URAL Motorcycles L4 SERIES User manual

Motorcycles
Category L4
Owner Manual

Content
1. Introduction..................................................................................5-6
2. Motorcycle controls and controlling devices........................7-8
3. Getting-ready of your motorcycle for use.............................9-10
4. Driving the motorcycle..............................................................11-12
5. Engine design and engine maintenance tips......................13-19
6. Powertrain...................................................................................20-22
7. Runninggear...............................................................................23-28
8. Controls........................................................................................29-30
9. Electrical equipment..................................................................31-34
10. Auxiliary equipment ..................................................................35-36
11. Troubleshooting.........................................................................37-40
12. Maintenance of the motorcycle...............................................40-42

Motorcycle IMZ-8.1034/37 Classic

MotorcycleIMZ-8.1034/37Sportsman

Fig. 1c
1. iNTRODUCTION
1.1.MotorcyclesURALwithsidecarmanufacturedbyIrbitMotorcyclePlantareofheavy-dutyclassof
L4Categoryand are designedtotransportpassengers and goodsinvariousenvironments.
1.2.Theupper partofthe righthand framepipehasVIN-code (VehicleIdentificationNumber)which
is to be read from bottom to up.
Thestructureand content oftheVIN is asfollows:
Pos.1-4:X8JM–Russia,IMZ-IrbitMotorcyclePlant
Pos. 5-8: 8103- Type of the Transportation vehicle
Pos. 9: 0, 1, 2, 3, 4, 5 or 7 -version
Pos. 10: Year of Manufacture (Y – 2000 , 1 - 2001, 2 - 2002 .);
Pos.11-17:serialnumberoftransportationvehicle
1.3TheupperpartoftherighthandframepipelocatestheManufacture’sLabelhavingthe
followinginformation(Fig.1a):
-VIN-code
-Engine version
-List of ECE Regulations under which the Typeofthe TransportationVehiclewasapproved.
-EngineNumber,ECE Regulations numbers according to which thetypeofthemotorcyclewere
approved
1.3.Theengineversion identification,yearofmanufactureandserialnumberarealsoembossedonthe
lefthandsideofenginecrankcaseandare to be read from bottom to up. (Fig.1b)
1.4The serial number of gearbox is embossed on the left hand side of gear case. (Fig.1c)
Fig.1a
Fig.1b

3
12
45
678
2. Motorcycle controls and controlling devices
Fig2.
1-Ignitionlock;2- Steering lock;3-Fuelcock; 4-Gear shiftpedal;5- Kick starterpedal
Fig2a.
6-Side car drive shift lever; 7-Neutral gear lever; 8-Brake pedal

9 10 11 12
13
14 15 16
17
18
19
20
21
22
23
24
Fig. 2b
9-Clutchlever;10-Lightswitch;11-Turnsignalswitch;12-Hornbutton;13-Highbeamtelltale;
14-Alternatortelltale;15-Speedometer;16-Turn signal telltale;17-Odometer reset button;18-
Neutralgearand reverse gear telltale;19-Damperbolt; 20-Starter button; 21-Day-Nightswitch;
22-Ignitionkillswitch;23-Frontbrake lever; 24-Throttletwistgrip;
Topreventyour motorcyclefromunauthorized use, the steer-
ing lock with individual key is provided on the LH side of frame
headpipe. (Fig.2c)To lock it,turnthehandlebar to the right,insert
thekey, turn it to the left anddepressslightly,thenrelease and take
thekey out.To unlock the steering, insert the key, turn it totheleft,
pullslightly, release,andtakeitout.
Fig.2c

3 Getting-ready of your motorcycle for use
1. Chargethe battery,mountit ontothemotorcycleand connecttothe circuitwithminus poletothe
“ground”.Please,read indetailstheInstruction ManualforBatterybefore puttingthebatteryinto oper-
ation.
2. Checkthe oillevelinengine,gear box,finaldrive andtop upwhennecessary. Theoillevel incases
shouldbe betweentheupper andlowerlimit markswiththe plugsundone.
3. Checkthe operation ofbrakes.Should thehydraulicdrive during transportation beun-
sealed,removetheairfrom the brake system (See BRAKES).
4. Checkoutandtighten thethread fasteningsvital fordriving safety.
5. Take clamping rings outofthespare part kit and mount them onthecarbu-
retorfuel pipesbeforepriming thegastank.
Attention!Themotorcycleunits arefactory-primedwith the oilthegrade of
whichconformsthemanufacturingseason.
Warning!Neverdisconnectthe battery whentheengine is inoperationor short
thebatteryterminals tothe“Ground” or toeachother. Failure todoitinevitably
resultsin alternatormajordamage.
Engine start-up.
Tostart theengineproceed asfollows:
-Shiftthe gearshift pedal into Neutralposition(betweenIand II gears) sothat
theNeutral telltaleonthe dashboardgoeson withtheignition on.
-OpenthefuelcockintoPosition I (open), see Fig. 7.
-Pushthecarburetordepressorsand make sure that the fuel is supplied tothecarburetorsand floatcham-
bersare full.
-Switchtheignitionon.
Theignitionlockhasthreefixedpositions,Fig.3a:
1- Thekey isinPosition0 (leftposition)–all userarecut off.
2- Thekey isturnedclockwise intoPositionI–driving
3- Thekeyis turnedintoPosition II –parking,presencelights are
on.
Thekeymay be takenoutofthe ignition lockinPositions0 and II.
Fig.3
Fig.3a

Tobetterstart-up theengine,operatethechokeofthecarbure-
torandshutitoff after the engine starts (see Fig. 3b).Thereis
noneedtoenrich the mixture orusethechokewhen the weath-
eriswarm or engineiswarmedup.
Thefollowingspecificfeaturesshouldbetakeninconsideration
whilststartinguptheenginewithelectricstarter:
-Whenstartingthe engine in thecoldweatherset the carbure-
torsinenrichmentmode,rotatetheengineseveraltimeswith
kickstarterlever andoperatetheelectricstarter.
-Pushtheelectricstart button on therighthandlebar.Fig. 3b

4. Driving the motorcycle
Checkthe motorcycleforoperable conditionbeforestartingupthe engine,whichincludes neutralgearpo-
sition,fuel levelin thegastank,controlsfunctioning.Openthefuelvalve andfill thefloatchambersofcar-
buretorswith gas.Theswitch theignitionon. Having startup theengine withelectricstart button.
Afterenginewarms up atlowspeedwithin 2…4 minutes,opentheair shutter andyouareready to drive
away. .
Thecorrect ridingposturemakes theridingeasier anddecreasesfatigue. Situpright,leaning forwardalit-
tle,with handsfreelycovering thehandlebarand feetonthe footpegs.
Youroll offromthe stoponlywhentheengine iswarmedup. Rolloutthethrottlea little,shiftdown into
firstgearandrollingthethrottleonslightlyincreasefuelsupply,andslowlyreleasing ofthe clutchlever
rollstherig.
Neverrevthe engine at toohighspeedwith the clutchengaged,theengine speed should bethatthatthe
enginedoes notstallwhilst easingouttheclutch gently.Alsoyou shouldnotease outtheclutchlever
abruptlyto preventthe enginefromstallingandthemotorcyclefrom bouncingforward.
Havingincreasedthespeed to 10… 15 km per hour shift to II gear.Toshiftgears,squeeze the clutchle-
ver,rollofthe throttle decreasing theenginespeedandstep firmly on the heelpad.Easeout the clutch le-
verandadjust the throttle,increasingenginespeed. Shift intheIIIgear the samewaywhenthe speed is
about 20…30 km per hour, then IV gear when the speed is 35…40 km per hour.Thenadjust the speed
rollingthrottleoff and on. The useofII,III and IV gearsisstrictlynotrecommended at speeds belowthe
abovesaid limitsasthe engineoverworksandmay operatewithtwitches.
DonotusegearsIandII for a long time , when environment does not dictateitastheenginerevsattoo
highspeed, overheats and wears our fast. Use lower gears to drive at low speeds.
Whenyouneedtoshiftthegearstoooftenoverdo not change the speed by clutch slippage as it wears out
theclutch platesbadly.
Toshifttolowergearsdecrease the speed, roll of the throttle, squeeze theclutchleverand brakedown
whennecessary, shifttolower gear,thenease outtheclutch lever gentlyrollingon the throttle.
Ifyouare planning tocometoa complete stop,rolloffthe throttle andletthemotorcycle stop rollingand
brakeitdown. Then shifttoneutral , easetheclutch out andstoptheengine.
Youmaybrakedown the motorcycles through threeways:bybrakes,by engine and both waysincombi-
nation.
Whenusing the brakesonlyroll offthethrottleand squeezetheclutch lever,startbraking withrearbrake
activatingthe front brakeimmediatelyafter sothatfront brakeoperatesa littlelaterthanthe frontone.
Usingfront brakeonlyis strictlynotrecommended especiallyathighspeedsand whilstturningas itmayre-
sultinskiddingorintopplingover.
Tobrake downusingengine only,rollofthethrottlewithoutdisengagingtheclutch. Whenfaster decelera-
tionis ofneed,downshift thegear.
Thejointbraking uses boththedragtorque of engineandbrake systems. Thiswayisgenerally used to
stoptherig instantaneouslytopreventaccident orhead-oncrashas wellaswhengoing downthesteephill.
Tothispurposerolloff the throttle and decelerate the rigwithbothbrakes.

Tohave themotorcycleturned usethecountersteeringand thenleaningthe motorcycleoverto thedirection
oftheturn (bikes usedwithoutside-car). The sidecardrivercompensates by leaningbodyweighttoward
theturnand applying forcetothe handlebars.
Iftheroad isslipperydonot turn sharply,neitherroll the throttleonlike a shot.Changetheengine speed
thewaytherearwheeldoesnot slip. Reduce the tire pressure on slippery road.
Controlthetemperature of engine,powertrainand other parts.Thenormal summer timetemperatureof
engineis nothigherthan 180…200Cmeasuredunderthe sparkplug.The normaltemperatureof engineoil
isnot higherthan90C.

5. Engine design and engine maintenance tips
URALMotorcycles have 4-stroke,2-cylinder,air cooledengineof carburetortype.Thegeneral viewof
theengineis shown on Fig.5.
Fig.5.
Engine maintenance.
Whilstdailyinspectionoftheengine,dothefollowing:
-Removedirt anddustfrom theenginepaying specialattentiontothecooling finsasdirty finsdonot cool
theenginesufficiently.Washtheenginewhennecessary.Lettheenginecooldownbeforewashing.The air
shutterand aircleanershould beadequatelycovered duringwashingtopreventthe moisturefromgetting
insidethese units.
-Checkroutinely theoillevelwiththe dipstickby screwingitoutandusing upperandlowerlimitmarks as
reference.Top up whennecessary.Keepthe oillevelcloseto the upper mark of the dipstick.
Checkthe condition andfasteningsengine crankcase,cylinders andcylinderheads.
Checkthe followingevery1000…1500km:
-KEIHINcarburetorsadjustment (see CARBURETORSADJUSTMENT)
-Ignitionsetting(see IGNITION SETTING)
-Valvesetting(seeVALVEADJUSTMENT).

VALVEADJUSTMENT
Thethermal gapbetweenvalve stemandpushing armofthe
rockershould be between 0,1…0,15 mm (see Fig. 5a). The
valveshould beadjustedaftervalvegrinding ordisassembly of
timinggearmechanism.
Toadjustthe valves, proceedasfollows:
-Removethe cylinderheadcover anddrainthe oilfromit.
-Revolvethecrank shaft oftheenginewith kick starterpedal.
-Adjustthegapforexhaustvalvewhenintakevalvestartsclosing,
andadjustthegapforintakevalvewhenexhaustvalvestartsopen-
ing.
Fig.5a
Lubrication system
Theenginehascombinedlubricationsystem,i.e.somepartsoiledbypressurefromtheoilpumpandotherby
splashing.Afull-flow oilfilterisprovided forlongerlife of theengine,
having paper insert. The dipstick gas two marks indicating upper and
lowerlimitsforoillevel.Tochecktheoillevel,wipethedipstickanddip
itinto theoil withoutscrewingintheplug.Changethe oilafterfirst500-
kmrunandthenevery2500km.
Warmuptheenginebeforeengineoilchange(Fig.5).Itisrecommended
to change the oil after your getting back home as the engine is warm.
Draintheoilfromtheoilfilterhousingaswell(Fig.5a).Thoroughlyclean
the surfacesofplugsofdrainopening,fillerandoilfiltercover.Remove
headerpipestochangetheoilfilter. Please,be sureto dipthe oilfilter into
engineoil beforeinstalling itintotheengine.Thenplacethesealingring
intothefilter,placethefilterwithringassyontothetipofthe plug and
screwin thepluginto thefrontcover.
Fill inthe freshoilto uppermarkof thedipstick,start uptheengine and
let warm up within 3…5 minutes to let the fill the oil ducts . Stop the
engineand checktheengineoilonce againafter3…5minutes,top upto
uppermarkonthe dipstick. The priming capacity oftheengineis2,3L
oil. Useonlycleanvesselforoilandneverletdust,dirt andmoistureget
intothe enginecrankcase.
Theoilfilterisrecommendedtochangeevery5000 km.Flushtheengine
lubricationsystembeforeoilfilterchange.Tohaveitdone,fillin1…2L
offlushing oilintocrankcase,start theengineandletidle atlow revsfor
2…3minutes.Draintheflushingoil fromthe oilpan, cylinderhead cov-
ersandoilfilterhousingandprimethenewoil.
Fig.5
Fig.5a

Fuel supply system
Fuelvalve
Thefuel valveleverhas threepositions (Fig.7).
I- Openfor fuelfeed
II- Closed
III- Openforreserve fuelfeed
The reserve is about 2 L gas.
Fig. 7 Fuel valve
Air filter
Tocleantheair supplied to carburetors, motorcycles IMZ-8.1034/37 have airfilterswithdrypaper insert
requiringnomaintenanceduringservicelife(Fig.8).
Thefilter elementshouldbe replacedevery5000km runtowhich purposethebolts fasteningtheside cover
offiltercase mustbeundone.
Fig.8Airfilterwith dry paper insertforIMZ-8.1034/37
Checkperiodically thetightnessofjunctionsand sealing partsinair intakeline,as inflowofnon-cleaned
airresults inquickwear-outofthe engine.

Carburetors
Theenginesusestwo L22 AA Keihin carburetors (Fig. 9),
Fig.9.Generalviewofcarburetor
Carburetor adjustment
ToadjustL22AA Keihin carburetors, proceed asfollows:
1. Usingcableadjustmentscrew, provide free travel of 2…3 mm between cable sheath and throttle
cableadjustmentscrew(Fig 9a).
2. Startand warmupthe engineatidling.
3. Screwin themixture screw(8)untilitstopsandprovide minimumsteady speedoftheengineusing
screw (7)
4. Undoscrew(8)to have as high enginespeedaspossiblewith screw (7) at the sameposition.
5. Usingscrew(7), providepossiblyminimumsteady enginespeed.
6. Repeat steps 3…5 for the second carburetor.
7.Usingscrews(7),adjust steady operation of both cylinders atidlingbyalternativelyshuttingdown
cylinders(HVwiresmustbe grounded during these operations) thus providing steady operationatengine
speedaslowaspossible.
8.Measure CO inexhaustgases thecontentof whichmustnot exceed 4,5%(ECERegulation 40).The
samplerofgasanalyzershouldbeputintothe silencerfornotlessthan60mmdeep.Measure exhaustinboth
silencers
-Screw in screws (8) on both carburetors to ¼ of the turn.
-Adjustcarburetorsagainas described in Point 7
-Measurenoxiousgases againforeach silencer.
-Repeatprocedure,Point9,whenevernecessary.
Thecarburetorfails to adjust andconformtorequirementstated above should bereplaced.

1
2
4
56
7
8
3
3
Fig.9a
1-Startingcompensatorlever; 2-Throttle lever; 3-Throttlecable stop; 4-Vacuum pistonnipple;
5-Floatchamberunbalancingnipple;6-Floatchambernipple;7-Throttleadjustmentscrew;
8-Idlingadjustmentscrew;
9.Adjust steadyoperationofcylinders usingcablesadjustment screwsby alternativelyshutting down
cylinders(HVwires must begroundedduring these operations).Usespeedometerreadings ifyourskillsin
determiningenginespeedaurallyarenotsufficient.Todothatputthe motorcycleoncentralstandand runthe
engine at speed corresponding to speed of 50 km per hour with one cylinder in operation. Follow up the
speedometerreadings alternativelyshutting downeithercylinder.Unsteadyoperationwithin±5istolerated.
CARBURETOR MAINTENANCE
Checkthecarburetorsforthe condition of fastenings of carburetors tothecylinderhead,fasteningof
branchpipesand theirtightnessto air filterandcarburetors.
Flushthepartsof fueland airducts every5000-kmrun.Blowthepartsbycompressedairafterflushing.
Exhaust system
Theexhaustsystem consistsofheader pipes andtwomufflers. Thesystemisfactory-marked inaccor-
dancewithECERegulation.

TechnicalSpecification
Withignitiononandengine
offtheinputcurrentisnot
more than 0.1 A.
Thesystemprovides for con-
tinuessparkingatrotational
speedofcrankshaftbetween
200and6000rpm,withthe
consumedcurrent notmore
than 1, 5 A.
Thesystem provides for
sparkinginthevoltagerange
between7to16Volt.
Whilst operationthesystem
automaticallyprovides forre-
quiredignitiontimingwithtol-
erance of + 1°.
The system is able to operate
withinthe temperaturerange
of-50°Ñto +100°Ñ.
Thebestsparkparametersare
ensured in combination with
3705060-typeignitioncoil,but
thesystemisalsoworkablewith
othertypesof coils likeB-204
and B-201.
Mountingofthesystemonto
engine(seeFig.10,10a)
-Mountthe systemhousingon
thetiminggearcoverusing
threeM5x16screws
Fig.10Microprocessor Ignition system
-Mountrotoron theenginecamshaftusing M6x12screws
-Mountthe microprocessorunitintothehousing theway thewiresaredirectedto ignitioncoilandfixit
withtwoM5x10 screws.
-ConnectleadsK3and“+” (blackandredcorrespondingly)ofthemicroprocessorunittoterminalsof
ignitioncoil(seeWiringDiagram,Fig.10.a).
Microprocessor Ignition System
TheMicroprocessor IgnitionSystem(Fig 10)isdesigned forworkwiththeelectrical systemof2-cylinder
carburetorengines ofUral motorcycles,havingnominalvoltageof12V
Bolt M6-12
Washer 6 spring
Washer 6 special
Curl The unit microprocessor
Screw M5-10 Screw M5-20
Washer 5
Washer 5
Washer 5 spring
Washer 5 special
Body
Induction coil

Ignition timing
Totime theignition, proceed asfollows:
-Matchthefirst arrow(havingthe point)ontheflywheel withmarkM3 on theenginecrankcase.
-Loosenthe fasteningscrewsofthe microprocessorunitand turnitcounterclockwise untilitstops.
-Powertheignitionsystemhavingswitchedtheignitionlockon.
-Turnslowly themicroprocessorunit clockwise,theLED shouldbeon
-Stopturning the microprocessorunitwhen theLEDgoes out.
-Tightenthe fasteningscrewsofthemicroprocessorunitand switchtheignitionoff.
Spark plugs
Themotorcycleuses spark plugsofthetypes of À14Â (N17C) or A17B (N15YC).Thegapbetween
thelower endofthe electrodeandtheside oneshould0,5-0,65 mmforthe mechanicalinterrupteror 0,8-1,0
mmforelectronicignition system.To sealthesparkplugbodywithcylinder head,sealingringisprovided.
Fig.10a.Wiringdiagramofmicroprocessorignition system
Induction coil
Red
The light emitting diode
The unit
ÁÌÑÇ
Black

6. Power Train
Thepower trainofthe motorcycleconsistsofclutch,gearbox, driveshaftand maindrive.
Theclutchisof two-plate dry type.
Thenormal freetravel oftheclutchleverensuresfullengagementanddisengagement oftheclutch.Adjust
thefreetravel of theclutchusing twoadjustmentscrewson theendof theclutchcable.
Gearbox
Thegearbox ofthemotorcyclehas fourgearswith constantgearmesh andmovableengagement sleeves.
Adjustment of the gear shift mechanism
Adjustthegearshiftmechanism,usingstops(adjusting
screws)limitingtheturnofthepawlcrankandgearshift
quadrant.
Toadjust thegearshift mechanism,proceedas follows:
-Undofour screwsMõ5 andremovethe righthandcov-
erofthegearbox, covering the shaft of thequadrant.
(Fig.11a)
-Putthemotorcycleonthestand or jack letting the rear
wheelfreely rotates.
-Shifttothe neutralgearandstart theengine.
Toadjustthelower stop “A” limitingtheturnofthequadrantwhenup-shifting(acceleration),
proceed as follows (see Fig. 11):
-Depressingtheupper armofthe pedal, engagethequadrant in thepositionof IIgear,theretaining roller
shouldfullygetinto the flute onthequadrantandlock it in thePos.1(Fig.11) by means ofthespring.
Fig.11a
Fig.11Adjustmentofthe gear shift mechanism