncoil 135.3705-2
Sparkplugs Autolite273
Ignitiontiming Automaticsparktimer
Alternator 35 amp / 12 Volt
Battery Interstate#YTX20L-BSorequivalent
Headlight Sylvania Halogen 6024,7"round sealedbeam
TRANSMISSION
Clutch Drydouble-disk clutch
Gearbox 4 speedgearbox withreversegearlever
GEARRATIOS
Igear 3.6
II gear 2.28
III gear 1.5
IVgear 1.19
Reversegear 4.2
Speedometerdriveratio 0.4
Finaldriveratio 4.62
FLUIDCAPACITIES Tourist,BC-75 Patrol
LC-75Adirondac
Fueltank 5 Gal /19L 5 Gal / 19L
Reserve .5 Gal / 2L .5Gal /2L
Engine 68 oz / 2L 68oz/ 2L
Transmission 34 oz / 1 L 34oz/ 1 L
Finaldrive 3.5 oz /105ml 4.5 oz/135 ml
TelescopicForks N/AonTourist N/AonPatrol
(LC-75& BC-75) 135ml/ 4.5 oz
ShockAbsorbers 105ml/ 3.5 oz 105ml/ 3.5oz

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RUNNINGGEAR Tourist, Patrol & BC-75 & LC-75
Adirondac
Frame Tubularwelded TubularWelded
Rearwheelsuspension Swingarmswith Same
spring shockabsorbers
Frontfork Leadinglink Telescopicspring
Sidecar Cushionedbody(onrubber
cushions)andwheelwith
hydraulicspringshockabsorber
Brakes Shoe-typewithmechanical driveonfront,rearand sidecar
wheels,frontwheelhasdualcams.
Tires 4” x 19” 3.5”x 18”
Front22 psi cold (1.5 Bar/150 kPa) Front22psicold
Side 22 psi cold (1.5 Bar / 150 kPa) Side 22 psicold
Rear 36 psi cold (2.5 Bar / 250 kPa) Rear 36 psi cold
CLEARANCES mm in
Valveswithenginecold 0.05to 0.1 0.002to0.004
Betweensparkplugelectrodes 1.016 0.040
Backlashbetweentoothfaces of
bevel gearsin finaldrive 0.1 - 0.3 0.004
FREETRAVEL/ADJUSTMENTS mm in
Handbrakecontrollever 5 - 8 0.2 - 0.3
Clutchcontrollever 5 - 8 0.2 - 0.3
Footbrake drivepedal ¼ offull strokeof pedal,
25 - 30 1.0 - 1.2
Toe-indistance 10mm 3/8inch
Lean-out 1°away fromsidecar

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TORQUESPECIFICATIONS
Metric USEquivalent Location on Bike
54 to 61 Nm 40 ft/lb to 45 ft/lb cylinderheads
237 to251Nm 175ft/lb to 185ft/lb flywheeltighteningscrews
19 to 30 Nm top 14 ft/lb to 22 ft/lb shockabsorber
38 to 49 Nm bottom 28 ft/lb to 36 ft/lb shockabsorber
30 to 35 Nm 22 ft/lb to 26 ft/lb bearingnut
30 to 35 Nm 22 ft/lb to 26 ft/lb finaldrivetoswingarmbolts
16 to 19 Nm 12 ft/lb to 14 ft/lb oilpumpbolt
6.7 to 11 Nm 5 ft/lb to 8 ft/lb enginesump
14 to 19 Nm 10 ft/lb to 14 ft/lb finaldrivecasenuts
25 to 30 Nm 18 ft/lb to 22 ft/lb nutfasteningthepinionbearing
(Patrol rear axle only)
68 to 90 Nm 50 ft/lb to 66 ft/lb nutfasteningthepinionbearing
22 to 27 Nm 16 ft/lb to 20 ft/lb reversegearbrakelever
19 to 22 Nm 14 ft/lb to 16 ft/lb generatorgearnut
136 to 163 Nm 100ft/lb to 120 ft/lb steeringstemnut
CONVERSIONS
Toconvert frommmto in,divide by25.4 (thereare 25.4mmper inch).
Toconvert fromliterstogallons,divide by3.785(there are3.78liters pergallon).
Toconvert fromliters toquarts,multiplyby1.056(there are1.056 quartsper liter).
Toconvert fromliters topints,multiplyby 2.112(thereare 2.112pintsperliter).
Toconvert fromkm to miles,multiply by.62(thereis.62mileperkm).
Toconvert fromkm/hrto mph,multiplyby .62.
ToconvertfromNewton-meter(Nm)toinch-pound,multiplyby8.86.
ToconvertfromNewton-meter(Nm)tofoot-pound,multiplyby.7376.
To convertfromcm3(cc) to pints,divide by 473(thereare 473 ccper pint).
Toconvert Celcius toFahrenheit: F°=C°x1.8+ 32.
Toconvert FahrenheittoCelcius, C°=(F°−32) divide by1.8.

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Chapter 2
MOTORCYCLE CONTROLS & INSTRUMENTATION
Figure1. 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 and reverse gear engagement 15 - “High-low” beam switch
indicator lamp 16 - Clutch control lever
5 - Front brake control lever 17 - Steering damper tightening bolt
6 - Throttle control twist grip 18 - High-beam indicator lamp
7 - Ignition cutoff switch 19 - Ignition Switch
8 - Electric Start Button 20 - Battery discharge warning lamp
9 - Rear brake pedal & sidecar wheel brake 21 - Parking brake
10 - Reverse gear lever 22-Master battery switch (under seat)
11 - Kick start lever

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CONTROLS
Clutch control lever (Fig.1,#16). Whentheclutch leveris squeezed,the engineisdisengaged
fromthegearbox. Whenthe leverisreleased,theengineandgearbox areengaged.
WARNING: MAKE SURE FINGERS ARE NOT POSITIONED BETWEEN HAND CONTROL LEVERS AND HANDLEBAR
GRIPS OR OPERATION OF VEHICLE COULD BE IMPAIRED.
WARNING: BEFORE STARTING ENGINE, ALWAYS SHIFT TRANSMISSION TO NEUTRAL TO PREVENT ACCIDENTAL
MOVEMENT WHICH COULD CAUSE POSSIBLE DAMAGE TO MOTORCYCLE AND PERSONAL INJURY.
Front brake control lever (Fig.1,#5). Whentheleverissqueezed, thefront wheelbrake is
actuated. Thefrontbrakeshould beusedtogetherwithrearbrake.
Whenthebrakeleveris squeezed,thestopsignallampsareswitchedon.
Kick lever (Fig.1,#11)isdesigned tostartthe engine. Onpressingtheleverthe crankshaftof the
engineisactuated throughthegearbox. The leverisreturned toitsinitial positionbythe spring
inside the gearbox. Note: this is a backup to the electric starter.
Gear shift foot pedal (Fig.1,#12) is a two-armtype. When the frontarm ispressed,shifting
fromhigh tolowergearstakesplace. Whenthereararmispressed,shiftingfromlowtohigher
gearstakes place. Sincethe heel-toeshift leveris short-coupled,you willfind iteasier toshift upif
yourotate theheel ofyour leftfoot intowards therear armbefore steppingon itwith yourheel.
TheneutralpositionisfixedbetweentheIandIIgears.
IMPORTANT! Thegreen pilot lampglows when the transmission is in neutral and when
the reverse gear is engaged (see “Starting the Engine”).
Reverse gear engagement lever (Fig.1,#10) Forwardfor neutraland/orforward runningand
backforreverse. The reversegear may beengaged only afterthe motorcycle iscompletely
stopped!
Toengage reversegear,shiftinto neutral(orfirst), thenpushback thereverselever.
Todisengage thereversegear,pressleverup(forward)tothelimit,then thegearshiftmechanism
isreset tothe neutralposition. Now youcanshiftinto firstgear.
Ifdesired,neutral maybe selectedbyshifting intoreverse whenthefirstgearis engaged,andthen
movingthereversegearleverforwardintoneutral.

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Therear brake pedal (Fig.1,#9) appliestherearwheel andsidecarwheelbrakes simultaneously.
WARNING: DONOT APPLY EITHER BRAKE STRONGLY ENOUGH TO LOCK THE WHEELS BECAUSE THIS MAY
CAUSE POSSIBLE LOSS OF CONTROL OF THE MOTORCYCLE. ALWAYS USE BOTH BRAKES. NEVER STOP WITH
FRONT OR REAR BRAKE ONLY.
WARNING: ANIMPROPERLY ADJUSTED REAR BRAKE PEDAL COULD INTERFERE WITH PROPER REAR BRAKE
OPERATION RESULTING IN POOR BRAKE ACTION.
Tourist, Patrol BC-75
Adirondac & LC-75
Off Allelectricalsystemsare off.
Run Voltageissuppliedtoallelectricalsystems.
Parking Voltageissuppliedto runninglightsonly.
Unused Allelectricalsystems areoff.
Note:Leaving the key inthe Run or Parkingpositionwill discharge thebattery.
Always return the key to the Off position before taking it out.
Speedometer isonthedashboard,withtrip (Note..BC-75 hasnotrip odometer)
andtotalodometer. The tripodometerisresetto zerobyrotatingpush-button(Fig.1, #3) counter-
clockwise. Notethattheodometerreadsinkilometersnotmiles.
Ignition Switch (Fig.1,#19) hasthree fixedpositionsofthekey. Theposition andswitching
diagramoftheignitionlocks areshownabove.

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Theindicatorlampsaremountedontheinstrumentboard:
(Fig. 1, # 2) — turn indicator pilot lamp, (orange)
(Fig. 1, #4) —gearbox neutraland reversegearengagement,(green)
(Fig. 1, #18) —headlamp highbeamindicator,(dark blue)
(Fig. 1, #20) —alternatorfault indicatorlamp,(red)
Note:If the redalternatorfault light stayson continuously duringnormaloperation above ap-
proximately 1500 RPM, there is a problem with the charging system or battery.
Throttle Control (Fig.1,#6) ison therighthandlebar.Turning thetwist gripcounterclockwise
increasesenginespeed.
Ignition Cutoff Switch (Fig.1,# 7)has twopositions, ignitionoff (up),and ignitionon (down).
Low and High Beam Light Switch (Fig.1,# 15),turn indicator switch (Fig.1,#13)andhorn
push-button (Fig.1,#14) arecombined inone unitontheleft-handhandle barcontrol housing.
Master Battery Switch (Fig.1,#21) isunder theseat.
Electric Start Button (Fig.1,#8)is locatedon theright-hand twistgrip, belowthe killswitch.
TheSteering Damper absorbslateralkicksonthefront wheel.Turningtightening bolt(Fig.1,#17)
clockwiseincreasesfriction. Thiscanbeusedwhile ridingover badroads.
WARNING: DONOT TIGHTEN THE DAMPER TO THE POINT WHERE THE STEERING BECOMES STIFF. DOING SO
WILL ADVERSELY AFFECT HANDLING QUALITIES.
Parkingbrake (Fig. 1,# 22)islocated ontheright sideofthe motorcyclenextto thefootpeg. It is
engagedbyapplyingthe footbrakepedalfullyandturningthe handleandpushingit downtohold
thefootbrakeleverintheappliedposition.
Alwaysdisengagetheparkingbrakebeforemovingthemotorcycle.

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Chapter 3
ENGINE OPERATION AND MAINTENANCE
PRE-TRIPPRELIMINARIES
Beforeeachtrip,attend toalltherequirementsoftheeveryday maintenanceasoutlinedinthis
manual. Whenaddingfueland oiltothemotorcycle,takeallprecautions tokeepeverythingneat
andclean.
Gasolinelevelinthetankfullyfilled shouldbe 10- 15mm /½ -¾ in.below theloweredgeofthe
tankfiller. Donotoverfillthetank,especiallyonCaliforniamodelswhereoverfilling cancausefuel
contaminationofthecharcoal cannister. Seethattheoillevel intheenginecrankcase isnothigher
thanthetopandnotlowerthanthebottommarksonthedipstickwiththefillerplugundone.(See
chapter4LubricationSystem)
CAUTION: Whendrainingandrefillingoil , be careful that dirt and debris does not contami-
natethe fresh oil. Do notallow draining oil toget on the rearwheel, tire, or brakecompo-
nents. STARTING THEENGINE
WARNING: BEFORE STARTING THE ENGINE, MAKE SURE THAT THE GEAR SHIFT MECHANISM IS IN THE NEU-
TRAL POSITION (BETWEEN 1ST AND 2ND GEARS) TO PREVENT ACCIDENTAL MOVEMENT WHICH COULD CAUSE
POSSIBLE DAMAGE TO MOTORCYCLE AND PERSONAL INJURY. ( FOR MORE THAN JUST STARTING, I.E. IDLING, IT
IS ADVISABLE TO USE NEUTRAL GEAR.)
Whentheignition isswitchedon, thegreen& redlampson theinstrumentboard shouldlightup.
Makesurethatthereverse gearengagement(lever)isset tothefrontposition.Thisisimportant
sincethegreen lampwill alsobe litifthe motorcycleis inreverse gear. Movingthe reversegear
leverforwardwillputthegearboxinneutral.
Gasolinepetcockpositionsareasfollows:
OFF ON RESERVE

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Dependingontheengineandambient temperature,usethecarburetorenrichenersand starting
procedureasfollows:
ManualStarting(withoutelectricstarter)
1. Turnon theignition anddepress thekick lever(see Fig.1) about
1/4of itstravel (enoughto firmlyget theball ofyour footon thelever) witheither yourleft
footorright foot,dependingon whatpositionis mostcomfortablewith yourrighthand onthe
throttle.Takeuptheslackinthethrottleuntil youcanfeelsome slightresistancefromthe
returnspringsinthecarburetors. However,donotadvancethethrottle,sincethis mayflood
theengine.
Note: You may find it more comfortable to stand on the left passenger foot peg with your right
foot and kick with your left foot.
Givethekick levera swiftkick. Whentheenginestarts, ticklethe throttle(quicklyincrease
anddecreaseit) tokeep theenginerunning,butnot toofast. Iftheenginedoesn’tstart,
repeatthekickingprocedure. Aproperlyadjustedwarmengineshouldstartwithinafew
kicks. Ifthe enginedoesn’tstart, trythe procedure describedbelow in item3. If itstill
doesn’tstart orfire, itmay beflooded.
Note: Donot open the throttlewhile kicking the engineoversince it mayfloodthe spark plugs.
Electric Starting
1.Setcarburetorenricheners aswithkickstarting. Unlikemanualstarting,however,the
gearboxdoesnothave tobein neutralastheelectricstartermaybe engagedwiththeclutch
leverpulledin, orwiththegearboxin neutral. MakesuretheIgnitionCutoff Switchisset to
“Ignition On”and pushthestarter buttonto turnoverthe engine.
2. Whentheenginehas beenstandingforseveralhoursbutthe ambienttemperatureis
high(60°F/15°C degreesor above),trystarting itwithout anyenricheners. If itdoesn’tfire,
thenusetheproceduredescribedbelow.
3. Whentheengine iscoolorcoldand theambienttemperature isbetween40°F-60°F/5°C-
15°C,depressboth enrichenerstostart. Assoonas theenginestarts,immediatelyretract
theenricheners. Run theengine atmoderate speedfor 30-60seconds. If itstarts todie,
blipthetwistgripthrottle(rapidlytwist partwaytowardsfullthrottleandthen backoff)to
keeptheenginerunning. After1to 3minutes,depending onambienttemperature, the
engineshouldrunsmoothlywithout“blipping”thethrottle.
4. Iftheengineiscold andambient temperatureis below40°F, first,givetheengine5-10
(dependingon howcold itis) primingkickswith theignition off. Thiswill getsome oilcircu-
latedtokeyinternalparts. Engagetheenrichenersonbothcarburetors. Theengineshould