2015 EFI Manual
Contents
1. WARNING ALWAYS WEAR EYE PROTECTION WHEN REMOVING LAMP RETAINING CLIPS WARNING IT IS UNSAFE TO OPERATE YOUR MOTORCYCLE WITHOUT A FUNCTIONING HEADLIGHT 6 2 LAMP 8 BULB REPLACEMENT TAIL LIGHT Tail Light Replacement Step 1 Remove the tail light lenses retaining screws Step 2 Inspect and replace bulbs as needed The upper bulb in the running brake lamp and the lower is the license plate lamp Step 3 To remove the bulb twist and pull Step 4 Re install the bulbs in reverse order NOTE TO HELP PREVENT CORODED CONTACTS USE DIELECTRIC GREASE WARNING IT IS UNSAFE TO OPERATE YOUR MOTORCYCLE WITHOUT A FUNCTIONING TAIL AND BRAKE LIGHT 6 3 LAMP 8 BULB REPLACEMENT TURN SIGNALS Turn Signal Bulb Replacement Step 1 Remove the turn signal lenses retaining screws Step 2 Inspect and replace bulbs as needed Step 3 To remove the bulb twist and pull Step 4 Re install the bulbs in reverse order NOTE TO HELP PREVENT CORODED CONTACTS USE DIELECTRIC GREASE WARNING IT IS UNSAFE TO OPERATE YOUR MOTORCYCLE WITHOUT FUNCTIONING TURN SIGNALS 6 4 LAMP 8 BULB REPLACEMENT SIDECAR LAMPS Sidecar Lamps Step 1 Remove the lenses retaining screws Step 2 Inspect and replace bulbs as needed Step 3 To remove the bulb twist and pull Step 4 Be sure to re install the lenses gasket Step 5 Re install the2. CAUTION DO NOT ACCELERATE WHILE STARTING THE BIKE DO NOT RUN STARTER FOR MORE THAN 5 SECONDS NEVER STAND IN FRONT OF THE MOTORCYCLE WHILE THE ENGINE IS RUNNING STARTING THE ENGINE WHEN WARM OR HOT Use the following instructions when starting a warm or hot engine Check to be sure you have enough fuel Switch ignition on Be sure the transmission is in neutral Switch the kill switch to run Press the starter button or use the kick starter until engine starts MI pee T CAUTION DO NOT ACCELERATE WHILE STARTING THE BIKE DO NOT RUN STARTER FOR MORE THAN 5 SECONDS NEVER STAND IN FRONT OF THE MOTORCYCLE WHILE THE ENGINE IS RUNNING 3 5 ENGINE RUN IN During the first 1000 kilometers it is important not to overload or over rev the engine while riding To ensure proper break in you should ride the motorcycle conservatively at varying speeds and loads Use the following guidelines during the first 1000 kilometers prior to the initial break in service Do not overload or lug the engine Do not exceed a top speed beyond 60mph Do not ride at a constant rpm for long periods of time Try to vary speed and load when riding Shift smoothly between gears and do not down shift at high rpm Always be sure the engine is warmed up before riding Follow the pre ride inspection MouBUNP MnwB2 3 6 4 Lubrication Recommended Fluids Lubricants amp Capacities Lubricat
3. Step 3 Be sure to clean any metal contaminates from the drain plug and replace the drain plug sealing washer Step 4 Re install drain plug and washer and torque to specification ENGINE OIL amp FILTER REPLACEMENT Step 5 Lightly lubricate the new oil filter sealing ring with fresh oil and install filter tightening approximately turn after seat of seal CAUTION DO NOT OVER TIGHTEN THE OIL FILTER Step 6 Fill engine with 2 1L of recommended motor oil Step 7 Start the engine and let run for 30 seconds confirming you have no oil leaks at filter Step 8 Check oil level oil should be full to the upper mark on the dipstick add oil as needed NOTE ALWAYS DISPOSE OF MOTOR OIL PROPERLY Step 1 Place a drain pan under the gearbox and remove drain plug using a 17mm socket wrench Step 2 Be sure the clean any metal contaminates from the drain plug and replace the drain plug sealing washer Step 3 Re install drain plug and washer and torque to specification Step 4 Fill the gearbox with 9L of recommended motor oil Step 5 Re install fill plug and torque to specification NOTE ALWAYS DISPOSE OF MOTOR OIL PROPERLY FINAL DRIVE OIL REPLACEMENT Step 1 Place a drain pan under the final drive and remove the drain plug using a 17mm socket wrench Step 2 Be sure the clean any metal contaminates
4. YOUR NEW URAL MOTORCYLE THIS MANUAL CONTAINS INFORMATION AND ADVICE THAT WILL HELP YOU PROPERLY OPERATE AND MAINTAIN YOUR MOTORCYCLE PLEASE PAY SPECIAL ATTENTION TO NOTICES IN THIS MANUAL MARKED AS FOLLOWS CAUTION INDICATES POSSIBILITY OF EQUIPMENT FAILURE THAT MAY RESULT IN YOUR MOTORCYLE BE UNSAFE TO OPERATE IF INSTRUCTIONS ARE NOT FOLLOWED WARNING INDICATES A VERY STRONG POSSIBLILITY OF INJURY TO YOURSELF AND OTHERS OR LOSS OF LIFE IF INSTRUCTIONS ARE NOT FOLLOWED NOTE PROVIDES HELPFUL INFORMATION AND TIPS Table of Contents Section General Information Motorcycle Controls and Instrumentation Motorcycle Operation Warranty Information Emission Control Information Owner Documents 1 General Information Service Rules Model Identification Model Specifications Torque Chart Clearance and Adjustment Specifications Tire Data Periodic Maintenance Chart Motorcycle Storage and Care 1 1 SERVICE RULES 1 Do imo um Always wear proper safety equipment including but not limited to safety glasses and gloves Allow your motorcycle to cool down completely prior to servicing to avoid getting burned Always use genuine Ural or Ural recommended parts fluids and components when servicing your motorcycle Parts that do not meet these requirements may result in damage Follow the service procedures as outlined in this manual Always follow the torque specifications wh
5. 2wd Move the lever to the forward position to dis engage 2wd CAUTION 2WD SHOULD ONLY BE USED FOR LOOSE ROAD CONDITIONS AND OR OFF ROAD PURPOSES WARNING USE OF 2WD ON THE STREET CAN MAKE THE MOTORCYLE DIFFICULT TO STEER POSSIBLY RESULTING IN LOSS OF CONTROL HYDRAULIC SPRING SHOCK ABSORBERS Adjustable Shock Absorbers The shock absorbers have 5 preload adjustments Rotate the adjustment ring counter clockwise as shown to increase spring preload using the supplied wrench in your tool kit N 3 Motorcycle Operation Pre ride Inspections Initial Ride Instructions Sidecar Safety Starting Procedures Run In 3 1 PRE RIDE INSPECTIONS Prior to each ride you should inspect the motorcycles technical condition for safety Use the following pre ride inspection list to ensure your motorcycle is safe and ready to ride 1 Check the oil level Low oil level causes premature wear and possible engine damage Check the fuel level Check the tire pressure Low tire pressure can cause poor handling also inspect the tire for abnormal and or excessive wear that may lead to a flat tire Check all lights for proper operations including headlight running lights turn signals and brake lights Check the brakes for proper operations and correct fluid level If for any reason the brakes feel abnormal or spongy do not ride the bike as it may be unsafe Inspect all cables to insure
6. Each code has a three digit sequence with each digit having a value of 1 5 A short pause occurs between individual digits while a long pause between repeating the code or displaying the next code depending on the number of fault events To identify the fault initiate the blink sequence and count out blinks for each of the three digits Writing down the pattern helps The light will blink on half second intervals for each digit Between each digit a one second pause will occur Between each blink code or the repetition of the code if a single fault is present a three second pause exists When a fault presents a specific component on the vehicle system the component must be inspected along with electrical connections and harness components leading up to the component This will aid in diagnosing and fixing the problem The blink sequence will continue to repeat until the function is deactivated To deactivate the feature toggle the kill switch three times within a two second time frame the same as to activate the feature Fault Category The first digit is used to indicate the category of fault This helps to identify if the problem is specific to one ECU or to the vehicle as a whole These categories are defined as follows First Digit Category Description Value Cylinder 1 Faults Faults specific to the left EMS Cylinder 2 Faults Faults specific to the right EMS System Faults Vehicle level EMS faults 7 2 Blink Code 111 2
7. OR REMOVE EMISSION RELATED COMPONENTS 9 3 VEHICLE EMISSION CONTROL LABEL The emission control label is located on the left hand frame down tube on all motorcycles Please see the sample diagram below VEHICLE EMISSION CONTROL INFORMATION Engine tune up specification for Irbit Motorcycle Factory Ltd IMZ Engine Displacement 749cc EIMFC 750A02 EIMFPMETALU 1 Please Read Owner s Manual for Details Idle Speed 800 RPM at normal temp Max RPM 5 600 Ignition Timing Factory Preset Idle Mixture factory preset Plug type NGK BPR6HS Lubricant SAE 20W50 Plug Gap 0 040 1 0 1 02mm Fuel 91 Octane min Valve Clearance cold 0 05 0 10 mm 002 004in exhaust and intake Exhaust Emission Control System 3TWC This vehicle conforms to all US EPA and California regulations applicable to 2015 Model Year New Motorcycles 10 Owner s Documents New Owner Form New Address Form 10 1 BS URAL NEW OWNER FORM To transfer warranty register with Ural when purchasing a pre owned Ural Motorcycle please fill out this form and mail to the address below This will ensure that you will benefit from any remaining warranty coverage VEHICLE IDENTIFICATION NUMBER Check here if you also want to receive newsletters and other promotional materials from Ural NEW OWNER S NAME ADDRESS CITY STATE PHONE NUMBER ZIP CODE E MAIL optional DATE OF SALE
8. Reconnect battery and or disconnect charger 3 Follow starting procedures 4 Take the motorcycle for a short ride prior to any long trips CLEANING It is important to maintain your motorcycle properly and clean on a regular basis Use the following guidelines when washing your motorcycle e Make sure the engine is completely cool e Use warm soapy water and wash thoroughly e Avoid water from entering the air filter and electrical components e After washing dry the motorcycle with a cloth e Lubricate joints and cables as necessary e Run motorcycle to evaporate remaining water WINTER CONSIDERATIONS Motorists in many areas of the US experience the use of salt and other chemicals that are applied to road surfaces in the winter Salt and other caustic chemicals should always be washed of you bike with fresh water as soon as possible to avoid rust and corrosion NOTE RUSTED OR CORRODED PARTS CAUSED BY SALT ARE NOT COVERED BY WARRANTY 1 8 2 Motorcycle Controls amp Instrumentation Hand Controls Foot Controls Ignition Switch Speedometer Indicator Lamps Hydraulic Steering Damper Parking Brake Reverse Lever Kick Starter 2wd Engagement Lever Hydraulic Spring Shock Absorbers 2 1 HAND CONTROLS High Beam Switch Clutch Lever Turn Signal Switch Left Hand Grip Front Brake Lever Starter Button Throttle Grip Clutch Lever Pulling the clutch lever will disengage the clutch
9. _ MO DAY YEAR ODOMETER READING AT THE TIME OF TRANSFER Purchased From City State Mail this form to Irbit Motorworks of America Inc 14700 NE 95 St Suite 102 Redmond WA 98052 Zip Code Or fax to 425 250 6762 We never sell or rent your personal information to third parties unaffiliated with Ural 10 2 BS URAL NEW ADDRESS FORM If you move please fill out the form and mail to the address below This will insure that you continue to receive all correspondence from Irbit Motorworks of America VEHICLE IDENTIFICATION NUMBER OWNER S NAME OLD ADDRESS APT NO CITY STATE ZIP CODE MY NEW ADDRESS IS NEW ADDRESS APT NO CITY STATE ZIP CODE Mail this form to Irbit Motorworks of America Inc Or fax to 425 250 6762 14700 NE 95 St Suite 102 Redmond WA 98052 We never sell or rent your personal information to third parties unaffiliated with Ural 10 3 11 Schematics Wiring Diagram 11 2 i i INSTRUMENT CLUSTER EFEFEF i MARARA HER ie 1 93224030 TWYN PTOC spes u matus aeg romeo a N fe of 4 5 N
10. from the drain plug and replace the drain plug sealing washer Step 3 Re install drain plug and washer and torque to specification Step 4 Fill the final drive with 135ml 2wd or 105ml 1wd of recommend gear oil Step 6 Check oil level by threading the dipstick into the case oil should be full to the upper mark add fluid as needed NOTE ALWAYS DISPOSE OF GEAR OIL PROPERLY DRIVE SHAFT amp SPLINE LUBRICATION Final Drive Shaft U Joints should be lubricated with grease using a grease gun The rear drive shaft has one grease zerk located at the u joint grease this joint per the maintenance intervals or after off road use Sidecar Drive Shaft On 2wd models only the sidecar drive shaft has two grease zerks located at each u joint grease these joints per the maintenance intervals or after off road use Drive Wheel Splines The rear wheel drive splines should be greased per the maintenance intervals or after off road use 2wd models also have drive splines located on the sidecar wheel splines should be greased per the maintenance intervals or after off road use CABLE LUBRICATION All cables including the clutch speedometer throttle and parking brake cables should be lubricated with cable lube or WD 40 per the maintenance intervals You should also lubricate all cables before and after extended periods of storage and or after off road use To lubricate the cables pull back the protecti
11. service schedule Retain all service records for future reference CALIFORNIA EMISSION CONTROL SYSTEM WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Irbit MotorWorks of America Inc hereinafter IMWA is pleased to explain the Emission Control System Warranty on your 2005 and later motorcycle In California new motor vehicles must be designed built and equipped to meet the State s stringent anti smog standards IMWA must warrant the emission control system on your motorcycle for the periods of time listed below provided there has been no abuse neglect or improper maintenance of your motorcycle Your emission control system may include parts such as the carburetor the ignition system catalytic converter and engine computer Also included may be hoses belts connectors and other emission related assemblies Where a warrantable condition exists IMWA will repair your motorcycle at no cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE Class 111 motorcycles 280cc and larger for a period of use of five 5 years or 30 000 kilometers 18 641 miles whichever first occurs If an emission related part on your motorcycle is defective the part will be repaired or replaced by IMWA This is your emission control system DEFECTS WARRANTY OWNER S WARRANTY RESPONSIBILITIES As the owner of Ural motorcycle you are responsible for the performance of the require
12. they are not pinched or routed improperly also inspect the clutch cable for correct free play Check for any loose fasteners and tighten as necessary Be sure any luggage is secured before riding INSTRUCTIONS FOR INITIAL RIDE The following steps should be taken prior and during your first ride UNBE Read the entire owner s manual prior to starting and or taking you first ride Familiarize yourself with all controls and instruments Make any required adjustments to mirrors and controls for comfort Always wear safety gear including but not limited to helmet boots gloves and jacket regardless of weather Ride in a safe environment such as a parking lot or area you are familiar with while you learn the specific handling characteristics of your new sidecar motorcycle Follow the Engine Run in instructions 3 2 SIDECAR SAFETY The Ural sidecar motorcycle since it has three wheels behaves quite differently from either a solo motorcycle or a car For these reasons the following label has been attached to your motorcycle tank WARNING LEFT HAND AND RIGHT HAND TURNS MAY BE DANGEROUS EXCESSIVE SPEED AND AN UNWEIGHTED SIDECAR MUST BE AVOIDED Like any other motor vehicle if the Ural is driven beyond its design limits you can get hurt Properly driven since you have the added stability of the third wheel in case of sand ice or slippery road conditions the Ural will give you a much safer ride than a sol
13. 1040 06002 IMZ 8 1040 06002 01 142 8 1240 06002 1MZ 8 1240 06002 01 Circlip DIN 472 47x1 75 Distance bushing with washers IMZ 8 1040 06018 Bearing 6204 2RSH Collar 1M2 8 1040 06016 LH distance bushing 1MZ 8 1040 06134 Circlip DIN 472 Hub IMZ 8 1040 06020 Sidecar wheel 2000 IMZ 8 1041 20024 IMZ 8 1041 20024 01 Rear wheel IMZ 8 1240 07002 1M2 8 1240 07002 01 Screw DIN 6912 M8x25 102 8 1040 06018 1MZ 8 1037 07105 LH distance bushing IMZ 81040 06124 Bearing 6024 2RSH RH distance bushing Collar IMZ 8 1040 06016 Thrust washer IMZ 8 1040 06109 Circlip DIN 472 471 75 Hub IMZ 8 1040 06020 The wheel bearings are sealed type and cannot be service only replaced The bearings should be inspected and replaced per the maintenance intervals Step 1 Remove the wheel Step 2 Remove the dust seals and retaining clips Step 3 Carefully drive the bearings out of the hub and replace Step 4 Re install in reverse order replacing the dust seals as needed NOTE WHEEL BEARINGS SHOULD BE INSPECTED AND REPLACED MORE FREQUENTLY THAN OUTLINED IN THE MAINTENANCE SCHEDULE WHEN THE MOTORCYCLE IS USED OFF ROAD OR IN ADVERSE WEATHER ON A REGULAR BASIS CAUTION FAILURE TO REPLACE THE WHEEL BEARINGS WHEN NEEDED CAN DAMAGE THE WHEEL HUB AND AXLE WARNING DAMAGED AND OR WORN BEARINGS PREVENT THE WHEEL FROM ROTATING F
14. 11 112 212 113 213 121 221 122 222 123 223 124 224 125 225 131 231 132 232 133 233 134 234 141 241 142 242 143 243 144 244 151 251 311 312 313 321 322 323 331 341 342 Category Cylinder 1 2 Cylinder 1 2 Cylinder 1 2 Cylinder 1 2 Cylinder 1 2 Cylinder 1 2 Cylinder 1 2 Cylinder 1 2 Cylinder 1 2 Cylinder 1 2 Cylinder 1 2 Cylinder 1 2 Cylinder 1 2 Cylinder 1 2 Cylinder 1 2 Cylinder 1 2 Cylinder 1 2 System System System System System System System System System Sub Category Internal CPU Internal CPU Internal CPU Internal ECU Internal ECU Internal ECU Internal ECU Internal ECU INJ or IGN INJ or IGN INJ or IGN INJ or IGN O2 or O2 Heater O2 or O2 Heater O2 or O2 Heater O2 or O2 Heater Other Battery Battery Battery Fuel Pump Pres Fuel Pump Pres Fuel Pump Pres VCOM Immobilizer Immobilizer Fault Description Cal CRC mismatch EEPROM Failure Program Error MAT Sensor Failure BAP Sensor Failed BAP Comm Failure MAP Failure MC33814 Failure INJ open or short to ground INJ short to battery IGN open or short to ground IGN short to battery 02 Sensor Circuit Failed Low O2 Sensor Circuit Failed High O2 Heater open or short to ground O2 Heater short to battery Engine Temperature Sensor fault High Voltage Low Voltage Unstable Voltage Pump open or short to ground Pump short to batter
15. 2015 OWNERS MANUAL GEAR UP PATROL cT ay CF INTRODUCTION Welcome to the URAL Motorcycling Family Your Ural has been built by the Irbit Motorcycle Factory in Russia and distributed by Irbit Motorworks of America the United States affiliate of the Irbit Motorcycle Factory This Ural motorcycle conforms to all applicable US Federal Motor Vehicle Safety Standards and US Environmental Protection Agency regulations effective on the date of manufacture This manual covers the Gear Up Patrol and T model and has been prepared to acquaint you with the operation care and maintenance of your motorcycle and to provide you with important safety information Follow these instructions carefully for maximum motorcycle performance and for your personal motorcycling safety and pleasure It is critical that a beginning sidecar driver becomes thoroughly familiar with the special operating characteristics of sidecar outfit before venturing out on the busy roads Your Owner s Manual contains instructions for operation maintenance and minor repairs Major repairs require the attention of a skilled mechanic and the use of special tools and equipment Your Authorized IMWA Ural Dealer has the facilities experience and genuine Ural parts necessary to properly render this valuable service Any suggestions or comments are welcome Happy Uraling IMPORTANT SAFTEY INFORMATION WE STRORLY SUGGEST THAT YOU READ THIS MANUAL COMPLETELY PRIOR TO RIDING
16. ENT Step 1 Locate the cable adjuster connected to the parking brake handle and be sure the parking brake is in the off position Step 2 Adjust the cable to remove excess free play Step 3 With the parking brake set you will have approximately 12mm between the caliper stop bracket and the brake arm with spring 5 11 SIDECAR BRAKE SYSTEM MAINTENANCE Step 1 Remove the caliper mounting bolts Step 2 Remove the caliper from the sidecar swing arm Step 3 Remove the caliper safety clip and carefully drive the retaining pin out of the caliper with a punch or drift SIDECAR BRAKE SYSTEM MAINTENANCE CONT Step 4 Remove the brake pads by pulling them out of the bottom of the caliper Step 5 Inspect the brake pads and replace as needed NOTE MINIMUM PAD THICKNESS IS 1MM Step 6 Re install the brake pads and caliper in reverse order DO NOT forget to install the safety clip Step 7 Confirm the brake fluid level is full in the reservoir and add as needed to FULL line DO NOTE OVER FILL CAUTION OPERATING THE MOTORYCLE WITH WORN BRAKE PADS CAN CAUSE DAMAGE TO THE BRAKE ROTORS WARNING OPERATING THE MOTORCYCLE WITH WORN BRAKE PADS BELOW THE MINIMUM THICKNESS CAN RESULT IN POOR BRAKING AND POSSIBLE ACCIDENT WARNING OPERATING THE MOTORCYCLE WITH LOW FLUID LEVEL CAN CAUSE LOSS OF BRAKING FORCE FRONT WHEEL REMOVAL amp I
17. HE BATTERY AT ALL TIMES ALWAYS PROTECT HANDS AND FACE WHEN WORKING ON AND OR NEAR A BATTERY KEEP BATTERIES OUT OF REACH OF CHILDREN AND PETS 6 6 Step 1 Disconnect the white negative battery cable Step 2 Disconnect the positive battery cable Step 3 Remove the battery hold down straps Step 4 Loosen both the upper and lower starter bolts to allow clearance for battery removal CAUTION ALWAYS DISCONNECT THE NEGATIVE BATTERY CABLE FIRST TO AVOID SHORTING THE BATTERY WARNING SHORTING THE BATERY TERMINALS COULD RESULT IN A FIRE 6 7 BATTERY REPLACEMENT Step 5 Carefully slide the battery out between the frame tube and air box Step 6 Re install in reverse order by sliding the battery back into place and reconnecting all straps and cables Step 7 Be sure to re tighten the starter bolts CAUTION ALWAYS RECONNECT THE POSITIVE BATTERY CABLE FIRST TO AVOID SPARKS NOTE USE DIELECTRIC GREASE ON THE BATTERY CONNECTIONS TO PREVENT CORROSION 6 O FUSE LOCATIONS FUSEBOX1 ECU POWER ECU RELAY STARTER TURN SIGNALS BRAKE LIGHTS HORN LIGHTS HIGH BEAM PARKING LIGHTS FUSEBOX2 POWER OUTLET SPOTLIGHT IF EQUIPPED ACC OPEN ACC OPEN Fuse Box 1 The main motorcycle fuse box is located on the right side of the steering neck Th
18. NSTALLATION Step 1 Remove the lower caliper mounting bracket bolts Step 2 Carefully support the brake caliper using a strap Step 3 Loosen the axle pinch bolt 5 14 FRONT WHEEL REMOVAL amp INSTALLATION CONT Step 4 Loosen the axle by rotating clockwise and remove from the wheel Step 5 To re install the wheel first place the caliper mount into the wheel Step 6 Position the wheel back on the bike and install the axle DO NOT tighten fully at this point FRONT WHEEL REMOVAL amp INSTALLATION CONT Step 7 Re attach the caliper with mounting brackets and tighten to specification Step 8 Tighten the axle by rotating counter clockwise Step 9 Tighten the axle pinch bolts to specification 5 16 REAR WHEEL REMOVAL amp INSTALLATION Step 1 Place the motorcycle on the center stand Step 2 Carefully remove the caliper retaining bolt safety clips Step 3 Remove the caliper retaining bolts and brake pads REAR WHEEL REMOVAL amp INSTALLATION CONT Step 4 Support the brake caliper using a strap Step 5 Remove the brake caliper mounting bracket bolts Swing the support brace bracket up Step 6 Remove the rear axle nut 5 18 REAR WHEEL REMOVAL amp INSTALLATION CONT Step 7 Loosen the axle pinch bolt and remove the axle Step 8 Remove the rear wheel by tilting the outwards towards you and rolling it back as shown Step 9 To re install the rear wheel plac
19. REELY TIRE amp TUBE REPLACEMENT Step 1 Remove the valve stem and deflate the tire Step 2 Using the provided tire spoons in your tool kit carefully remove one side of the tire from the rim Step 3 Remove the tube from the tire Step 4 Remove the tire from the rim Step 5 Re install the tire in reverse order be careful not to pinch the tube during installation NOTE WHEN INFLATING THE TIRE BE SURE THE TIRE BEAD IS FULLY SEATED AND EVEN AROUND THE RIM Un D SIDECAR ALIGNMENT The sidecar should be installed in a definite position relative to the motorcycle The position is determined by the camber and toe in of the motorcycle and the side car wheels An incorrectly aligned side car will drag the motorcycle to either side and cause extensive tire wear If the motorcycle is not stable on the road or is difficult to steer check the alignment Checking and measuring the alignment should be done on level ground Check toe in of the motorcycle and the side car wheels with two straight bars applied to the side faces of the wheels just below the ax les The toe in should be 3 to 8mm 2wd models or 8 to 12mm 1wd models at the front wheel When adjusting unbolt the top of the strut legs fastening the side car to the motorcycle loosen the bolt clamping the lower rear bracket and adjust the position of the bracket relative to the rear tube of the side car frame to obtain necess
20. ary toe in of the wheels Tighten up the bolt fastening the bracket adjust the length of the strut legs and secure them with bolts Check the lean out of the motorcycle using a level gauge or protractor with a plumb bob and ruler standard lean out is 1 2 degrees Adjust the two inclined legs by screwing the forks in or out When the lean out is correct the rider will remain vertical while riding on the local roads which may be slightly sloped to assist with water runoff Check the toe in while the motorcycle is running on the road With the toe in properly adjusted the motorcycle will not pull to either side while running at normal road speed If it pulls to the right increase the toe in if it pulls to the left decrease the toe in CAUTION DOUBLE CHECK FOR CORRECT TOE IN BEFORE MAKING ANY CHANGE TO LEAN OUT 5 25 SIDECAR ALIGNMENT DIAGRAM Lit ff 1 6 mm toe in for 2W 8 22 mm foe in for WP e 22S lean Hegre 6 Electrical Lamp amp Bulb Replacement Battery Maintenance amp Replacement Fuse Locations Relay Locations Starter Alternator ECU Data Port 6 1 LAMP amp BULB REPLACEMENT HEADLIGHT Headlight Replacement Step 1 Remove the lamp retaining ring screw and pull the lamp out of the bucket Step 2 Disconnect the lamp Step 3 Carefully remove the lamp retaining clips and replace lamp Step 4 Re install in reverse order
21. bulbs in reverse order NOTE TAIL LIGHT BRAKE ON LEFT AND SIGNAL ON RIGHT NOTE TO HELP PREVENT CORODED CONTACTS USE DIELECTRIC GREASE WARNING IT IS UNSAFE TO OPERATE YOUR MOTORCYCLE WITHOUT FUNCTIONING SIDECAR LAMPS BATTERY MAINTENANCE Stock battery on the motorcycle should function at ambient air temperature from 40 C to plus 60 C 40 F to 140 F As the battery is in service Regularly check the voltage for 13 8 14 2 V Do not allow the battery to discharge Coat bolts nuts washers and tips with petroleum jelly or battery grease Use two wrenches for clamping or undoing the nuts to avoid breaking battery parts Before storage fully charge the batteries wash the battery surface with water and wipe dry clean the bolts and nuts of dirt WARNING BATTERIES CONTAIN SULFURIC ACID WHICH CAN CAUSE SEVERE BURNS AVOID CONTACT WITH SKIN EYS OR CLOTHING ANTIDOTE EXTERNAL FLUSH WITH WATER INTERNAL DRINK LARGE QUANTITIES OF WATER FOLLOWED BY MILK OF MAGNESIA VEGETABLE OIL OR BEATEN EGGS CALL DOCTOR IMMEDIATELY CAUTION WHEN CHARGING THE BATTERY DISCONNECT THE NEGATIVE TERMINAL FROM THE BATTERY TO PREVENT DAMAGE TO ELECTRICAL COMPONENTS NEVER JUMP START THE MOTORCYCLE WARNING BATTERIES PRODUCE EXPLOSIVE HYDROGEN GAS AT ALL TIMES ESPECIALLY WHEN BEING CHARGED KEEP ANY OPEN FLAMES AND OR SPARKS AWAY FROM T
22. d maintenance listed in your owner s manual IMWA recommends that you retain all receipts covering maintenance on your motorcycle but IMWA cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance You are responsible for presenting your motorcycle to an IMWA dealer as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 thirty days As the motorcycle owner you should also be aware that IMWA may deny you warranty coverage if your motorcycle or a part has failed due to abuse neglect improper maintenance or unapproved modifications If you have any questions regarding your warranty rights and responsibilities you should contact Irbit MotorWorks of America at 1 866 943 7454 or the California Air Resource Board at 9528 Telstar Avenue El Monte CA 91731 LIMITED WARRANTY ON EMISSION CONTROL SYSTEM Irbit MotorWorks of America Inc 14700 NE 95th St Suite 102 Redmond WA 98052 USA hereinafter IMWA warrants that each new 2004 and later Ural motorcycle that includes as standard equipment a headlight taillight and stoplight and is street legal A is designed built and equipped so as to conform at the time of initial retail purchase with all applicable regulations of the United States Environmental Protection Agency and the California Air Resources Board and B is free from defects in material and workmanshi
23. e the wheel back on the bike and push the axle through both the wheel and brake mounting bracket as shown REAR WHEEL REMOVAL amp INSTALLATION CONT Step 10 Torque the caliper mounting bracket bolts to specification Step 11 Re install the brake caliper and brake pads Torque the caliper retaining bolts to specification Step 12 Re install the caliper retaining bolt safety clips SIDECAR WHEEL REMOVAL amp INSTALLATION Step 1 Remove the sidecar brake caliper Step 2 Carefully remove the sidecar hub cap Step 3 Remove the axle cotter pin and axle nut Step 4 Re install the sidecar wheel in reverse order USING THE SPARE WHEEL WARNING THE SPARE WHEEL IS INTENDED FOR USE ON THE REAR POSITION ONLY Step 1 Remove the rear wheel and rear brake rotor Step 2 Install the brake rotor on the spare wheel and torque to specification Step 3 Install the spare wheel on the motorcycle The wheel spokes should be checked regular basis and per the maintenance intervals You check spoke tension by lightly tapping each spoke and listening to the ring Loose spokes will make a low flat sound Step 1 Tap each spoke and compare the sound from one to another Step 2 Tighten spokes as needed If spokes require more than turn to tighten you may need to remove the tire and have the wheel professionally trued WHEEL BEARING REPLACEMENT amp DIAGRAMS Front wheels 1 02 8
24. en tightening nuts and bolts Clean all parts with non flammable solvents prior to reassembly after servicing Always replace seals O rings gaskets and cotter pins when reassembling If you remove self locking nuts they should always be replaced with new ones Be responsible with solvents cleaners and waste oils Always dispose of them in accordance with your local regulations WARNING IF THE ENGINE MUST BE RUNNING TO PREFORM A PARTICULAR SERVICE PROCEEDURE BE SURE YOU ARE IN A WELL VENTALATED AREA EXHAUST CONTAINS CARBON MONOXIDE GAS WARNING GASOLINE IS VERY FLAMMABLE AND CAN BE EXPLOSIVE UNDER CERTAIN CONDITIONS IT IS ALSO VERY HARMFUL TO THE SKIN AND EYES DO NOT SMOKE ALLOW SPARKS IN OR NEAR YOUR WORK AREA 1 2 MODEL IDENTIFICATION VIN Vehicle Identification Number The VIN label is located on the right hand frame down tube and is also stamped on the frame directly above the label List Your VIN Here 3 x 5 5 E o S x 5 E Engine Number The engine number is stamped near the crankcase breather it is the second number List Your Engine Number Here Gearbox Number The gearbox number is stamped on the left side of the gearbox directly above the shift lever List Your Gearbox Number Here MODEL SPECIFICATIONS model Engine and transmission Displacement cc 749 Valve per cylinder 2 Max output hp 41 5500 rpm 41 9 5500 rpm Com
25. er incidental or consequential damage i e storage Duration of Implied Warranties Any implied warranties including the implied warranty of merchantability and fitness for a particular purpose are limited to the duration of this written warranty State Laws May Vary The previous listed limitations or exclusions may not apply to a motorcycle because of state laws Some states may not allow limitations on how long an implied warranty lasts Some states may not allow exclusion or limitation of incidental or consequential damages These Warranties Do Not Cover 1 Failures or required services that is not due to a defect in material or factory workmanship 2 Parts or accessories affected or damaged by Lack of required maintenance Owner abuse Accident and or collision e Misuse Normal wear Neglect Improper installation Unsuitable use in an application for which the part was not designed The incorporation or use of unsuitable attachments or parts The unauthorized alteration of any part or system Deterioration from the elements Failure to follow running in break in procedure 3 Replacement of expendable maintenance including but not limited to spark plugs filters lubricants compliance fittings throttle body mounting flanges tires gaskets fuel line fuses bulbs battery after 1 year in service 8 3 THESE WARRANTIES DO COVER CONTINUED 1 Paint and or decal
26. fading peeling blistering chipping or rusting 2 Use for the following activities such use will VOID coverage e Racing Competition Rental or other commercial use Alteration of engine or drive train Any operation or use outside of that described in Owner s Manual 3 Alteration of the odometer so that the actual mileage cannot be determined alteration will VOID coverage 4 Use of bike for towing purpose will VOID warranty Dealer Is Responsible to Thoroughly check and road test new units before delivery Fill out sign and send Warranty Registration and Card of Delivery to IMWA Inc within 3 business days of the sale of Motorcycle Accept all eligible motorcycles for warranty service regardless of selling Dealer Keep records of all warranty work e Attend service schools as provided by IMWA Inc Submit warranty claims to IMWA Inc IN WRITING within 10 business days of the repair date Obtain authorizations for warranty repairs from IMWA Inc when estimated cost will exceed 100 00 see Advance Warranty Authorization Send failed parts and or parts assemblies for an inspection to IMWA Inc within 3 three business days upon IMWA s request at IMWA Inc shipping expense Provide digital pictures of failed parts and or parts assemblies immediately upon IMWA s request Customer Is Responsible to Operate and maintain the motorcycle according to the IMWA Inc Owner s Manual and
27. he engine using the kick start lever until both valves are closed and the TDC top dead center mark located on the flywheel is centered in the window Step 3 Using a feeler gage check the free play on both valves to confirm they are within specifications VALVE TRAIN INSPECTION amp ADJUSTMENT CONT Step 4 If the free play clearance is not within specifications adjust as necessary First loosen the jam nut and turn the adjustment bolt Step 5 After adjustment reconfirm the clearance is within specifications Step 6 Replace the valve cover gasket if needed and re install the valve cover Step 7 Repeat the process on the right side by rotating the engine with the kick starter 360 degrees Again both valves will be closed and the TDC mark should be centered in the window CAUTION OPERATING THE ENGINE WITH IMPROPERLY ADJUSTED VALVES CAN LEAD TO POOR PERFORMANCE AND POSSIBLE ENGINE DAMAGE 5 6 FRONT BRAKE SYSTEM MAINTENANCE Step 1 Remove the retaining pin safety clips Step 2 Carefully drive the retaining pins out of the caliper using a small punch or drift Step 3 Remove the brake pads by pulling them out the top of the caliper FRONT BRAKE SYSTEM MAINTENANCE Step 4 Inspect the brake pads and replace as needed NOTE MINIMUM PAD THICKNESS IS 1MM Step 5 Re install brake pads in reverse order Be sure to fully seat the retaining pins and install the
28. ine fuel filter R R R Air filter 1 1 R R 1 R Compliance flanges check for cracks and other damage 1 1 R 1 1 R Shock absorbers Tightness of spokes 1 1 1 1 Disc brake pads disc hoses calipers and cylinders lever travel 1 1 1 1 1 1 1 Check operations of parking brake Clutch throttle and odometer cables clutch lever travel I 1 1 l 1 Steering head bearings Sidecar alignment Electrical equipment I 1 I 1 I I Lubrication of lever axels cable ends rear brakes cams splined parts of the drive shafts and hubs drive shaft U joints 1 L W L W L 1 Inspect if necessary adjust clean or replace Replace Also repeat after 1 year in use and after long storage L Lubricate P Perform Also inspect when replacing tires 1 7 MOTORCYCLE STORAGE AND CARE Storage If you will be storing your motorcycle for the winter or long term take the following steps 1 The motorcycle should be cleaned Check all fluid levels and add as necessary Check tire pressure Lubricate all shafts splines cables and joints Use a battery maintenance charger or disconnect battery Always store in a warm dry place to avoid rust and moisture build up Use a protective cover when needed After storage take the following steps prior to running your motorcycle 1 Perform the pre ride inspection 2
29. ion Diagram Lubrication Points Engine oil and filter replacement Gearbox oil replacement Final drive oil replacement Drive Shaft Lubrication Cable Lubrication Page 4 2 4 3 4 4 4 5 4 7 4 8 4 9 4 10 4 1 FLUIDS LUBRICANTS amp CAPACITIES ENGINE OIL VISCOSITY GRADES 27 Temperature range anticipated before next oil change Engine oil should meet API SG SH with correct viscosity for temperature Location Capacity Type Final Drive 2wd 135ml 80W 90 GL 5 Gear Oil 4 2 LUBRICATION DIAGRAM i AN m 4 3 LUBRICATION POINTS Diagram Position Location Type 1 Engine Oil Fill 20w 50 API SG SH Final Drive Oil Fill 80W 90 GL 5 Gear Oil 5 Final Drive Output Spines Moly EP Grease 7 Axles General Purpose Lithium Grease 9 Sidecar Brake Linkage Bushing General Purpose Lithium Grease 1 U Joints General Purpose Lithium Grease 13 Clutch Cable WD 40 15 Throttle Cables WD 40 17 Front Brake Mount Axle Bushings General Purpose Lithium Grease ENGINE OIL amp FILTER REPLACEMENT Step 1 Place a drain pan under the oil sump and remove the drain plug using a 17mm socket wrench Step 2 With the drain pan in place remove the oil filter NOTE AN OIL FILTER WRENCH MAY BE REQUIRED FOR REMOVAL CAUTION BE SURE TO REMOVE THE OIL FILTER SEALING RING FROM THE ENGINE COVER TO AVOID OIL LEAKS
30. is diagram shows the position and function for each fuse Fuse Box 2 if equipped The sidecar on all models except T has a separate fuse box This fuse box is located inside the sidecar nose on the right upper corner This diagram shows the position and function of each fuse RELAY LOCATIONS Turn Signal Relay The turn signal relay is located behind the headlight bucket To access this relay you must first remove the headlight bucket assembly EFI and Starter Relays To access the EFI and starter relays you must first remove the seat The relays are mounted to the frame base plate as shown ELECTRIC STARTER The starter must provide 300 400 rpm to start the engine and requires a well maintained battery If battery is below required voltage the electric starter may not operate efficiently If the battery becomes low you may need to use the kick starter ALTERNATOR This motorcycle is equipped with a Denso Alternator Specifications Rated Voltage 12V Rated Output 40A 480W Peak Output 560W 14V Testing the Alternator on the Motorcycle If no test bench is available check the output of the alternator with the engine running e Connect the voltmeter to positive and negative terminals of the storage battery e Start the engine e While starting the voltage will drop to as low as 9 5 V At 3500 4000 rpm output voltage should be 13 5 14 5 VDC In the course of daily inspection check the fastening of wires to the a
31. issions will be discharged directly into the ambient atmosphere throughout the useful life by any vehicle to be covered by EPA Certification Crankcase exhaust emitted by the timed breather is routed to the air filter box and ends prior to the filter The crankcase exhaust is recycled through the air filter and inducted back into the engine Please see the diagram below Air Box puc Bu Air Filter Element RH LH Intake Intake Pipe Pipe PH Breather Pipe Throttle IT IS AGAINST FEDERAL LAW TAMPER WITH REMOVE EMISSION RELATED COMPONENTS CALIFORNIA EMISSION CONTROL DIAGRAM EVAPORATIVE EMISSION CONTROL All models sold and shipped into the state of California are equipped with an evaporative emission control system This system prevents fuel vapors from being discharged directly into the ambient atmosphere throughout the useful life Evaporative emission are routed from the fuel tank through a carbon canister to the air box and controlled by an electrical valve The evaporative emissions are recycled through the air filter and inducted back into the engine Please see the diagram below 1 Engine 2 Throttle Body Left 3 Throttle Body Right 4 Crankcase Breather Tube 5 6 intake Tubes 7 Ar Fiter 8 Fuel Tank 9 Carbon Absorber Canster 10 Over Flow Valve 11 Contro Valve 12 13 14 15 Vent Tubes 16 Atmosphere Vent NOTE IT IS AGAINST FEDERAL LAW TO TAMPER WITH
32. lternator terminals and fastening of the alternator on the engine crankcase ECU DATA PORT The ECU Data port is located behind the left side panel This data port is intended for DEALER ONLY EFI DIAGNOSTICS The data port has a protective cap that should be left in place to prevent debris from contaminating the connector 7 EFI Troubleshooting Engine Management MIL Blink Codes Service Notes 7 1 URAL ENGINE MANAGEMENT SYSTEM BLINK DIAGNOSTICS Introduction A basic blink code system has been implemented on the Ural EFI bikes to aid EMS Engine Management System diagnostics without the need for an additional computer diagnostic tool greatly helping the user when during travels When activated the MIL malfunction indicator lamp blinks out a code sequence relating to the fault This document is intended as a quick reference guide as supplemental information to the EMS Service Manual Operation When the MIL is continuously lit with the key on an EMS fault has occurred With the key on and engine off toggle the kill switch three times within a two second timeframe to initiate the blink sequence Three changes are required not three complete kill run cycles For example if the switch is in engine kill state the sequence would be Kill gt Run gt Kill gt Run with the gt indicating a flick of the switch The MIL will now blink a code sequence corresponding with the EMS s diagnosed fault
33. nd Final Drive Drain Plugs 177 25 8 Engine Sump 14 8 118 CLEARANCES Location Intake Valves Cold Exhaust Valves Cold Spark Plug Electrode Minimum Tread Depth Minimum Brake Pad Thickness FREE PLAY amp ADJUSTMENTS Location Front Brake Lever Clutch Lever Rear Brake Lever Toe In 1wd Toe In 2wd Lean Out TIRE DATA Location Front Rear Sidecar Spare if equipped Optional Knobby Tires Millimeters Millimeters 5 to 8 5to8 1 4 of Full Travel 8 to 12 3to8 1 to 2 degrees Duro H 308 4 0x19 or 4 0x18 cT Duro H 308 4 0x19 or 4 0x18 cT Duro H 308 4 0x19 or 4 0x18 cT Duro H 308 4 0x19 or 4 0x18 cT Duro H 308 4 0x19 or 4 0x18 cT Inches Inches 2 to 3 2 to 3 1 4 of Full Travel 3 to 475 125 to 315 1 to 2 degrees Recommended PSI 32 PSI Cold 40 PSI Cold 32 PSI Cold 40 PSI Cold Per location on bike WARNING IMPROPER TIRE INFLATION WILL CAUSE ABNORMAL TREAD WEAR AND COULD RESULT IN UNSTABLE HANDLING UNDER INFLATION COULD RESULT IN THE TIRE SLIPPING ON THE RIM 1 6 PERIODIC MAINTENANCE CHART Description Odometer reading km miles New 1000 625 5000 3125 10000 6250 15000 9375 20000 12500 25000 15625 30000 18750 Check the painted and chromed surfaces for dents scratches and rust I 1 I 1 Oil filter R R R R R R R Check valve clearance 1 1 1 I 1 Spark plugs I R I R I R In l
34. o motorcycle in adverse conditions If possible an experienced sidecar driver preferably your Authorized Ural dealer should ride along during your first ride If not put about 100 LB of ballast in the sidecar during your initial training Although an experienced driver can safely drive the Ural with an empty sidecar a beginner should always have ballast or a passenger in the chair Check with your local IMWA Dealer to find out your particular state s sidecar driver s license requirements When you accelerate the Ural will pull slightly to the right due to the inertia and drag of the side car When you let off the gas it will pull slightly to the left due to the inertia of the sidecar Practice starting and stopping from various speeds shifting up and down accelerating and decelerating in each gear turning right and left at slow to medium speeds WARNING The Patrol and Gear up with engageable sidecar wheel handles differently with the sidecar driveshaft engaged and cannot turn on paved roads For this reason the sidecar drive must only be engaged when operating the vehicle off road or where snow ice and mud conditions are encountered on road 3 3 SIDECAR SAFETY CONT Finally practice lifting the sidecar To do this drive in a clockwise circle about 20 feet in diameter Gradually increase your speed until the sidecar wheel lifts from the surface 6 12 inches Then roll off the throttle and ease steering pre
35. ot complete within 30 days Any replacement part can be used in an emergency repair IMWA will reimburse the owner for the expenses including diagnosis not to exceed IMWA s suggested retail price for all warranted parts replaced and labor charges based on IMWA s recommended time allowance for the warranty repair and the geographically appropriate hourly labor rate The owner may be required to keep receipts and failed parts in order to receive compensation Il LIMITATIONS This Emission Control System warranty shall not cover any of the following A Repair or replacement required as a result of 1 Accident 2 Misuse 3 Repairs improperly performed or replacements improperly installed 4 Use of replacement parts or accessories not conforming to IMWA specifications which adversely affect performance and or 5 Use in competitive racing or related events A Inspections replacement of parts and other services and adjustments required for required maintenance B Any motorcycle on which the odometer mileage has been changed so that actual mileage cannot be readily determined LIMITED WARRANTY ON EMISSION CONTROL SYSTEM CONTINUED Il LIMITED LIABILITY A The liability of IMWA under this Emission Control System Warranty is limited solely to the remedying of defects in material or workmanship by authorized IMWA motorcycle dealers at its place of business during customary business hours This warranty does not cover inconvenience or lo
36. p 1 Place a rag under the fuel pump return line located on the left side of the pump and remove the fitting by pinching the release tabs Step 2 Connect a fuel hose to the pump outlet to drain the fuel into a fuel canister Step 3 Turn the ignition key on and switch the run switch to the on position so the pump can cycle all fuel from the tank into the canister This can take a few moments Be sure not to run the pump dry after all fuel has been drained from the tank Step 4 Re install the return fuel line to the pump Step 5 Carefully remove the one time use clamps from both sides of the in line fuel filter WARNING THE FUEL SYSTEM IS UNDER PRESSURE WARNING GASOLINE IS EXTREMELY FLAMABLE FUEL SYSTEM MAINTENANCE Step 6 Remove the in tank screen filter Step 7 Clean all debris for the intake filter and re install in the tank Step 8 Install the new in line fuel filter and replace all one time use clamps NOTE INSTALL IN LINE FILTER WITH DIRECTIONAL ARROW POINTED FORWARD WARNING THE FUEL SYSTEM IS UNDER PRESSURE WARNING GASOLINE IS EXTREMELY FLAMABLE 5 4 VALVE TRAIN INSPECTION amp ADJUSTMENT 5 5 Step 1 Starting with the left side cylinder remove the valve cover and clean any contaminates found inside with a shop towel Step 2 Remove the timing plug located on the right side of the engine case Slowly rotate t
37. p which cause such motorcycle to fail to conform with applicable regulations of the United States Environmental Protection Agency or the California Air Resources Board for a period of use depending on the engine displacement of 30 000 kilometers 18 641 miles if the motorcycle s engine displacement is 280 cubic centimeters or greater or 5 five years from the date of initial retail delivery whichever first occurs COVERAGE Warranty defects shall be remedied during customary business hours at any authorized IMWA motorcycle dealer located within the United States of America in compliance with the Clean Air Act and applicable regulations of the United States Environmental Protection Agency and the California Air Resources Board Any part or parts replaced under this warranty shall become the property of IMWA In the State of California only emission related warranted parts are specifically defined by the state s Emission Warranty Parts List These warranted parts are injectors electronic valves air box air cleaner element spark plug ignition coil ignition control valve module catalyst carbon absorber In the State of California only Emission Control System emergency repairs as provided for in the California Administrative Code may be performed by other than an authorized IMWA dealer An emergency situation occurs when an authorized IMWA dealer is not reasonably available a part is not available within 30 thirty days or a repair is n
38. pression 8 6 1 8 6 1 Starting Electric amp Kick start Electric amp Kick start Primary drive rear wheel Driveshaft Driveshaft Engagable sidecar wheel drive Yes driveshaft Overall heights inch Seat height unladen inch Dry weight Ibs Chassis Rear suspension Double sided swing arm with two Sachs Double sided swing arm with two Sachs hydraulic spring shock absorbers 5x hydraulic spring shock absorbers 5x adjustable adjustable Wheels 2 5X19 Aluminum rims with steel spokes 2 5X19 Aluminum rims with steel spokes Front brake 4 piston fixed Brembo caliper with 4 piston fixed Brembo caliper with 295mm floating NG rotor 295mm floating NG rotor Sidecar brake 2 piston fixed Brembo caliper with 2 piston fixed Brembo caliper with 245mm floating NG rotor 245mm floating NG rotor Other Fuel tank capacity gallons 5 0 Estimated fuel economy mpg 31 37 Recommended max cruising speed mph 70 Trunk volume cubic ft Electrical Battery FAYTX20HL 12V 20 FAYTX20HL 12V 20A Spark plugs NGK BPR6HS NGK BPR6HS Warranty 2 years parts and labor unlimited mileage 2 parts and labor unlimited mileage Es TORQUE SPECIFICATIONS Newton Meters Foot Pounds Fork Pinch Bolts Upper and Lower Bridges 25 1 22 1 36 9 36 9 51 6 Rear Swing Arm Mounting Bolts 36 9 Sidecar Strut Mounting Bolts Drive Train VA Engine Gearbox a
39. safety clips Step 6 Confirm the brake fluid level is full in the reservoir and add as needed to FULL line DO NOTE OVER FILL CAUTION OPERATING THE MOTORYCLE WITH WORN BRAKE PADS CAN CAUSE DAMAGE TO THE BRAKE ROTORS WARNING OPERATING THE MOTORCYCLE WITH WORN BRAKE PADS BELOW THE MINIMUM THICKNESS CAN RESULT IN POOR BRAKING AND POSSIBLE ACCIDENT WARNING OPERATING THE MOTORCYCLE WITH LOW FLUID LEVEL CAN CAUSE LOSS OF BRAKING FORCE REAR BRAKE SYSTEM MAINTENANCE Step 1 Remove the caliper retaining bolt safety clips Step 2 Remove the caliper retaining bolts Step 3 Remove the brake pads by pulling to the rear of the motorcycle REAR BRAKE SYSTEM MAINTENANCE Step 4 Inspect the brake pads and replace as needed NOTE MINIMUM PAD THICKNESS IS 1MM Step 5 Re install brake pads in reverse order DO NOT forget to install the safety clips Step 6 Confirm the brake fluid level is full in the reservoir and add as needed to FULL line DO NOT OVER FILL CAUTION OPERATING THE MOTORYCLE WITH WORN BRAKE PADS CAN CAUSE DAMAGE TO THE BRAKE ROTORS WARNING OPERATING THE MOTORCYCLE WITH WORN BRAKE PADS BELOW THE MINIMUM THICKNESS CAN RESULT IN POOR BRAKING AND POSSIBLE ACCIDENT WARNING OPERATING THE MOTORCYCLE WITH LOW FLUID LEVEL CAN CAUSE LOSS OF BRAKING FORCE 5 10 PARKING BRAKE ADJUSTM
40. ses when warranty repair takes longer than 14 days the warranty time period see Warranty Time Period is extended for the time period of repair during which the motorcycle could not been ridden due to failures IMWA Inc provides warranty for spare parts for the following period of time starting from the time of purchase of the parts by a Dealer or retail customer 1 Engine 12 months 2 Gearbox 12 months 3 Final drive 12 months 4 Alternator 6 months 5 Electric starter 6 months 6 EFI Components 6 months 7 The rest of the motorcycle parts and parts assemblies 30 days The above applies ONLY in cases when Dealer or retail customer identifies defects before using parts and or assemblies or these defects are identified during performance AND provided these parts have been properly installed by IMWA Inc or authorized IMWA Dealer IMWA Inc will reimburse non IMWA repair shops performing warranty repair for labor only if all the warranty processing and approval procedures are completely fulfilled and or carried out according to IMWA Inc guidelines stated in the Warranty Claim Filing Procedures 8 2 WARRANTY DISCLAIMERS LIMITATIONS amp EXCLUSIONS DISCLAIMER OF CONSEQUENTIAL DAMAGE amp LIMITATION OF IMPLIED WARRANTIES IRBIT MOTORWORKS OF AMERICA INC DISCLAIMS ANY RESPONSIBILITY FOR Loss of time due to warrantable issue Loss of use of motorcycle Transportation expenses Any oth
41. sition The steering damper is fully adjustable to accommodate different riding styles and conditions Rotate the adjustment rod clockwise to increase dampening and counter clockwise to reduce dampening CAUTION OVER ROTATION OF THE ADJUSTMENT ROD CAN DAMAGE THE DAMPER AND OR CAUSE FLUID LEAKS PARKING BRAKE REVERSE LEVER Parking Brake Lever The parking brake lever is located on the right side of the motorcycle near the side panel Pulling the handle up to the lock position sets the parking brake Release the parking brake by lowering the lever to the down position as shown CAUTION OPERATING THE MOTORCYCLE WHILE THE PARKING BRAKE IS ENGAGED CAN DAMAGE THE BRAKE SYSTEM Reverse Engagement Lever The reverse lever is located on the right side of the gearbox near the foot peg Pulling the lever back while in Neutral will engage the reverse gear Push the lever forward to put the gearbox back into Neutral and use forward gears CAUTION THE REVERSE LEVER MUST BE IN THE FULL FORWARD POSITION FOR THE GEARBOX TO SHIFT PROPERLY KICK START LEVER 2WD ENGAGEMENT LEVER 2 7 Kick Start Lever To use the kick start lever rapidly press the lever downward with you right foot as shown WARNING WHEN USING THE KICK STARTER ALWAYS BE SURE THE GEARBOX IS IN NEUTRAL 2wd Engagement Lever Shifting the lever into the rear locked position will engage
42. ss of use of the motorcycle or transportation of the motorcycle to or from the IMWA dealer IMWA SHALL NOT BE LIABLE FOR ANY OTHER EXPENSES LOSS OR DAMAGE WHETHER DIRECT INCIDENTAL CONSEQUENTIAL OR EXEMPLARY ARISING IN CONNECTION WITH THE SALE OR USE OF OR INABILITY TO USE THE IMWA MOTORCYCLE FOR ANY PURPOSE SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITAION OF ANY INCIDENTAL OR CONSEQUESTIAL DAMAGES SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU B NO EXPRESS EMISSION CONTROL SYSTEM WARRANTY IS GIVEN BY IMWA EXCEPT AS SPECIFICALLY SET FORTH HEREIN ANY EMISSION CONTROL SYSTEM WARRANTY IMPLIED BY LAW INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE IS LIMITED TO THE EXPRESS EMISSION CONTROL SYSTEM WARRANTY TERMS STATED IN THIS WARRANTY THE FOREGOING STATEMENT OF WARRANTY ARE EXCLUSIVE AND IN LIEU OF ALL OTHER REMEDIES SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU C No dealer is authorized to modify this IMWA Limited Emission Control System Warranty LEGAL RIGHTS THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE IV THIS WARRANTY IS IN ADDITION TO THE IMWA LIMITED MOTORCYCLE WARRANTY V ADDITIONAL INFORMATION Any replacement part that is equivalent in performance and durability may be used in the performance of any maintenance or repairs However IMWA is no
43. ssure on the grips so it gradually comes back down Repeat doing this until you feel comfortable with the wheel in the air Remember the moment you roll off the throttle it will come down When you have mastered flying the chair to the point where you can keep it in the air for a full circle you will have a good feel for the speed and turn radius that will lift the sidecar If after gaining proficiency with the Ural you plan to drive on the street with an empty sidecar go back to the parking lot and practice the above maneuvers with an empty sidecar You ll find that the sidecar will lift much more readily when it is empty especially if you enter a decreasing radius turn such as a freeway off ramp at too high a speed This is why we recommend generally carrying about 100 Ibs or more in the sidecar WARNING BALLAST WEIGHT SHOULD ALWAYS BE PROPERLY SECURED IN THE SIDECAR AND CENTERED FOR BEST BALANCE 3 4 STARTING THE ENGINE WHEN COLD Use the following instructions when starting a cold engine Check to be sure you have enough fuel Switch ignition on Be sure the transmission is in neutral Switch the kill switch to run Press the starter button or use the kick starter until engine starts Allow engine to warm for a few moments prior to riding um BR ENGINE CRANKING SPEED CAN BE REDUCED IN COLD WEATHER FOLLOW THE RECOMMENDATIONS FOR PROPER OIL WEIGHT FOUND ON PAGE 4 2
44. t liable for these parts The owner is responsible for the performance of all required maintenance Such maintenance may be performed at a service establishment or by any individual The warranty period begins on the date the motorcycle is delivered to an ultimate purchaser Irbit Motorworks of America 14700 95 St Suite 102 Redmond WA 98052 REPORTING SAFETY DEFECTS If you believe that your vehicle has a defect which could cause a crash or could cause injury or death you should immediately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying Irbit Motorworks of America Inc If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in any individual problems between you your dealer or Irbit Motorworks of America Inc To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 366 0123 in Washington DC area Or write to NHTSA U S DEPARTMENT of TRANSPORTATION 400 7th Street SW NSA 11 Washington DC 20590 You can also obtain other information about motor vehicle safety from the Hotline 9 Emission Control Information Crankcase Emission Diagram California Emission Control Diagram Vehicle Emission Control Label 9 1 CRANKCASE EMISSION DIAGRAM CLOSED CRANKCASE No crankcase em
45. tor Trip Meter 3 Position Switch In the Off position the engine cannot be started In the On position the engine can be started and all electrical functions can be used In the Park position only the running lamps not including headlight are illuminated Speedometer Indicator Displays motorcycle speed in both miles per hour and kilometers Odometer The odometer displays total motorcycle Kilometers Trip Meter The trip meter displays the total trip Kilometers and can be reset by twisting the reset knob on the right hand fork cover INDICATOR LAMPS Low Fuel Level Indicator While on Level ground lamp will flash when fuel level is low and become solid when on reserve level app 1 Gal NOTE FUEL LAMP CAN GIVE FALSE INDICATION DUE TO SLOSHING WHILE RIDING CHECK Low Fuel Level High Beam Indicator Indicator LAMP ON LEVEL GROUND send Gearbox Neutral Indicator Lamp will illuminate when gearbox is in neutral Charging System Engine MIL Failure Indicator Indicator Charging System Failure Indicator Lamp will illuminate if the alternator fails High Beam Indicator Lamp will illuminate when high beam is on Turn Signal Indicator Lamp flashes when signals are active Engine MIL Indicator If lamp illuminates while engine is running refer to Troubleshooting section of this HYDRAULIC STEERING DAMPER manual Adjustable Damper 16 Po
46. ve covers and apply lube directly to the cable as shown you can also use cable lubrication tools available by aftermarket companies 5 Engine amp Chassis Maintenance Air filter Inspection amp Replacement Fuel System Maintenance Valve Train Inspection amp Adjustment Front Brake System Maintenance Rear Brake System Maintenance Parking Brake Adjustment Sidecar Brake System Maintenance Wheel Removal amp Installation Using the Spare Wheel Spoke Maintenance Wheel Bearing Replacement amp Diagrams Tire amp Tube Replacement Sidecar Alignment Sidecar Alignment Diagram 5 1 AIR FILTER INSPECTION amp REPLACEMENT Step 1 Remove the four retaining bolts form the air box lid using a 5mm hex wrench Step 2 Carefully remove the air box lid by lifting the right side and sliding the lid to the left be very careful not to pull wiring and cables near the air box inlet Step 3 Remove the paper filter element for the housing and inspect for debris The filter should be replaced per the maintenance intervals and or as need during inspections Step 4 Re install the filter in reverse order be sure the replacement filter is fully seated in to the air box housing and the lid is properly installed prior to tightening the retaining bolts CAUTION A DIRTY OR CLOGGED AIR FILTER CAN REDUCE THE PERFORMANCE OF YOU ENGINE AND POSSIBLY DAMAGE INTERAL ENGINE PARTS 5 2 FUEL SYSTEM MAINTENANCE Ste
47. while releasing the lever will engage the clutch High Beam Switch Toggle the switch forward to turn on the high beam and toggle back for Flash to Pass feature Horn Button Press the button to sound the horn Turn Signal Switch Switch left or right to indicate turns and push the button to cancel Left Hand Grip Place you left hand on the grip to steer and control the motorcycle Front Brake Lever Pulling the lever will actuate the front brakes WARNING IF THE BRAKE LEVER FEELS SPONGY DO NOT RIDE THE BIKE AND CONTACT YOUR DEALER Starter Button Press the button to engage the starter motor CAUTION DO NOT RUN STARTER FOR MORE THAN 5 SECONDS WARNING WHEN USING THE STARTER ALWAYS BE SURE THE GEARBOX IS IN NEUTRAL Engine STOP Switch Toggle the switch forward to stop the engine toggle back to run Throttle Grip Place your right hand on the grip to steer and control the motorcycle Rotate the grip back to open the throttle 2 2 FOOT CONTROLS Heel Toe Shift Lever Shift Lever This is a heel toe type shifter to upshift use the heal portion of the shift lever to down shift use the toe portion of the shifter Rear Brake Lever Pressing the rear brake lever actuates the rear and sidecar brakes WARNING IF THE BRAKE LEVER FEELS SPONGY DO NOT RIDE THE BIKE AND CONTACT YOUR DEALER IGNITION SWITCH SPEEDOMETER Speed Indica
48. y Pressure Sensor failed VCOM A Failed LED open or short to ground LED short to battery 7 3 7 4 SERVICE NOTES 8 Warranty Information Warranty Agreement Warranty Disclaimers California Emissions Statement Limited Emissions Warranty Reporting Safety Defects 8 1 Irbit MotorWorks of America Inc IMWA Inc warrants to the first retail purchaser of the URAL motorcycle from an Authorized IMWA Dealer and each subsequent owner that the motorcycle is free from defects in materials and workmanship for the period stated below To Qualify For This Warranty The URAL motorcycle must be purchased from a Dealer within the United States who is authorized by IMWA Inc to sell motorcycles See www imz ural com for the authorized IMWA Dealer list Prior to delivery to the purchaser the Dealer who is authorized by IMWA Inc to sell motorcycles must perform set up and pre delivery service Warranty Time Period Duration two 2 years parts and labor There 15 no mileage limitation Coverage begins the date the motorcycle is sold to the first retail purchaser and the warranty registration card is received by IMWA Inc Warranty Coverage Inc will repair or replace at its options any part including parts of the emission control systems that is found to be defective in material or workmanship under normal use for the applicable time period In ca
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