URAL Motorcycles Wolf 2004 User manual

Irbit Motorcycle Factory
Irbit Motorworks ofAmerica
Owners Manual
2004Model
Wolf

Contents
Introduction.............................................................................................................................5
Warnings, Cautions, Notes.......................................................................................................5
Chapter 1 Specifications
Specifications .......................................................................................................................................7
Torque Specifications ...........................................................................................................................9
Chapter 2 Motorcycle Controls and Instruments
MotorcycleControls&Instrumentation .................................................................................................11
Controls ..............................................................................................................................................12
ControlandInstrumentmaintenance...............................................................................................................20
Chapter 3 Engine Operation
EngineOperationand Maintenance ....................................................................................................21
Pre-TripPreliminaries .........................................................................................................................21
Starting the Engine..............................................................................................................................21
OperatingPrecautions ........................................................................................................................25
Running-IntheNewMotorcycle ............................................................................................................25
Chapter 4 Engine Design
Brief Description of Design ...............................................................................................................27
LubricationSystem .............................................................................................................................28
FuelSystem ........................................................................................................................................29
IgnitionSystem....................................................................................................................................30
Chapter 5 Carburetors
Carburetors.........................................................................................................................................33
CarburetorMaintenance..................................................................................................................................34
Chapter 6 Power Transmission
PowerTransmission............................................................................................................................35
Clutch..................................................................................................................................................35
Gearbox..............................................................................................................................................35
FinalDrive ..........................................................................................................................................36
Chapter 7 Running Gear
Spring-Loaded HydraulicShockAbsorber...........................................................................................37
FrontFork ...........................................................................................................................................38

SteeringHeadBeaings......................................................................................................................................38
Chapter 8 Wheel & Tires
WheelsandTires ................................................................................................................................39
TireData...............................................................................................................................................................40
RunningGearMaintenance .................................................................................................................41
Chapter 9 Brakes
Brakes ................................................................................................................................................43
Chapter 11 Electrical
ElectricalEquipment ...........................................................................................................................47
ElectricalCircuits................................................................................................................................................48
ElectricalEquipmentMaintenance ......................................................................................................48
Chapter 12 Maintenance
MaintenanceofMotorcycle..................................................................................................................51
List of RecommendedLubricants ........................................................................................................51
LubricationChart.................................................................................................................................52
RequiredLubrication...........................................................................................................................52
Careof MotorcyclePaint .....................................................................................................................52
Preservationand Storage....................................................................................................................53
Battery ................................................................................................................................................53
Listof IndividualTool Set, SpareParts,Accessories&Documents......................................................55
Chapter 14 Learning to Ride the URAL
SafeOperating Rules..........................................................................................................................57
Chapter 15 Warranty
Warranty..............................................................................................................................................59
WarrantyClaimForm ..........................................................................................................................67
WarrantyFlatRateSchedule ...............................................................................................................68
Chapter 16 Service Coupons
ServiceCoupons ................................................................................................................................71
NewAddress Form .............................................................................................................................81
NewOwnerForm ................................................................................................................................82
URALStartingand RunningTips..........................................................................................................83

INTRODUCTION
Welcometothe URALMotorcycling Family! Your Uralhas been builtby the IrbitMotorcycle Factory in
Russiaand distributed by Irbit MotorworksofAmerica,the United Statesaffiliateof the IrbitMotorcycle
Factory. TheUral motorcycle conforms to all applicable US Federal Motor Vehicle Safety Standardsand
USEnvironmentalProtectionAgencyregulationseffectiveonthe dateofmanufacture.
Thismanualhas beenpreparedto acquaintyou with theoperation, care andmaintenance ofyourmotor-
cycle,andtoprovide youwithimportant safety information. Followtheseinstructions carefully formaxi-
mummotorcycleperformanceand for yourpersonalmotorcycling safety andpleasure.
Your Owner’sManual contains instructionsfor operation, maintenanceand minor repairs. Majorrepairs
requirethe attention ofa skilledmechanic andthe useof special toolsand equipment. YourAuthorized
IMWA Ural Dealerhasthe facilities, experienceand genuineUral parts necessary to properly renderthis
valuableservice.
Anysuggestions orcomments are welcome! Write to us or postan e-mail on the Ural Discussion bulle-
tinboardatwww.imz-ural.com.
Happy Riding!
Important Notice!
Statementsinthis manualpreceded bythe followingwords areof special importance:
WARNING: MEANS THERE IS THE POSSIBILITY OF PERSONAL INJURY TO
YOURSELF OR OTHERS.
CAUTION: Meansthereis thepossibility ofdamageto thevehicle.
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 mecha-
nisms 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.” Follow-
ing those procedures will ensure that you have the most powerful & smoothly operating engine
after break-in.
Maintenanceintervals recommended arebased onoperational experience under various climaticand
roadconditions. However, these intervals maybe extendedor reducedfollowing repeated checks of the
lubricantconditionand general mechanicalcondition of themotorcycle.
CarefullystudythisOwner’sManual before startingthemotorcycle.
Specifications anddesign aresubject to changewithout notice.

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7
Chapter 1
SPECIFICATIONS
GENERAL
Model Wolf
Maximum speedof motorcycle 130 km/h 80 mph
Drymassof motorcycle 548 lb
Maximumload-carryingcapacity 330 lb.
Noiselevel below 80db
OVERALL DIMENSIONS
Length 2530 mm / 8.3 ft
Width 850 mm / 2.8 ft
Height 1300 mm / 4.3 ft
RoadClearance 150 mm / 5.9 in
Seatheight 840 mm / 33 in
Wheelbase 1470 mm / 58 in
ENGINE
Type 4 stroke, overheadvalves,opposed twin-cylinder
Displacement 745 cc
Cylinderbore 78 mm
Piston stroke 78 mm
Compression ratio 8.6 :1
Ratedhorsepower 29 KW / 40 BHp
Ratedrotational speed 5600 RPM
Rated torque 38 ft.-lbs @ 3750 RPM
Lubricationsystem Dualsystem offorcedlubrication andsplashing
Lubricant SAE 20W/50
CARBURETOR
Carburetortype 32 CVK Keihin
Numberofcarburetors 2
Air cleaner Paper Filter Element
Fuel 91 octanepremium unleaded gasoline
PCV Valve InternalBreather
ELECTRICAL
Ignitionsystem Electronic Ignition
Spark plugs NGKBP7HS orEquivalent
Ignitiontiming Automaticadvance

8
Alternator 35 amp / 12 Volt
Battery Interstate#YTX20L-BSorequivalent
Headlight Helaor equivalent 7"round sealedbeam
TRANSMISSION
Clutch Drydouble-diskclutch
Gearbox 4 speed gearbox
GEAR RATIOS
Igear 3.6
IIgear 2.28
IIIgear 1.5
IVgear 1.19
Speedometer drive ratio 0.4
Finaldrive ratio 3.89
FLUID CAPACITIES
Fueltank(gasoline) 5.5 Gal / 21L
Reserve (gasoline) .5gal / 2L
Engine (oil) 68 oz. / 2L
Transmission (oil) 34 oz. / 1 L
Finaldrive (gear oil) 4.5 oz./ 105 ml
ShockAbsorbers (shock oil) 105 ml / 3.5 oz.
Brake Reservoir DOT 3 or 4 brake fluid to upper line
RUNNING GEAR
Frame Tubularwelded
Rearwheelsuspension Swing arms with spring shock absorbers
Frontfork Telescopic
Brakes Disc-typewithhydraulic drive onfront, disc typewith
hydraulicdriveon rear
Tires Front: MC90/90-18 TIRE; 18X2.15RIM. CIP
150KPA(22PSI)
Rear: MC130/90-16TIRE;16x3.5RIM. CIP
200KPA(29PSI)
CLEARANCES mm in
Valveswith enginecold 0.05 to 0.1 0.002 to 0.004
Betweenspark plug electrodes 1.016 0.040

9
Backlashbetween tooth facesof
bevel gearsin finaldrive 0.1 - 0.3 0.004
FREE TRAVEL / ADJUSTMENTS mm in
Clutchcontrollever 5 - 8 0.2 - 0.3
TORQUESPECIFICATIONS
Metric USEquivalent Location on Bike
54 to 61 NM 40 ft/lb to 45 ft/lb cylinderheads
237 to 251 NM 175 ft/lb to 185 ft/lb flywheeltighteningscrews
19 to 30 NM top 14 ft/lb to 22 ft/lb shock absorber
38 to 49 NM bottom 28 ft/lb to 36 ft/lb shock absorber
30 to 35 NM 22 ft/lb to 26 ft/lb bearingnut
30 to 35 NM 22 ft/lb to 26 ft/lb final driveto swingarm bolts
16 to 19 NM 12 ft/lb to 14 ft/lb oil pumpbolt
6.7 to 11 NM 5 ft/lb to 8 ft/lb enginesump
14 to 19 NM 10 ft/lb to 14 ft/lb final drive casenuts
68 to 90 NM 50 ft/lb to 66 ft/lb nut fastening thepinionbearing
19 to 22 NM 14 ft/lb to 16 ft/lb generator gear nut
136 to 163 NM 100 ft/lb to 120 ft/lb steeringstemnut

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Chapter 2
MOTORCYCLE CONTROLS & INSTRUMENTATION
ControlsandInstrumentation
1Speedometer 11 Front brake controllever
2 Indicatorlights 12 ElectricstartButton
3 Trip odometer reset knob 13 Enginekill switch
5 Clutchcontrol lever 14 Throttlecontroltwistgrip
6 High/ lowbeam switch 15 Rear brake pedal
7 Turnsignal switch
8 Hornpush-button
9 Gearshift (foot) pedal
10 Ignitionswitch
1
2
3
56
789
10
11
12
13
14
15

12
Clutchcontrol lever When theclutchleverissqueezed,theengineisdisengaged from the
gearbox. Whentheleverisreleased,the engineandgearboxareengaged.
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: Alwaysengage the clutch releaseleverwhen shifting. Seriousinternal damage may
result to the transmission if the clutch release lever is not engaged.
Front brake control lever Whentheleverissqueezed,thefrontwheelbrakeisactuated. The
frontbrakeshouldbeusedtogetherwith rearbrake.
Whenthebrakeleverissqueezed,thestopsignallightsareswitched on.
ClutchControlLever
FrontBrakeControlLever

13
Kick starter Isdesignedtostarttheengine. Onpressingtheleverthecrankshaftoftheengineis
actuatedthrough the gearbox. Theleverisreturnedtoitsinitialposition by thespringinsidethe
gearbox.
Gear shift foot pedal. When the front arm is pressed,shiftingfromhigher to lower gear takes
place. Whenthereararmispressed,shiftingfromlower to higher gear takes place. Theneutral
positionis fixed between the 1st and 2nd gears. Itisimportanttoshiftsmoothlywithaconstantforce
andnottokickthegearshiftpedal.
IMPORTANT! Thegreen pilot lampwill illuminate whenthe transmission isin neutral (see
“Starting the Engine”).
GearShift Foot Pedal Kick Starter

14
Rear brakepedal isusedtoactuatetherearbrakes.
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.
RearBrakePedal
WARNING: DONOT LET YOUR FOOT REST ON THE EXHAUST HEADER PIPE. SERIOUS INJURY OR BURNS MAY
RESULT FROM VERY HOT EXHAUST PIPES.

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16
Off Allelectricalsystemsareoff.
Run Voltageissuppliedtoallelectricalsystems.
Parking Voltageissuppliedtorunninglightsonly.
Note:Leaving the keyin theRun orParkingposition will dischargethe battery.
Always return the key to the Off position before removing it.
IgnitionSwitch hasthreefixedpositionsofthekey.
Thepositionsoftheignitionareshownabove.
IgnitionSwitch

17
The indicator lamps are located on the instrument panel:
TurnSignal Indicatorindicatesthattheturnsignalsareactivated
Alternatorfault indicator indicatesthatthechargingsystemismalfunctioningand needsimme-
diateattention
NeutralIndicator indicates thatthegearboxisinneutral.
HighBeam Indicator,indicatesthattheheadlighthighbeamisactivated.
Speedometer isonthedashboard,withtripandtotalodometer. Thetripodometerisresettozero
byrotatingknobcounterclockwise. Notethattheodometerreadsinkilometers notmiles.
Alternator
Fault
Indicator
Turn
Signal
Indicator
Neutral
Indicator High
Beam
Indicator

18
Electric Start Button Ignition Cutoff Switch
Low/HighBeamSwitch
HornPushButton
TurnSignalSwitch

19
ThrottleControl is on therighthandlebar.Turningthetwistgripcounterclockwise increases
enginespeed.
IgnitionCutoff Switch has two positions, ignition off (up), and ignition on (down).
ElectricStart Button is located on the right-hand twist grip, below the kill switch.
Lowand High Beam Light Switch hastwopositions,high beam(up),andlowbeam(down).
Turn indicator switch isusedforsignalingaturn
horn push-button isusedtoactivatethehorn
Tripodometerresetknob

20
SPEEDOMETERMAINTENANCE
Afterevery 10,000km,removethespeedometerfromthe motorcycleandaddfiveorsixdrops of
oilintothespeedometerwherethecableinsertsintothespeedometer.Thiswilllubricatethespeed-
ometerinternally.
Tolubricatethespeedometercable,removethecablefromthespeedometerandpullstraight. Use
speedometerlubricatingoilorlight machineoil.
CONTROLCABLEADJUSTMENT
Thecontrolcablesareadjustedbyscrewadjustmentsatthecableends.
Withthecontrollevers released:
•fortheclutch a play atthe clutchlever end shouldbe equal to5 - 8mm/0.2 - 0.3in.
•forthe carburetors - carburetorthrottlecablessynchronized
Withthecontrollevers(handles)fullydepressed:
•fortheclutch—completedisengagementoftheenginefrom thetransmission;noiselessshifting
ofgearsmeansgoodadjustment of the clutchcable.
•forthecarburetors—liftof throttlestothemaximumandequalheight
CONTROLCABLEMAINTENANCE
Thedailypreventativemaintenanceinvolvescheckingthefunctioning,conditionandfasteningof
thetierods,cables and braking action. Refer to the Service Coupons for lubrication schedule.
Asper the service coupons, lubricate the throttlecontroltwistgrip,theleverpinsandendsof
cablesusedintheclutchandthethrottles.