URAL Motorcycles Deco 2001 User manual

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URAL Classic Motorcycles
Owner’s Manual
2001 Models (All States)
Deco & Bavarian Classic
Tourist & Patrol
Classic Motorcycles & Sidecars, Inc.
P.O. Box 969
Preston, WA 98050
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
Chapter 3 Engine Operation & Maintenance
EngineOperationandMaintenance ........................................................................................................................ 19
Pre-TripPreliminaries ............................................................................................................................................ 19
StartingtheEngine ................................................................................................................................................. 19
OperatingPrecautions............................................................................................................................................ 21
Running-IntheNewMotorcycle ............................................................................................................................ 22
Chapter 4 Design & Maintenance
BriefDescriptionofDesign&Maintenance ............................................................................................................ 23
Engine ................................................................................................................................................................... 23
LubricationSystem ................................................................................................................................................ 23
FuelSystem........................................................................................................................................................... 24
Air Cleaner..............................................................................................................................................................25
IgnitionSystem ...................................................................................................................................................... 26
Chapter 5 Carburetors
Carburetors ........................................................................................................................................................... 26
Chapter 6 Power Transmission
PowerTransmission ............................................................................................................................................... 29
Clutch ................................................................................................................................................................... 29
FinalDrive............................................................................................................................................................. 29
Chapter 7 Running Gear
RunningGear......................................................................................................................................................... 31
Motorcycleand SidecarFrames ............................................................................................................................ 31
AdjustmentofSidecarInstallation ........................................................................................................................ ..32
Front Fork ............................................................................................................................................................ 33
SteeringHeadBearings.......................................................................................................................................... 33

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Chapter 8 Wheel & Tires
WheelsandTires ................................................................................................................................................... 34
Tire Data ................................................................................................................................................................36
RunningGearMaintenance .................................................................................................................................... 37
Chapter 9 Controls & Instruments
ControlLevers andCables .................................................................................................................................... 39
HandleBar andControls ....................................................................................................................................... 39
Brakes .................................................................................................................................................................. 39
BrakeAdjustment.................................................................................................................................................. 39
ControlCableAdjustment ..................................................................................................................................... 40
ControlCableMaintenance ................................................................................................................................... 41
Speedometer ......................................................................................................................................................... 41
Chapter 10 Electrical
ElectricalEquipment .............................................................................................................................................. 43
Electrical Symbols....................................................................................................................................................44
Electrical Wiring Diagrams........................................................................................................................................45
ElectricalEquipmentMaintenance .......................................................................................................................... 54
Chapter 11 Maintenance
MaintenanceofMotorcycle ................................................................................................................................... 55
LubricationChart................................................................................................................................................... 56
RequiredLubrication ............................................................................................................................................. 58
ListofRecommendedLubricants ........................................................................................................................... 58
Careof MotorcyclePaint....................................................................................................................................... 59
Preservationand Storage ....................................................................................................................................... 59
Battery .................................................................................................................................................................. 60
Listof IndividualTool Set,SpareParts, Accessories& Documents ........................................................................ 62
Chapter 12 Patrol Model
Patrol MotorcyclewithEngageable Sidecar Drive ................................................................................................ 63
Description ............................................................................................................................................................ 63
HandlingDifferencesfromtheSingleWheelDrive .................................................................................................. 63
SidecarMaintenance ............................................................................................................................................. 64
Chapter 13 Learn to Ride the URAL
LearningtoRide theUralMotorcyclewithSidecar Accessory ................................................................................ 65
SafeOperatingRules ............................................................................................................................................. 67

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Chapter 14 Warranty
Warranty ............................................................................................................................................................... 69
TermsUsed inthisWarranty Section ..................................................................................................................... 69
WarrantyResponsibilities ....................................................................................................................................... 69
WarrantyDisclaimers,Limitations&Exclusions ...................................................................................................... 71
DistributorsLimitedWarranties-New Motorcycle................................................................................................. 72
WarrantyTime Period ............................................................................................................................................ 73
URAL DFS Advantage - Buyer Protection Plan ......................................................................................................73
Ural Motorcycle Plus Compnent Coverage .............................................................................................................74
Distributor’sLimitedWarranties-MotorcycleTires................................................................................................ 76
Distributor’sLimitedWarrantiesEmissionControlSystem ...................................................................................... 77
Distributor’sLimited Warranties-NoiseControl Systems ...................................................................................... 78
Distributor’sLimited Warranties-ReplacementParts ............................................................................................. 79
Distributor’sLimitedWarranties-UralAccessories................................................................................................ 80
California Air Resources Board Warranty ................................................................................................................81
EPANoiseRegulations .......................................................................................................................................... 84
ClassicMotorcyclesEmision ControlSystem Waranty .......................................................................................... 85
Classic Motorcycles NoiseControlSystem Warranty ............................................................................................ 86
ReportingSafetyDefects ....................................................................................................................................... 87
Chapter 15 Service Coupons
ServiceCoupons ................................................................................................................................................... 89
CaliforniaEmissionsPackage ................................................................................................................................. 99
New Address Form............................................................................................................................................ 103
New Owner Form .............................................................................................................................................. 104
URALStartingandRunningTips.................................................................................................... InsideBack Cover

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INTRODUCTION
Welcome tothe URALMotorcyclingFamily! Yournew URALmotorcycle conformsto allapplicable US
FederalMotor VehicleSafetyStandardsand USEnvironmental ProtectionAgency regulationseffective
onthe dateofmanufacture. This manualcoversthe IMZ-8.103-40 (Tourist)and IMZ-8.103-10(Deco
Classicand BC-65Bavarian Classic) andthemotorcyclewithan engageabledriven sidecarwheel, IMZ-
8.107(Patrol).
Thismanual hasbeenpreparedtoacquaint youwith theoperation,careandmaintenance ofyour motor-
cycle,and toprovideyou withimportantsafety information. Followtheseinstructions carefullyformaxi-
mummotorcycle performanceandfor yourpersonal motorcyclingsafetyand pleasure. Pleasepay
particularattention tothe section“Learning toRide theURAL Motorcyclewith Sidecar”and theseparate
manual“Driving the URALSidecarMotorcycle.” It is criticalthat abeginning sidecardriver becomes
thoroughlyfamiliar withthe specialoperatingcharacteristics ofsidecar outfitsbefore venturingouton the
roads.
Your Owner’s Manualcontainsinstructions foroperation, maintenanceandminorrepairs. Majorrepairs
requirethe attentionof askilled mechanicand theuse ofspecialtoolsandequipment. YourAuthorized
URALDealer and URAL certified Service Center has the facilities, experience and genuine URALparts
necessaryto properlyrenderthis valuableservice.
TheURALrepresentsanimportantpiece ofGerman andRussianhistorysinceit hasbeen continually
manufacturedwith thesamegeneralarrangementand outwardappearance forthepast60years after
Russianengineers initiallycopied theBMW’s of1939. It trulyisan“instantantique” asmany ofour
ownershave said.
SincetheURALweighs 700lb. empty withthe attached sidecar, hasa large frontalarea and ispowered
by an old fashioned 649cc engine, it is not a fast motorcycle. The URALRugged Classics’ top speed is
65mph witha cruisingspeedsof 55 mph butonlyafter faithfuladherence tothe break-inperiod.
Ifyouare avintageenthusiast,collector,localcommuter,hunter,fisherman,havechildren, 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!
Theclassic boxertwin hasa Germanheritage. Soeffective,simpleand powerfulis thisdesign that
Porsche,Volkswagen,and evenHarley (duringthe warwiththeXAmodel) madethis designtheir choice.
Thereliability and torqueof thiselegant motoris due toits originaldesign in1912 by MaxFriz, abrilliant
Germanaircraft-engine builder. He deviseda compactand ruggedengine thatdelivered significant
torquefor itsdisplacement,atlowand constantrpms, withoutthegyro effectsof othertwins. Themilitary
andcivilian usesbecame legendary.The Germanmotorbike builderBMW,began singthe designin their
motorcyclesin 1922.
Becauseof itsopposed cylinderlayout the“Boxer” asitwasdubbed,turns thecrankshaft inline withthe
motorcycle(orairplane!). Thisallowsforastraight-throughshaftconnectionfromtheengine,throughthe

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gearboxand througha stainlesssteel driveshafttoarearwheel finaldrive gearin thewheel hub. This
drivetraindesign isexactly likethe millionsof rearwheel driveautomobiles builtover thepasteighty
years! Itis atime tested,proven drivesystem madeelegantly simpleby the“Boxer” opposedcylinder
engine.
Todaythe “Boxer”engine hasevolvedintothehigh techand electronicallysophisticatedandcomplicated
versionsthat canbe foundnotonlyinBMWs butalso inPorsches, Hondasand others. Thesearewon-
drousengines at
wondrousprices! But theystill retainthebasic“soul”ofMaxFriz’sfirstengines. And
althoughit isnot asevolved asthe mostmodern “boxers”,theIMZ 750cc istrue tothe earlierversions in
looks,but alsohasmany moderninternalcomponents. Theseparts,like pistons,rings,valves, valve
seatsand oil sealsare modernand westernmade. The carburetors aremade inJapan. These parts
makethe enginemore reliableand cleaner.
However, the“boxer”isstillanair cooledpowerplant. As suchit mustbe carefullymonitored during
operationto preventoverheating. As thegear makingandother machinetools inthe IMZplant are
“vintage”ones,a carefulbreak-in oftheengineisvery important. Neglectingto followthe prescribed
speedsduring break-inor thefrequent oilchanges willcause thiswonderful engineto rebelagainst its
“abusing”owner. However,by treatingthe “boxer”withrespectand raisingit well,youwillberewarded!
Soitstrue thatsometimes simple isbetter, andold fashioned ideasand designs havestrong reasonsfor
theability tocontinue fora longtime. It isthe mainreason whyovermillionsofURALshavebeen sold
aroundtheworld.
Finally,all newowners willreceive acomplementarymembership inthe URALMotorcycle Owner’s of
America(UMOA) whichis anowner’s clubthat wehaveformedtofacilitate communication,adventure
andmotorcycling experiencefor thenew URALowners acrossAmerica.
Welookforward toseeing youat afuture rally.
Anysuggestionsor commentsare welcome! Write tous or postan e-mail onthe URAL Discussion
bulletinboardatwww.ural.com.
Happy Riding!

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Important Notice!
Statementsin thismanual precededby thefollowing wordsareofspecialimpor-
tance:
WARNING: M EANS THERE IS THE POSSIBILITY OF PERSONAL
INJURY
TO YOURSELF OR OTHERS .
CAUTION: Meansthere isthepossibilityofdamageto
thevehicle.
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.
Maintenanceintervals recommendedare basedon operationalexperience undervariousclimaticand
roadconditions. However,theseintervalsmay beextended orreduced followingrepeated checksof the
lubricantcondition andgeneraltechnical conditionofthemotorcycle.
Carefullystudythis Owner’sManualbefore startingthemotorcycle.
Specificationsand designare subjectto changewithout notice.

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Chapter 1
SPECIFICATIONS
GENERAL
Tourist&Patrol Deco & Bavarian
Maximumspeedofmotorcycle 108km/h 65mph 119 km/h 70 mph
Referencefuelconsumptionat85% of 12.5km/L 29mpg 14 km/L 32.5 mpg
maximumspeed
Dry mass of motorcycle 700lb 680 lb.
Maximumload-carrying capacity 500lb./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
Seat height 840 mm / 33 in
Wheelbase 1470mm/58in
ENGINE
Type 4stroke,overheadvalves,opposedtwin-cylinder
Displacement 649 cc
Cylinder bore 78mm
Pistonstroke 68mm
Compressionratio 9.1:1
Ratedhorsepower 25.8 KW / 35 Hp
Ratedrotationalspeed 5600RPM
Rated torque,Nm 45 Nm / 33.2 ft.-lbs.
Lubricationsystem Dual systemofforcedlubricationandbysplashing
Lubricant SAE20W/50
CARBURETOR
Carburetortype 32CVKKeihin
Numberofcarburetors 2
Air cleaner K & N Air filter
Fuel 91octanepremiumunleadedgasoline
PCVValve InternalBreather

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ELECTRICAL
Ignitionsystem (CDI)
Ignitioncoil 135.AC.B
Sparkplugs NGKBP7HVX/orequivalent
Ignitiontiming Automaticspark timer
Alternator 35 amp / 12 Volt
Battery Interstate#YTX20L-BSorequivalent
Headlight Sylvania Halogen 6024,7"roundsealed beam
TRANSMISSION
Clutch Drydouble-diskclutch
Gearbox 4 speedgearbox withreversegear lever
GEARRATIOS
Igear 3.6
II gear 2.28
III gear 1.7
IVgear 1.3
Reversegear 4.2
Speedometerdriveratio 0.4 Deco & BC-65 0.5
Finaldriveratio 4.62
FLUIDCAPACITIES
Tourist,Bavarian Patrol
&Deco
Fueltank 5 Gal /19L 5 Gal / 19L
Reserve .5 Gal / 2L .5 Gal / 2L
Engine 76 oz / 2.25L 76oz/2.25L
Transmission 34 oz / 1 L 34oz / 1 L
Finaldrive 3.5 oz / 105 ml 4.5 oz / 135 ml
TelescopicForks N/AonTourist N/AonPatrol
(LC-75&Deco) 135ml/ 4.5oz
ShockAbsorbers 105 ml / 3.5 oz 105ml /3.5oz

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RUNNINGGEAR
Tourist& Patrol Deco & Bavarian
Frame Tubularwelded TubularWelded
Rearwheelsuspension Swingarmswith Same
spring shockabsorbers
Frontfork Leadinglink Telescopicspring
Sidecar Cushionedbody(onrubber
cushions)andwheelwith
hydraulicspringshock absorber
Brakes Shoe-typewithmechanical driveonfront,rearand sidecar
wheels,frontwheelhasdualcams.
Tires 4”x 19”3.5”x 18”
Front22psi cold (1.5 Bar /150 kPa) Front22psicold
Side 22 psi cold (1.5 Bar / 150 kPa) Side 22 psi cold
Rear 36 psi cold (2.5 Bar / 250 kPa) Rear: 36psi cold
CLEARANCES
mm in
Valveswithenginecold 0.05 to0.1 0.002to0.004
Betweensparkplugelectrodes 1.016 0.040
Backlashbetweentoothfacesof
bevelgearsinfinaldrive 0.1 - 0.3 0.004
FREETRAVEL/ ADJUSTMENTS
mm in
Handbrakecontrollever 5 - 8 0.2 - 0.3
Clutchcontrol lever 5 - 8 0.2 - 0.3
Footbrakedrive pedal ¼offullstrokeofpedal,
25 - 30 1.0 - 1.2
Toe-indistance 10mm 3/8inch
Lean-out 1°awayfromsidecar

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TORQUESPECIFICATIONS
Metric(in repair manual) USEquivalent Location on Bike
34Nm 25ft/lb cylinderheads
22to25 kgf-m 175ft/lbto 185 ft/lb flywheeltighteningscrews
2.1to3.0kgf-mtop 14ft/lbto22ft/lb shockabsorber
3.6to5.0kgf-mbottom 28ft/lb to36ft/lbs shockabsorber
3.0to3.4kgf-m 22ft/lbto26ft/lb bearingnut
3.0to3-4kgf-m 22 ft/lbto26ft/lbs finaldrivetoswingarmbolts
1.6to1.8kgf-m 12ft/lbto14ft/lb oilpumpbolt
.8to1.0kgf-m 5ft/lbto8ft/lb enginesump
1.4to1.8kgf-m 10ft/lbto14ft/lb finaldrivecasenuts
7to9kgf-m 50ft/lbto66ft/lb nutfasteningthepinionbearing
2.2to2.8kgf-m 16ft/lbto20ft/lb reversegearbrakelever
1.8to2.0kgf-m 14ft/lbto16ft/lb alternatorgearnut
14to16.8 kgt-m 100ft/lbto 120ft/lb steeringstemnut
CONVERSIONS
Toconvertfrommmtoin,divideby25.4 (there are 25.4 mmperinch).
Toconvertfromlitersto gallons,divideby3.785(thereare3.78litersper gallon).
Toconvertfromlitersto quarts, multiplyby1.056(thereare 1.056quartsperliter).
Toconvertfromliterstopints, multiply by2.112(there are2.112pintsper liter).
Toconvertfromkmto miles,multiplyby .62 (there is.62mileperkm).
Toconvertfromkm/hrtomph,multiplyby.62.
ToconvertfromNewton-meter(Nm)toinch-pound,multiplyby8.86.
ToconvertfromNewton-meter(Nm)tofoot-pound,multiplyby.7376.
To convert from cm3(cc) to pints,divideby473(thereare473ccper pint).
ToconvertCelciustoFahrenheit: F°=C°x 1.8 + 32.
ToconvertFahrenheittoCelcius,C°=(F°- 32)divide by 1.8.

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Chapter 2
MOTORCYCLE CONTROLS & INSTRUMENTATION
Figure1. Controlsand 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”beamswitch
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(underseat)
11 - Kick start lever

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CONTROLS
Clutch control lever (Fig.1,#16). Whenthe clutch leverissqueezed,theengineis disengaged
fromthegearbox. Whentheleverisreleased,theengineisengagedtothegearbox.
WARNING: M AKE 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 .
Front brake control lever (Fig.1,#5). Whenthelever is squeezed, thefrontwheelbrakeis
actuated. Thefrontbrakeshouldbeused togetherwithrearbrake.
Whenthebrakeleverissqueezed,thestopsignallampsareswitchedon.
Kick lever (Fig.1,#11)isdesignedto starttheengine. Onpressingthelever thecrankshaftofthe
engineisactuated throughthegearbox. Theleverisreturnedtoitsinitial positionbythespring
inside the gearbox. Note: this is a backup to the electric starter.
Gear shift foot pedal (Fig.1,#12) isatwo-armtype. Whenthefrontarmispressed,shifting
fromhightolowergears takes place. Whenthereararmispressed,shifting from low tohigher
gearstakesplace. Sincetheheel-toe shift lever isshort-coupled,youwillfinditeasierto shift upif
yourotatetheheelof your left footintowardsthereararmbeforestepping on itwithyourheel.
Theneutralposition isfixedbetweenthe IandIIgears.
IMPORTANT! Thegreenpilot lamp glowswhenthe transmission isin neutral andwhen
the reverse gear is engaged (see “Starting the Engine”).
Reverse gear engagement lever (Fig.1,#10) Forwardfor neutraland/orforwardrunningand
backforreverse. The reverse gear maybe engaged only afterthe motorcycle is completely
stopped!
To engagereversegear,shift intoneutral(orfirst),then pushbackthe reverselever.
Todisengagethereversegear, pressleverup(forward)tothelimit,thenthegearshiftmechanism
isresettotheneutralposition. Now you can shift intofirstgear.
Ifdesired,neutralmay beselectedbyshiftinginto reversewhenthefirstgear is engaged,andthen
movingthereversegearleverforwardintoneutral.

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Therear brake pedal (Fig.1,#9)applies therearwheelandsidecarwheelbrakessimultaneously.
WARNING: D O NOT APPLY EITHER BRAKE STRONGLY ENOUGH TO LOCK THE WHEELS BECAUSE THIS MAY
CAUSE
POSSIBLE LOSS OF CONTROL OF THE MOTORCYCLE . A LWAYS USE BOTH BRAKES . N EVER STOP WITH
FRONT
OR REAR BRAKE ONLY .
WARNING: A N IMPROPERLY ADJUSTED REAR BRAKE PEDAL COULD INTERFERE WITH PROPER REAR BRAKE
OPERATION
RESULTING IN POOR BRAKE ACTION .
Ignition Switch (Fig.1,#19)has threefixedpositionsofthe key. Thepositionandswitching
diagramoftheignitionlocksareshownabove.
Off Allelectricalsystemsareoff.
Run Voltageissuppliedtoallelectricalsystems.
Parking Voltageissuppliedtorunninglightsonly.
Note:Leaving the keyin the Runor Parking positionwill discharge thebattery.
Always return the key to the Off position before taking it out.
Speedometerisonthedashboard,withtrip (Note-Bavarianhas notripodometer)
andtotalodometer. Thetripodometer isresettozeroby rotatingpush-button(Fig.1,#3) counter-
clockwise. Notethattheodometerreadsinkilometersnotmiles.

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Theindicatorlampsaremountedontheinstrumentboard:
(Fig. 1, # 2) —turn indicator pilot lamp, (orange)
(Fig.1, #4)—gearboxneutral and reverse gear engagement,(green)
(Fig.1,#18)—headlamphighbeamindicator, (dark blue)
(Fig.1,#20)—alternatorfaultindicatorlamp,(red)
Note:If the red alternatorfault light stayson continuously during normaloperation above ap-
proximately 1500 RPM, there is a problem with the charging system or battery.
Throttle Control (Fig.1,# 6)isontheright handlebar. Turningthetwistgrip counterclockwise
increasesenginespeed.
Engine cutoff switch (Fig.1,#7)hastwopositions,ignition off (up),andignitionon(down).
Low and high beam light switch (Fig.1,#15),turn indicator switch (Fig.1,#13) and horn
push-button (Fig.1,#14)are combinedinoneunitonthe left-handhandlebarcontrolhousing.
Master battery switch (Fig.1,#21)isundertheseat.
Electric Start Button (Fig.1,#8)islocatedonthe right-hand twist grip, belowthekillswitch.
Thesteering damper absorbslateralkicksonthefrontwheel. Turningtighteningbolt(Fig.1,#17)
clockwiseincreasesfriction. Thiscan be usedwhileridingoverbadroads.
WARNING: D O NOT TIGHTEN THE DAMPER TO THE POINT WHERE THE STEERING BECOMES STIFF . D OING SO
WILL
ADVERSELY AFFECT HANDLING QUALITIES .
Parkingbrake(Fig.1,#22)islocatedontherightsideofthemotorcyclenexttothefootpeg. Itis
engagedbyapplyingthefootbrake pedalfullyandturningthehandleandpushingitdowntohold
thefootbrakeleverintheappliedposition.
Alwaysdisengagetheparkingbrakebeforemovingthemotorcycle.

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Chapter 3
ENGINE OPERATION AND MAINTENANCE
PRE-TRIPPRELIMINARIES
Beforeeachtrip,attendtoalltherequirementsofthe everydaymaintenanceasoutlinedinthis
manual. Whenaddingfuelandoiltothemotorcycle,takeall precautionstokeepeverythingneat
andclean.
Gasolinelevelinthe tank fullyfilledshouldbe10-15 mm /½-¾in.belowthelower edge ofthe
tankfiller. Donotoverfill thetank,especiallyon Californiamodelswhereoverfillingcancausefuel
contaminationofthe charcoalcannister. Seethat the oillevel intheenginecrankcaseis nothigher
thanthetopandnot lowerthanthebottommarksonthedipstickwiththefillerplugundone.(See
chapter4LubricationSystem)
CAUTION: Whendrainingandrefillingoil ,becareful thatdirtand debrisdoesnot contami-
natethefreshoil. Do not allow draining oiltogeton the rear wheel,tire,orbrakecompo-
nents.
STARTINGTHEENGINE
WARNING: B EFORE STARTING THE ENGINE , MAKE SURE THAT THE GEAR SHIFT MECHANISM IS IN THE NEU -
TRAL POSITION ( BETWEEN 1
ST
AND 2
ND
GEARS ) TO PREVENT ACCIDENTAL MOVEMENT WHICH COULD CAUSE
POSSIBLE
DAMAGE TO MOTORCYCLE AND PERSONAL INJURY . ( F OR MORE THAN JUST STARTING , I . E . IDLING , IT
IS
ADVISABLE TO USE NEUTRAL GEAR .)
Whentheignition isswitchedon,the green&redlampsontheinstrumentboardshouldlightup.
Makesurethatthereversegearengagement(lever)issettothefrontposition.Thisisimportant
sincethegreenlamp willalsobelitifthe motorcycleisinreversegear. Movingthereverse gear
leverforwardwillputthegearboxinneutral.
Gasolinepetcockpositionsareasfollows:
OFF ON RESERVE

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Dependingontheengineandambienttemperature,usethecarburetorenrichenersandstarting
procedureasfollows:
ManualStarting(withoutelectricstarter)
1. Turnontheignition and depressthekicklever(seeFig.1)about
1/4ofitstravel(enough to firmly gettheballofyourfootonthe lever) witheitheryourleft
footorright foot,dependingonwhat positionismostcomfortablewith yourrighthandon the
throttle.Takeupthe slackinthethrottleuntilyoucan feelsomeslightresistancefromthe
returnspringsin thecarburetors. However,donotadvance thethrottle,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 leveraswiftkick. Whenthe enginestarts,ticklethethrottle(quicklyadvance
andretardit)to keeptheenginerunning,butnot toofast.Iftheenginedoesn’tstart,repeat
thekickingprocedure. Aproperly adjusted warmengineshouldstartwithina fewkicks. If
theenginedoesn’t start,trytheproceduredescribedbelow in item3. Ifitstilldoesn’tstart
orfire,it may be flooded.
Note: Donot open thethrottle while kickingthe engine oversince it mayflood thesparkplugs.
1a Electricstarter:1.Set carburetor enrichenersaswithkickstarting. Unlikemanual start-
ing,however,the gearboxdoes nothavetobein neutralastheelectric startermaybe
engagedwiththeclutchleverpulled in,orwiththegearboxinneutral. Make surethekill
switchisset to“run”andpushthestarterbuttontoturn overtheengine.
2. Whentheenginehasbeenstandingforseveralhoursbut theambienttemperatureis
high(60°F/15°Cdegreesorabove),trystartingit without any enricheners. If it doesn’tfire,
thenuse theproceduredescribedbelow.
3. Whentheengine iscoolorcoldand theambienttemperatureisbetween40°F-60°F/5°C-
15°C,depressbothenricheners tostart. Assoonas theenginestarts,immediately retract
theenricheners. Runtheengineat moderate speedfor30-60seconds. Ifitstartstodie,
ticklethetwistgripthrottle(rapidlytwistpartwaytowards fullthrottleandthenbackoff)to
keeptheenginerunning. After1to3minutes,dependingonambienttemperature,the
engineshouldrunsmoothlywithout“tickling”thethrottle.
4. Iftheengineis coldandambienttemperatureisbelow 40°F,first,givethe engine 5-10
(dependingonhowcolditis) priming kicks with the ignitionoff. Thiswillgetsomeoilcircu-
latedtokey internalparts. Engagetheenricheners onbothcarburetors. Theengine should