The device described in this manual is a Ural motorcycle with a sidecar accessory, specifically the 2007 Gear Up, Patrol, and Tourist models. It is a two-cylinder, four-stroke, air-cooled engine motorcycle manufactured by the Irbit Motorcycle Factory in Russia and distributed by Irbit Motorworks of America. The Ural motorcycle conforms to US Federal Motor Vehicle Safety Standards and Environmental Protection Agency regulations.
Function Description
The Ural motorcycle is designed for both on-road and off-road use, offering a unique three-wheeled riding experience with its integrated sidecar. The primary function is transportation, with the added stability and cargo capacity provided by the sidecar. The Patrol and Gear Up models feature an engageable sidecar drive, allowing for enhanced traction in challenging off-road conditions.
Key operational components include:
- Engine: A two-cylinder, four-stroke, air-cooled engine provides power. Its opposed cylinder arrangement ensures proper cooling and crank gear balancing.
- Power Transmission: Comprises a dry double-disk clutch, a 4-speed gearbox with reverse, and a final drive system. The sidecar drive on specific models is engaged via a drive shaft with a universal joint.
- Running Gear: Features a tubular welded frame, swing arms with spring shock absorbers for the rear wheel suspension, and a leading link front fork with spring-loaded hydraulic shock absorbers.
- Brakes: Equipped with a hydraulic disc brake on the front wheel and manual shoe-type brakes on the rear motorcycle wheel and sidecar wheel. The sidecar brake is connected to the rear brake pedal.
- Electrical System: Includes an electronic ignition system, spark plugs, alternator, battery, and headlights. Specific models may also feature a sidecar spotlight.
Important Technical Specifications
Overall Dimensions:
- Length: 2580 mm / 8 ft
- Width: 1700 mm / 5 ft 6 in
- Height: 1100 mm / 3 ft 6 in
- Road Clearance: 125 mm / 5 in
- Seat Height: 840 mm / 33 in
- Wheel Base: 1470 mm / 58 in
Engine:
- Type: 4 stroke, overhead valves, opposed twin-cylinder
- Displacement: 749 cc
- Cylinder Bore: 78 mm
- Piston Stroke: 78 mm
- Compression Ratio: 8.6 :1
- Rated Horsepower: 23 KW / 45 Bhp at 5600 RPM
- Rated Torque: 52 N-M @ 3750 RPM
- Lubrication System: Dual system of forced lubrication and splashing
- Lubricant: SAE 20W/50 petroleum based detergent oil (used in both engine and transmission)
Carburetor:
- Type: 32 CVK Keihin
- Number of Carburetors: 2
- Air Cleaner: Paper Filter Element
- Fuel: 91 octane premium unleaded gasoline
- PCV Valve: Internal Breather
Electrical:
- Ignition System: Electronic Ignition
- Spark Plugs: NGK BP7HS or Equivalent
- Ignition Timing: Automatic advance
- Alternator: 50 amp / 14 Volt
- Battery: Interstate FAYTX-20HL or equivalent
- Headlight: Wagner, 7" round sealed beam
Transmission:
- Clutch: Dry double-disk clutch
- Gearbox: 4 speed gearbox with reverse
- Gear Ratios: I gear (3.6), II gear (2.28), III gear (1.56), IV gear (1.19), Reverse gear (4.36)
- Speedometer Drive Ratio: 0.4
- Final Drive Ratio: 4.62
Fluid Capacities:
- Fuel Tank (gasoline): 5 Gal / 19L (main), 0.5 Gal / 2L (reserve)
- Engine (oil): 68 Oz / 2L
- Transmission (oil): 34 Oz / 1L
- Final Drive (gear oil): 4.5 Oz / 105 ml (Patrol, Gear Up), 3.5 Oz / 135 ml (Tourist)
- Shock Absorbers (shock oil): 105 ml / 3.5 oz
- Brake Reservoir: DOT 3 or 4 brake fluid to upper line
Running Gear:
- Frame: Tubular welded
- Rear Wheel Suspension: Swing arms with spring shock absorbers
- Front Fork: Leading link
- Sidecar: Cushioned body (on rubber cushions) and wheel with hydraulic spring shock absorber
- Brakes: Disc-type with hydraulic drive on front, Shoe type with mechanical drive on rear and sidecar wheels
- Tires: 4" x 19"
- Front: 32 psi cold (1.5 Bar / 150 kPa)
- Side: 30 psi cold (1.5 Bar / 150 kPa)
- Rear: 40 psi cold (2.5 Bar / 250 kPa)
Clearances / Free Travel / Adjustments:
- Valves with engine cold: 0.05 to 0.1 mm (0.002 to 0.004 in)
- Between spark plug electrodes: 1.016 mm (0.040 in)
- Backlash between tooth faces of bevel gears in final drive: 0.1 - 0.3 mm (0.004 in)
- Hand brake control lever: 5-8 mm (0.2-0.3 in)
- Clutch control lever: 5-8 mm (0.2-0.3 in)
- Foot brake drive pedal: ¼ of full stroke of pedal, 25-30 mm (1.0 - 1.2 in)
- Toe-in distance: 10 mm (3/8 inch)
- Lean-out: 1º away from sidecar
Usage Features
The Ural motorcycle is a three-wheeled vehicle that handles differently from both solo motorcycles and cars.
- Starting the Engine: Can be started manually with a kick lever or electrically. Carburetor enricheners are used for cold starts, increasing the fuel-to-air ratio. The fuel petcock has "ON," "RES" (reserve), and "PRI" (prime) positions. "ON" is for regular use, automatically activating with the engine. "PRI" is for filling carburetors after extended parking or emptying.
- Gear Shifting: Features a heel-toe shift lever. Neutral is between 1st and 2nd gears. Smooth, constant force is required for shifting to prevent damage. The clutch lever must always be engaged when shifting.
- Sidecar Drive (Patrol & Gear Up): Engageable for off-road use only. Engaging on concrete or hard surfaces can cause severe drivetrain damage and is hazardous. The sidecar drive provides extra traction in mud, snow, gravel, and loose dirt.
- Braking: Both front and rear brakes should be used simultaneously. Avoid locking wheels. The rear brake pedal also actuates the sidecar wheel brake. The parking brake is engaged by pressing the rear brake pedal, pushing down, and twisting the parking brake lever counter-clockwise.
- Steering: The friction-type steering damper absorbs lateral kicks to the front wheel. Tightening the bolt clockwise increases friction, useful on bad roads, but overtightening can make steering stiff and affect handling.
- Handling Characteristics: The motorcycle pulls slightly to the right during acceleration and to the left when decelerating due to the sidecar's inertia and drag. Excessive speed and an unweighted sidecar must be avoided, as left-hand and right-hand turns can be dangerous. Beginners should use ballast (approx. 100 lbs) or a passenger in the sidecar during initial training.
- Running-In Period: The initial 1,500 km is a critical bedding-in period. During this time, avoid racing, overloading, or lugging the engine. Vary throttle settings frequently and allow for rest periods to cool the engine.
- Operating Precautions: Do not run the engine at extremely high RPMs with the clutch disengaged or transmission in neutral. Avoid continuous speeds above 65 mph for extended periods; allow for cooling breaks. Use caution on wet roads as braking efficiency is reduced. Do not let the motorcycle idle for more than three minutes to prevent overheating.
Maintenance Features
The manual outlines a comprehensive maintenance schedule with specific intervals (e.g., 500 km, 2,500 km, 5,000 km, 7,500 km, 10,000 km, 12,500 km, 15,000 km, 17,500 km, 20,000 km, 22,500 km, 25,000 km, 27,500 km, 30,000 km).
General Maintenance:
- Pre-Trip Check List: Includes checking lights, horn, brakes, clutch, wheel fasteners, carburetor flanges, air filter ducts, tire tread depth, and sidecar attachment mounts.
- Fluid Checks: Regularly check engine oil level (using dipstick), transmission oil, and final drive oil.
- Lubrication: Follow the lubrication chart for various components, including engine crankcase, transmission, final drive, sidecar collet joint hinges, brake system hinge joints, brake pedal shaft, drive shaft universal joint, lever pins, clutch and hand brake cables, brake shoe pins and cams, wheel bearings, front forks, carburetor throttle control twist grip, speedometer cable, and steering column bearings.
- Filter Replacement: Change engine oil filter and fuel filters periodically (e.g., every 10,000 km for fuel filters).
- Spark Plugs: Inspect and replace spark plugs and ignition leads as needed. Carry an extra set.
- Tires: Maintain proper inflation pressure. Check tread depth (replace when less than 3/32 inch). Avoid overinflating.
- Brakes: Inspect brake pads (replace when less than 1/8 inch remaining). Check brake fluid reservoir level and refill with DOT 3 or 4 fluid. Adjust rear and sidecar brakes to minimize gap between shoes and drums.
- Steering Head Bearings: Adjust periodically to prevent excessive play and ensure smooth turning.
- Cosmetic Maintenance: Clean the motorcycle regularly with a weak stream of cold or slightly heated water. Avoid pressure washers, harsh chemicals, and dry rubbing. Polish painted surfaces as needed.
- Electrical System: Periodically check all wires for crimps or loose connections. Inspect alternator fastening and backlash of gears. Do not add electrical accessories, as this voids the warranty.
- Battery: Regularly check voltage (13.8 - 14.2 V), prevent discharge, use distilled water to maintain electrolyte level, and coat bolts/nuts with petroleum jelly.
- Storage: For extended storage, clean the bike, drain carburetors (or run engine until fuel is depleted), spray storage oil into cylinders, lubricate chrome/zinc parts, seal mufflers, and ensure proper tire pressure.
Specific Adjustments:
- Valves: Adjust valve tappet clearance.
- Ignition Timing: Set by connecting a timing light and adjusting the timing plate.
- Wheel Bearings: Adjust every 5000 km to prevent play.
- Wheel Spokes: Check and adjust tension.
The manual emphasizes the importance of following maintenance procedures for optimal performance, safety, and warranty validity. It also recommends seeking service from an Authorized IMWA Ural Dealer for major repairs and specific maintenance tasks.
Need help?
General
To Next Page