URAL Motorcycles Gear Up 2004 User manual

Irbit Motorcycle Factory
Irbit Motorworks ofAmerica
Owners Manual
2004Model
Gear Up, Patrol, Tourist, Troyka
www.imz-ural.com

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Contents
Introduction...............................................................................................................................................................7
Warnings,Cautions, Notes.........................................................................................................................................9
Chapter 1 Specifications
Specifications .........................................................................................................................................................11
TorqueSpecifications............................................................................................................................................. 15
Chapter 2 Motorcycle Controls and Instruments
MotorcycleControls&Instrumentation.................................................................................................................. 17
Controls ................................................................................................................................................................ 17
Control and Instrument maintenance ....................................................................................................................... 25
Chapter 3 Engine Operation
EngineOperationandMaintenance ........................................................................................................................ 27
Pre-TripPreliminaries ............................................................................................................................................ 27
StartingtheEngine ................................................................................................................................................. 27
OperatingPrecautions............................................................................................................................................ 31
Running-IntheNewMotorcycle ............................................................................................................................ 32
Chapter 4 Engine Design
Brief Descriptionof Design .................................................................................................................................. 33
LubricationSystem ................................................................................................................................................ 34
FuelSystem........................................................................................................................................................... 35
IgnitionSystem ...................................................................................................................................................... 37
Chapter 5 Carburetors
Carburetors ........................................................................................................................................................... 39
Carburetor Maintenance ........................................................................................................................................ 40
Chapter 6 Power Transmission
PowerTransmission ............................................................................................................................................... 41
Clutch ................................................................................................................................................................... 41
Gearbox ................................................................................................................................................................ 41
FinalDrive ............................................................................................................................................................. 42

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Chapter 7 Running Gear
RunningGear ......................................................................................................................................................... 43
Motorcycleand SidecarFrames ............................................................................................................................ 43
Spring-LoadedHydraulic ShockAbsorber............................................................................................................. 44
AdjustmentofSidecarInstallation ........................................................................................................................ ..45
FrontFork ............................................................................................................................................................ 46
Steering Head Bearings............................................................................................................................................48
Chapter 8 Wheel & Tires
WheelsandTires ................................................................................................................................................... 49
Tire Data ................................................................................................................................................................50
RunningGearMaintenance .................................................................................................................................... 51
Chapter 9 Brakes
Brakes .................................................................................................................................................................. 53
BrakeAdjustment .................................................................................................................................................. 53
Chapter 11 Electrical
ElectricalEquipment .............................................................................................................................................. 57
Electrical Circuits.....................................................................................................................................................59
ElectricalEquipmentMaintenance .......................................................................................................................... 59
WiringDiagram...................................................................................................................................................... 60
Chapter 12 Maintenance
MaintenanceofMotorcycle ................................................................................................................................... 61
ListofRecommendedLubricants ........................................................................................................................... 61
LubricationChart................................................................................................................................................... 63
RequiredLubrication ............................................................................................................................................. 64
Careof MotorcyclePaint....................................................................................................................................... 64
Preservationand Storage ....................................................................................................................................... 65
Battery .................................................................................................................................................................. 65
Listof IndividualToolSet,Spare Parts,Accessories&Documents......................................................................... 66
Chapter 13 Gear-Up & Patrol Motorcycle With Engageable Sidecar Drive
Patrol Motorcyclewith EngageableSidecarDrive ................................................................................................. 69
Description ............................................................................................................................................................ 69
HandlingDifferencesfromtheSingleWheelDrive .................................................................................................. 69
SidecarMaintenance ............................................................................................................................................. 70
Chapter 14 Learning to Ride the URAL
LearningtoRidetheUral Motorcyclewith SidecarAccessory ................................................................................ 71
SafeOperatingRules ............................................................................................................................................. 73

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Chapter 15 Warranty
Warranty............................................................................................................................................................... 75
Warranty Claim Form........................................................................................................................................... 81
Flat Rate Schedule ............................................................................................................................................... 82
Chapter 16 Service Coupons
ServiceCoupons ................................................................................................................................................... 85
NewAddressForm ............................................................................................................................................... 95
New OwnerForm ................................................................................................................................................. 96
URALStartingandRunningTips ............................................................................................................................ 97

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INTRODUCTION
Welcometothe URALMotorcycling Family! YourUral hasbeen builtby theIrbit MotorcycleFactory in
Russiaand distributedbyIrbitMotorworksofAmerica, theUnited Statesaffiliateof theIrbit Motorcycle
Factory. The Uralmotorcycle conformsto allapplicable USFederalMotor Vehicle SafetyStandardsand
USEnvironmentalProtectionAgencyregulationseffectiveonthedateof manufacture.Thismanual
coversthe Gear-Up,Patrol, andTouristmodels.
Thismanual hasbeen preparedto acquaintyou withthe operation,care andmaintenance ofyour
motorcycle,and toprovideyouwithimportantsafetyinformation. Follow theseinstructionscarefullyfor
maximummotorcycle performanceand foryour personalmotorcyclingsafetyandpleasure. Pleasepay
particularattentiontothesection “Learningto Ridethe UralMotorcycle withSidecar”. Itis criticalthat a
beginningsidecardriverbecomesthoroughly familiarwith thespecial operatingcharacteristicsof
sidecaroutfits beforeventuring outon thebusy roads.
Your Owner’sManualcontainsinstructionsforoperation,maintenanceandminorrepairs. Majorrepairs
requirethe attentionofaskilledmechanicandthe useof specialtools andequipment.YourAuthorized
IMWA Ural Dealer hasthe facilities,experience andgenuine Uralpartsnecessary toproperly renderthis
valuableservice.
Anysuggestionsor commentsare welcome! Write tous orpostan e-mailonthe Ural Discussion
bulletinboardatwww.imz-ural.com.
Happy Riding!

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Important Notice!
Statementsin thismanual precededby thefollowingwords areof specialimportance:
WARNING: MEANS THERE IS THE POSSIBILITY OF PERSONAL INJURY TO
YOURSELF OR OTHERS.
CAUTION: Meansthere isthepossibilityofdamagetothevehicle.
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
mechanisms 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.”
Following those procedures will ensure that you have the most powerful & smoothly operating
engine after break-in.
Maintenanceintervals recommendedarebasedonoperationalexperienceunder variousclimatic and
roadconditions. However,theseintervalsmaybe modifiedfollowing repeatedchecks ofthe lubricant
conditionand generalmechanical conditionof themotorcycle.
Carefullystudy thisOwner’sManualbefore startingthe motorcycle.
Specifications anddesign aresubject tochange withoutnotice.

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Chapter 1
SPECIFICATIONS
GENERAL
Patrol&Gear-Up Tourist
Maximumspeedof motorcycle 95 km/h 59 mph 105km/h 65mph
Drymassofmotorcycle 736lb 736lb.
MaximumGrossVehicleWeight 1344lb. 1344lb.
Noiselevel below80db below80db
Fuelconsumption 31.3mpg 31.3mpg
OVERALL DIMENSIONS
Length 2580mm/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 1470 mm / 58 in
ENGINE
Type 4stroke,overheadvalves,opposedtwin-cylinder
Displacement 745 cc
Cylinder bore 78mm
Piston stroke 78mm
Compressionratio 8.6:1
Ratedhorsepower 23 KW / 45 BHp
Ratedrotationalspeed 5600RPM
Ratedtorque 52N-M@3750RPM
Lubricationsystem Dualsystemof forcedlubricationandsplashing
Lubricant SAE20W/50
CARBURETOR
Carburetortype 32 CVKKeihin
Number ofcarburetors 2
Air cleaner PaperFilterElement
Fuel 91octanepremiumunleadedgasoline
PCV Valve InternalBreather

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ELECTRICAL
Ignitionsystem Electronic Ignition
Sparkplugs NGKBP7HSorEquivalent
Ignitiontiming Automaticadvance
Alternator 35 amp / 12 Volt
Battery VARTAYB18L-Aor equivalent
Headlight Hela,7"roundsealedbeam
TRANSMISSION
Clutch Drydouble-diskclutch
Gearbox 4 speedgearboxwithreverse
GEARRATIOS
Igear 3.6
II gear 2.28
III gear 1.56
IVgear 1.19
Reversegear 4.36
Speedometerdriveratio 0.4
Finaldriveratio 4.62
FLUIDCAPACITIES Patrol,GearUp Tourist
Fueltank(gasoline) 5 Gal / 19L 5 Gal / 19L
Reserve (gasoline) .5 Gal / 2L .5 Gal /2L
Engine (oil) 68Oz/2L 68Oz/2L
Transmission(oil) 34 Oz / 1 L 34 Oz / 1 L
Finaldrive(gearoil) 4.5 Oz / 105 ml 3.5 Oz / 135 ml
ShockAbsorbers (shock oil) 105 ml / 3.5 oz 105 ml / 3.5 oz
BrakeReservoir DOT 3 or 4 brake fluid to upper line

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RUNNINGGEAR
Frame Tubularwelded
Rearwheelsuspension Swingarmswith
spring shockabsorbers
Frontfork Leadinglink
Sidecar Cushionedbody(on rubber
cushions)andwheelwith
hydraulicspringshockabsorber
Sidecardrive Steelshaftdrivenbyfinaldrive. Userselectableforengage
(PatrolandGearUponly) ment.
Brakes Disc-typewithhydraulicdrive on front,Shoetypewith
mechanicaldriveon rearandsidecarwheels
Tires 4” x 19”
Front 22 psi cold (1.5 Bar / 150 kPa) Front 22psi cold
Side 22 psi cold (1.5 Bar / 150 kPa) Side 22 psicold
Rear 36 psi cold (2.5 Bar / 250 kPa) Rear 36psi cold
CLEARANCES mm in
Valveswithenginecold 0.05to0.1 0.002to0.004
Betweensparkplugelectrodes 1.016 0.040
Backlashbetweentoothfacesof
bevel gears infinaldrive 0.1 - 0.3 0.004
FREETRAVEL/ADJUSTMENTS mm in
Handbrakecontrollever 5 - 8 0.2 - 0.3
Clutchcontrollever 5 - 8 0.2 - 0.3
Foot brakedrivepedal ¼offullstrokeof pedal,
25 - 30 1.0 - 1.2
Toe-in distance 10mm 3/8inch
Lean-out 1° awayfromsidecar

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TORQUESPECIFICATIONS
Metric USEquivalent Location on Bike
54 to 61 Nm 40 ft/lb to 45 ft/lb cylinderheads
237 to251 Nm 175ft/lb to185ft/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, Gear Up 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 reversegearlevernut
19 to 22 Nm 14 ft/lb to 16 ft/lb alternatorgearnut
136 to 163 Nm 100ft/lb to 120ft/lb steeringstemnut

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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
11 - Kick start lever

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ClutchControlLever Font Brake ControlLever
Clutch control lever . When theclutchleverissqueezed,theengine isdisengagedfromthe
gearbox. Whentheleverisreleased,theengineandgearboxareengaged.
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.
Caution:Alwaysengagetheclutchreleaseleverwhenshifting. Seriousinternaldamagemay
result to the transmission if the clutch release lever is not engaged.
Front brake control lever Whentheleverissqueezed,the frontwheelbrakeisactuated. The
frontbrakeshould beusedtogetherwith rearbrake.
Whenthebrake leverissqueezed,thestopsignallightsareswitchedon.

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Kick lever Isdesignedtostarttheengine. Onpressingthelever thecrankshaftoftheengine is
actuatedthroughthegearbox. Theleverisreturnedto itsinitialpositionbythe springinsidethe
gearbox.
Gear shift foot pedal Isatwo-arm type. When the front arm isdepressed,shiftingfromhigherto
lowergeartakesplace. Whenthe reararmisdepressed,shiftingfrom lower tohighergeartakes
place. Sincetheheel-toeshiftleveris short-coupled, you willfinditeasiertoshiftintoahigher
gearifyoudonotuseyourheeltoshift,rathertheballofyour foot. The neutral position is fixed
betweenthe1st and2nd gears. It isimportanttoshiftsmoothlywith aconstantforceandnotto kick
thegearshiftpedal. Serious damagemayresulttotheshifting mechanismifthegearshift pedalis
kicked,ratherthanpushed.
IMPORTANT! Thegreenpilot lampwillilluminate wheneitherthe transmissionisin neutral
or when the reverse gear is engaged (see “Starting the Engine”).
GearShiftFoot Pedal KickLever

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ParkingBrake SidecarDrive Lever Reverse Gear Lever RearBrakePedal
Parking Brake isusedto holdthebikewhenparked. To engage,depresstherearbrake pedal
andpushdownthentwisttheparkingbrakelevercounterclockwise.
Sidecar drive engagement lever isusedtoengagethedriveaxletothesidecarwheelonthe
PatrolandGearUpmodelmotorcycles.
WARNING: Neverengagesidecardriveonconcreteorhardsurface. Severedamage to
drivetrainwillresultifthesidecardrive is engaged on pavement.
Reverse gear lever isusedtomovethemotorcycle inreverse. Thetransmissionmustbein
neutralor1stgear forreversegeartobeengaged.
Rear brake lever isusedtoactuatethe rearbrakes.
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.