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INTRODUCTION

Welcome to the URAL Motorcycling Family! Your Ural has been built by the Irbit
Motorcycle Factory in Russia.

This Ural motorcycle conforms to all applicable European Safety and Environmental
regulations effective on the date of manufacture.

This manual covers the Sportsman, Ranger, Tourist, cT, T TWD 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 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
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 1
Motorcycle Controls and Instrumentation 2
Motorcycle Operation 3

Service & Maintenance Sections

Lubrication 4
Engine & Chassis Maintenance 5
Electrical 6
EFI Troubleshooting 7

Consumer Information Sections

Warranty Information 8
Emission Control Information 9

Schematics 10
1. General Information

Page
Service Rules 1-2
Model Identification 1-3
Model Specifications 1-4
Torque Chart 1-5
Clearance and Adjustment Specifications 1-6
Tire Data 1-6
Periodic Maintenance Chart 1-7
Motorcycle Storage and Care 1-8
SERVICE RULES

1. Always wear proper safety equipment including but not limited to safety glasses
and gloves.
2. Allow your motorcycle to cool down completely prior to servicing to avoid getting
burned.
3. 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.
4. Follow the service procedures as outlined in this manual.
5. Always follow the torque specifications when tightening nuts and bolts.
6. Clean all parts with non-flammable solvents prior to reassembly after servicing.
7. Always replace seals, O-rings, gaskets and cotter pins when reassembling.
8. If you remove self-locking nuts they should always be replaced with new ones.
9. 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 OR ALLOW SPARKS
IN OR NEAR YOUR WORK AREA.
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

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
TORQUE SPECIFICATIONS

Chassis Newton Meters Foot Pounds

Fork Pinch Bolts (Upper and Lower Bridges) 50 36.9
Upper fork Nuts 30 22.1
Steering Head Nut 34 25.1
Front fork Upper Shock Bolts 49 36.1
Upper Shock Bolts 30 22.1
Lower Shock Bolts 49 36.1
Front and Rear Brake Caliper Bracket Bolts 50 36.9
Rear Caliper Mounting Bolts 50 36.9
Front Caliper Mounting Bolts 50 36.9
Sidecar Caliper Mounting Bolts 50 36.9
Front Brake Reaction Link 70 51.6
Brake Rotors 30 22.1
Rear Swing Arm Mounting Bolts 88 64.9
Sidecar Swing Arm Mounting Bolts 88 64.9
Front Fork to Pivot of Swing Arm Mounting Bolts 50 36.9
Lower Sidecar Frame Mounting Bolts 88 64.9
Sidecar Strut Mounting Bolts 88 64.9
Spoke Nipple 4 to 6 2.9 to 4.4
Drive Train
Engine. Gearbox. and Final Drive Drain Plugs 22 16.2
Cylinder Head Nuts 50 36.9
Valve Cover Nuts 24 17.7
Oil Pump Drive Gear Cap Bolt 10 7.4
Final Drive to Swing Arm Mounting Nuts 35 25.8
Final Drive Case Nuts 24 17.7
Engine Sump 10 7.4
Alternator Mounting Nuts 22 16.2
Intake Flange Mounting Bolts 20 14.8
Exhaust Header Pipe Nuts 24 17.7
Exhaust Mounting Clamp Bolts 16 11.8
Drive Wheel Splines (Spline Flanges) 30 22.1
CLEARANCES

Location Millimeters Inches

Intake Valves (Cold) .1 .004
Exhaust Valves (Cold) .1 .004
Spark Plug Electrode 1.00 0.04
Minimum Tread Depth 3.175 0.125
Minimum Brake Pad Thickness 1 0.04

FREE PLAY & ADJUSTMENTS

Location Millimeters Inches

Front Brake Lever 5 to 8 .2 to .3
Clutch Lever 5 to 8 .2 to .3
Rear Brake Lever 1/4 of Full Travel 1/4 of Full Travel
Toe-In (1wd) 8 to 12 .3 to .475
Toe-In (2wd) 3 to 8 .125 to .315
Lean Out 1 to 2 degrees 1 to 2 degrees

TIRE DATA

Recommended Load index

Location Type KPA/PSI
Duro HF-308 (4.00x19) Heidenau K28 (4.00x18) A1:52 (200kg)
Front Heidenau K28 (4.00x19) Heidenau K37 (4.00x19) 150-160 KPA/32 PSI Cold
Duro HF-308 (4.00x19) Heidenau K28 (4.00x18) A2:70 (335kg)
Rear Heidenau K28 (4.00x19) Heidenau K37 (4.00x19) 250-260 KPA/36 PSI Cold
Duro HF-308 (4.00x19) Heidenau K28 (4.00x18) A3: 47 (175kg)
Sidecar Heidenau K28 (4.00x19) Heidenau K37 (4.00x19) 150-160 KPA/32 PSI Cold
Spare (if Duro HF-308 (4.00x19) Heidenau K28 (4.00x18)
equipped) Heidenau K28 (4.00x19) Heidenau K37 (4.00x19) 250-260 KPA/36 PSI Cold

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.
PERIODIC MAINTENANCE CHART
URAL SERVICE SCHEDULE

Description Odometer reading, km (miles)

New 500 (310) 5000 (3125) 10000 (6250) 15000 (9375) 20000 (12500) 25000 (15625) 30000 (18750)

Check the painted and chromed surfaces for

dents, scratches and rust I I I I

Engine oil* I R R R R R R R

Oil filter* R R R R R R R

Final drive and gearbox oil I R I R I R I R

Check valve clearance I I I I I I I

Check tightness of the cylinder stud nuts I I I I I I I

Spark plugs I I R I R I R

Fuel tank filter I I I I

In-line fuel filter R R R

Ignition timing I I I

Air filter* I I R I R I R

Check fuel hoses I I I I I I I

Compliance flanges (check for cracks and other

damage) I I R I R I R

Throttle body synchronization I I I I I I I

Shock absorbers I I

Inspect wheels and tires (tire pressure , tire wear,

rims breakage and bents, wheel balancing)* I I I I I I I I

Tightness of spokes I I I I I I I

Tightness of fasteners I I I I I I I I

Disc brake (pads, disc, hoses, calipers and

cylinders, lever travel) I I I I I I I

Brake fluid level* I I I I I I I/R

Check operations of parking brake I I I I

Front fork oil R

Clutch, throttle and odometer cables, clutch lever

travel I I I I I I I I

Bearings of the motorcycle and sidecar swing

arms. 2wd linkage on 2wd models, Retro reverse
linkage I I I

Steering head bearings I I I

Wheel bearings I I I

Sidecar alignment I I I

Battery (charge level, contacts) * I I I I I I I

Electrical equipment I I I I I I I I

Headlight position I I I I I I I I

Lubrication of lever axels, cable ends, rear brakes

cams, splined parts of the drive shafts and hubs,
drive shaft U-joints* I/L I/L I/L

Test drive P P P P P P P P
SERVICE LABOR .8hrs 2hrs 1.8hrs 3.5hrs 2hrs 3.5hrs 1.8hrs 4.5hrs

I - Inspect, if necessary – adjust, clean or replace R – Replace * - Also repeat after 1 year in use and after long storage
L – Lubricate P – Perform **- Also inspect when replacing tires
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.
2. Check all fluid levels and add as necessary.
3. Check tire pressure.
4. Lubricate all shafts, splines, cables and joints.
5. Use a battery maintenance charger or disconnect battery.
6. Always store in a warm dry place to avoid rust and moisture build up.
7. Use a protective cover when needed.

After storage take the following steps prior to running your motorcycle:
1. Perform the pre-ride inspection.
2. 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:
 Make sure the engine is completely cool
 Use warm soapy water and wash thoroughly
 Avoid water from entering the air filter and electrical components
 After washing dry the motorcycle with a cloth
 Lubricate joints and cables as necessary
 Run motorcycle to evaporate remaining water

WINTER CONSIDERATIONS
Motorists in many areas of the Europe 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.
2. Motorcycle Controls & Instrumentation

Page
Hand Controls 2-2
Foot Controls 2-3
Ignition Switch 2-4
Indicator Lamps 2-4
Speedometer Functions 2-5
Speedometer Operation 2-6
Parking Brake 2-7
Reverse Lever 2-7
Kick Starter 2-8
2wd Engagement Lever 2-8
Hydraulic Spring Shock Absorbers 2-9
Hydraulic Steering Damper 2-9
HAND CONTROLS
Clutch Lever
Pulling the clutch lever will disengage the
clutch 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.

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.
Spotlight Switch (If equipped)
Toggle the switch to control the sidecar
spotlight.
FOOT CONTROLS
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
(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.

INDICATOR LAMPS 1. Engine “MIL” Indicator

If lamp illuminates while engine is running
refer to “Troubleshooting” section of this
manual.
2. High Beam Indicator
Lamp will illuminate when high beam is on.
3. Charging System Failure Indicator
Lamp will illuminate if the alternator fails
4. Parking Brake Indicator
Lamp will illuminate when the parking brake is
engaged.
5. Gearbox Neutral Indicator
Lamp will illuminate when gearbox is in
neutral.
6. Turn Signal Indicator
Lamp flashes when signals are active.
7. 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 LAMP
ON LEVEL GROUND.
SPEDOMETER FUNCTIONS
Needle Speedometer:
Indicates speed by analogue needle.
RPM: Digital Tachometer
NOT ACTIVE
MAX RPM: Maximum Tachometer
NOT ACTIVE
SPD: Speedometer
Displays speed in MPH.
MAX SPD: Maximum Speed Meter
Displays highest speed achieved since last
Reset operation.
AVG: Average Speed Meter
It calculates average speed from last RESET.
TRIP 1 or 2: Trip Meter 1 or 2
TRIP function accumulates trip distance since
last RESET as long as bike/vehicle is moving.
ODO: Odometer
ODO accumulates total distance traveled.
RT: Riding Timer
1. Calculates total running time since last
RESET.
2. Counter automatically begins with
movement.
TT: Total Riding Timer
1. Calculates total riding time from the
beginning of the bike.
2. TT data is stored in memory, and cannot be
reset.
HRTT: Total Hour Meter
1. Calculates total engine operation time.
12/24 hour Clock:
It displays 12 or 24 hour current time.
Digital Voltage:
Indicates range 8-18VDC.
+TRIP: Maintenance Reminder
1. The maintenance reminder is set by trip
meter and an “Off” mode to switch it off.
2. The trip meter maintenance can be set up
to 9999.
SPEDOMETER OPERATION

MODE Button
Press the MODE button to move from one
function screen to another.
RESET Button
Press the reset button to cycle through
functions in reverse order.
Data Resetting
1. Press MODE or RESET button to reach the
desired screen then press RESET button for 2
seconds to reset TRIP 2, MAX SPD, MAX RPM
and MAX TEMP data from stored values to
zero individually. The maintenance reminder
will be reset to the pre-set value.
2. The data of Trip 1, AVG & RT will all be
reset at the same time when one of the
3 data functions are being reset.
3. ODO, clock, HRTT and TT data cannot be
reset.
Data Programing
Press both MODE & RESET buttons to go into
setting mode. In setting mode, pressing the
RESET button increments the flashing digit by
1 position. Press MODE button to confirm the
digit setting and jump to next digit or next
setting screen to be set. Press MODE button
for 2 seconds on any setting screen to finish
and go to normal mode.
12/24 Hour Clock Set-up
Clock displays 12 or 24H in XX:XX:XX format
and AM/PM when you select 12H option. Use
MODE and RESET buttons as described above
in Data Programing to finish clock setting and
jump to the maintenance reminder setting or
press MODE button for 2 seconds to finish
and go to normal mode.
Maintenance Reminder Set-up
The maintenance reminder displays a picture
of a wrench and is a separate TRIP meter. You
can program the maintenance trip meter for
the next scheduled service interval. Use
MODE and RESET buttons as described above
in Data Programing to finish maintenance
reminder setting. Press MODE button for 2
seconds to finish and go to normal mode.
PARKING BRAKE
Parking Brake Lever
The parking brake lever is located on the
left handle bar.

Pulling the handle to the left lock position

sets the parking brake.

Release the parking brake by pushing the

lever to the right position as shown.

CAUTION
OPERATING THE MOTORCYCLE WHILE
THE PARKING BRAKE IS ENGAGED CAN
DAMAGE THE BRAKE SYSTEM.

REVERSE LEVER

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

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

2wd Engagement Lever
Shifting the lever into the rear locked
position will engage 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.

HYDRAULIC STEERING DAMPER

Adjustable Damper (16 Position)

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.
3. Motorcycle Operation
Page
Pre-ride Inspections 3-2
Initial Ride Instructions 3-2
Sidecar Safety 3-3
Starting Procedures 3-5
Run-In 3-6
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.
2. Check the fuel level.
3. 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.
4. Check all lights for proper operations including headlight, running lights, turn
signals, and brake lights.
5. 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.
6. Inspect all cables to insure they are not pinched or routed improperly; also
inspect the clutch cable for correct free play.
7. Check for any loose fasteners and tighten as necessary.
8. Be sure any luggage is secured before riding.

INSTRUCTIONS FOR INITIAL RIDE

The following steps should be taken prior and during your first ride:

1. Read the entire owner’s manual prior to starting and/or taking you first ride.
2. Familiarize yourself with all controls and instruments.
3. Make any required adjustments to mirrors and controls for comfort.
4. Always wear safety gear including but not limited to: helmet, boots, gloves, and
jacket regardless of weather.
5. 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.
6. Follow the “Engine Run-in” instructions.
SIDECAR SAFETY

The Ural sidecar motorcycle, since it has three wheels, behaves quite differently from
either a solo motorcycle or a car.

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 solo
motorcycle in adverse conditions.

If possible, an experienced sidecar driver (preferably your Authorized Ural dealer)

should ride along during your first ride.

Check with your local 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 Sportsman and Ranger 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.
STARTING THE ENGINE WHEN COLD

Use the following instructions when starting a cold engine:

1. Check to be sure you have enough fuel.

2. Switch ignition on.
3. Be sure the transmission is in neutral.
4. Switch the kill switch to run.
5. Press the starter button or use the kick starter until engine starts.
6. Allow engine to warm for a few moments prior to riding.

NOTE
ENGINE CRANKING SPEED CAN BE REDUCED IN COLD WEATHER, FOLLOW THE
RECOMMENDATIONS FOR PROPER OIL WEIGHT FOUND ON PAGE 4-2.

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:

1. Check to be sure you have enough fuel.

2. Switch ignition on.
3. Be sure the transmission is in neutral.
4. Switch the kill switch to run.
5. Press the starter button or use the kick starter until engine starts.

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.
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:

1. Do not overload or “lug” the engine.

2. Do not exceed a top speed beyond 100 km/h (60mph).
3. Do not ride at a constant rpm for long periods of time.
4. Try to vary speed and load when riding.
5. Shift smoothly between gears and do not down shift at high rpm.
6. Always be sure the engine is warmed up before riding.
7. Follow the pre-ride inspection.
4. Lubrication
Page
Recommended Fluids, Lubricants & Capacities 4-2
Lubrication Diagram 4-3
Lubrication Points 4-4
Engine oil and filter replacement 4-5
Gearbox oil replacement 4-7
Final drive oil replacement 4-8
Drive Shaft Lubrication 4-9
FLUIDS, LUBRICANTS & CAPACITIES

ENGINE OIL VISCOSITY GRADES

20w-50
5w-40 (Cold Weather)

°F 0° 10° 20° 32° 60° 80° 100° °F

°C -18 -12 -7 0 16 27 38 °C

Temperature range anticipated before next oil change

Engine oil should meet API: SG, SH with correct viscosity for temperature

Location Capacity Type

Engine (with Filter Change) 2.3 l 20w-50 API: SG, SH
Gearbox 1.0 l SAE90
Final Drive 2wd 100ml 80W-90 GL-5 Gear Oil
Final Drive 1wd 100ml 80W-90 GL-5 Gear Oil
Front Brake Reservoir 20 cm³ DOT 4
Rear Brake Reservoir 15 cm³ DOT 4
Sidecar Brake Reservoir 30 cm³ DOT 4
Drive Shaft Joints N/A General Purpose Lithium Grease
Drive Shaft Spines N/A Moly EP Grease
Clutch Shaft Splines N/A Moly EP Grease
Drive Wheel Splines (Spline Flanges) N/A Moly EP Grease
Wheel Axles N/A General Purpose Lithium Grease
Brake Linkage and Pivots N/A General Purpose Lithium Grease
Cables N/A WD-40
LUBRICATION DIAGRAM
LUBRICATION POINTS

Diagram Position Location Type

1 Engine Oil Fill 20w-50 API: SG, SH
2 Gearbox Oil Fill SAE90
3 Final Drive Oil Fill 80W-90 GL-5 Gear Oil
4 Steering Head Bearing General Purpose Lithium Grease
5 Final Drive Output Spines Moly EP Grease
6 Sidecar Drive Shaft Splines (2wd) Moly EP Grease
7 Axles General Purpose Lithium Grease
8 Sidecar Mounting Pivots General Purpose Lithium Grease
9 Sidecar Brake Linkage Bushing General Purpose Lithium Grease
10 Clutch Shaft Splines Moly EP Grease
11 U-Joints General Purpose Lithium Grease
12 Speedometer Cable WD-40
13 Clutch Cable WD-40
14 Front Brake Lever Pivot Bolt WD-40
15 Throttle Cables WD-40
16 Parking Brake Cables WD-40
17 Front Brake Mount Axle Bushings General Purpose Lithium Grease
ENGINE OIL &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

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 & FILTER REPLACEMENT (CONT.)

Step 5
Lightly lubricate the new oil filter sealing ring
with fresh oil and install filter tightening
approximately ¼ turn after seat of seal.

CAUTION
DO NOT OVER-TIGHTEN THE OIL FILTER

Step 6
Fill engine with 2.3L 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
GEARBOX OIL REPLACEMENT

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 1.0L of recommended
gearbox 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 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 100ml 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 & 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.
5. Engine & Chassis Maintenance
Page
Air filter Inspection & Replacement 5-2
Fuel System Maintenance 5-3
Valve Train Inspection & Adjustment 5-5
Front Brake System Maintenance 5-7
Rear Brake System Maintenance 5-9
Parking Brake Adjustment 5-11
Sidecar Brake System Maintenance 5-12
Wheel Removal & Installation 5-14
Using the Spare Wheel 5-22
Spoke Maintenance 5-22
Wheel Bearing Replacement & Diagrams 5-23
Tire & Tube Replacement 5-24
Sidecar Alignment 5-25
Sidecar Alignment Diagram 5-26
AIR FILTER INSPECTION & 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.
FUEL SYSTEM MAINTENANCE

Step 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 (CONT.)

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.
VALVE TRAIN INSPECTION & ADJUSTMENT

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 the 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 & 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.
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 (CONT.)

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 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 (CONT.)
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.
PARKING BRAKE ADJUSTMENT

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.

NOTE

IF INCREMENTAL ADJUSTMENTS USING THE

TOP ADJUSTMENT NUT DO NOT RETURN THE
PARKING BRAKE TO NORMAL PERFORMANCE,
RETURN THE TOP ADJUSTMENT NUT TO A
FULLY SEATED (ZERO FREE PLAY) POSITION AND
MAKE ADJUSTMENTS ON THE LOWER CABLE
ADJUSTER TO REGAIN NORMAL OPERATION OF
THE PARKING BRAKE.

NOTE

WITH THE PARKING BRAKE SET YOU WILL HAVE

APPROXIMATELY 12MM BETWEEN THE
CALIPER STOP BRACKET AND THE BRAKE ARM
WITH SPRING.
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 & INSTALLATION

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.
FRONT WHEEL REMOVAL & 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 & 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.
REAR WHEEL REMOVAL & 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 & 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.
REAR WHEEL REMOVAL & 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 place the wheel back
on the bike and push the axle through both the
wheel and brake mounting bracket as shown.
REAR WHEEL REMOVAL & 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 & 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
ALL WHEEL POSITIONS.

CHANGE OF REAR WHEEL:

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.
WHEEL SPOKE MAINTENANCE

The wheel spokes should be checked on a

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 ½ turn to tighten you may need to
remove the tire and have the wheel
professionally trued.
WHEEL BEARING REPLACEMENT & DIAGRAMS

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 CAN
PREVENT THE WHEEL FROM ROTATING
FREELY.
TIRE & 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.
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 axles. 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 necessary 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 a 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.
SIDECAR ALIGNMENT DIAGRAM
6. Electrical
Page
Lamp & Bulb Replacement 6-2
Battery Maintenance & Replacement 6-6
Fuse & Relay Locations 6-9
Sidecar Fuse & Relay Locations 6-10
Starter 6-11
Alternator 6-11
ECU Data Port 6-11
LAMP & 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.

WARNING
ALWAYS WEAR EYE PROTECTION WHEN
REMOVING LAMP RETAINING CLIPS.

WARNING
IT IS UNSAFE TO OPERATE YOUR MOTORCYCLE
WITHOUT A FUNCTIONING HEADLIGHT.
LAMP & 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.
LAMP & 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.
LAMP & 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 the 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 THE 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!
BATTERY REPLACEMENT

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 BATTERY TERMINALS COULD
RESULT IN A FIRE.
BATTERY REPLACEMENT (CONT.)

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.
FUSE & RELAY LOCATIONS
Fuse Box Main
The main motorcycle fuse box is located under
the left side panel.

Fuse Box Diagram

This diagram shows the position and function
for each fuse and relay in the fuse box.

1. ECU Power 10a

2. ECU Relay Power 15a

3. Ignition/Starter/Signals 15a

4. Brake Lights/Horn/EVAP 15a

5. Lights/High Beam 15a

6. Parking Lights 15a

CA. EVAP Emissions 10a

7. Headlight Relay

8. ECU Relay

9. Starter Lock-out Relay

10. Lighting Relay

11. Starter Relay

FUSE & RELAY LOCATIONS (CONT.)

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.

SIDECAR FUSE & RELAY LOCATIONS

Fuse Box Sidecar

The sidecar fuse box is located on the left hand
interior body panel of the sidecar.

Fuse Box Diagram

This diagram shows the position and function for
each fuse and relay in the fuse box.

1. Power Outlet 15a

2. Accessory Switch 15a

3. Accessory 15a

4. Spotlight 15a

5. Spotlight Relay
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.
 Connect the voltmeter to positive and negative terminals of the storage battery
 Start the engine
 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 alternator 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
Page
Engine Management (MIL Blink Codes) 7-2
Service Notes 7-4
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 -> Run -> Kill -> Run” with the ‘->’ indicating a flick of the switch.

The MIL will now blink a code sequence corresponding with the EMS’s diagnosed fault. 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

1 Cylinder 1 Faults Faults specific to the left EMS

2 Cylinder 2 Faults Faults specific to the right EMS

3 System Faults Vehicle level EMS faults

 Blink Category Sub-Category Fault Description Action
Code

111 / 211 Cylinder 1 / 2 Internal CPU Cal CRC mismatch See Dealer

112 / 212 Cylinder 1 / 2 Internal CPU EEPROM Failure See Dealer

113 / 213 Cylinder 1 / 2 Internal CPU Program Error See Dealer

121 / 221 Cylinder 1 / 2 Internal ECU MAT Sensor Failure See Dealer

122 / 222 Cylinder 1 / 2 Internal ECU BAP Sensor Failed See Dealer

123 / 223 Cylinder 1 / 2 Internal ECU BAP Comm. Failure See Dealer

124 / 224 Cylinder 1 / 2 Internal ECU MAP Failure See Dealer

125 / 225 Cylinder 1 / 2 Internal ECU MC33814 Failure See Dealer

131 / 231 Cylinder 1 / 2 INJ or IGN INJ open or short to ground Check wires to injector

132 / 232 Cylinder 1 / 2 INJ or IGN INJ short to battery Check wires to injector

133 / 233 Cylinder 1 / 2 INJ or IGN IGN open or short to ground Check wires to ignition coil

134 / 234 Cylinder 1 / 2 INJ or IGN IGN short to battery Check wires to ignition coil

141 / 241 Cylinder 1 / 2 O2 or O2 Heater O2 Sensor Circuit Failed Low Check O2 sensor

142 / 242 Cylinder 1 / 2 O2 or O2 Heater O2 Sensor Circuit Failed High Check O2 sensor

143 / 243 Cylinder 1 / 2 O2 or O2 Heater O2 Heater open or short to ground Check wires to O2 sensor

144 / 244 Cylinder 1 / 2 O2 or O2 Heater O2 Heater short to battery Check wires to O2 sensor

151 / 251 Cylinder 1 / 2 Other Engine Temperature Sensor fault Check temperature sensor

311 System Battery High Voltage Inspect vehicle battery

312 System Battery Low Voltage Charge or replace battery

313 System Battery Unstable Voltage Inspect charging system

321 System Fuel Pump / Pres. Pump open or short to ground Check wires to fuel pump

322 System Fuel Pump / Pres. Pump short to battery Check fuel pump

323 System Fuel Pump / Pres. Pressure Sensor failed Check fuel pump

331 System VCOM VCOM A Failed Check ECU harness

341 System Immobilizer LED open or short to ground Check wires to LED

342 System Immobilizer LED short to battery Check wires to LED

 SERVICE NOTES
500 km 5.000 km
mile age ………………………………… mile age ………………………………..
date ……………………………………… date ………………………………………

stamp stamp

10.000 km 15.500 km
mile age ………………………………… mile age ………………………………..
date ……………………………………… date ………………………………………

stamp stamp

20.000 km 25.000 km
mile age ………………………………… mile age ………………………………..
date ……………………………………… date ………………………………………

stamp stamp

30.000 km 35.000 km
mile age ………………………………… mile age ………………………………..
date ……………………………………… date ………………………………………

stamp stamp
8. Warranty Information
Page
Warranty Agreement 8-2
Warranty Disclaimers 8-3
URAL MOTORCYCLES LIMITED WARRANTY
Ural Motorcycles warrants to the first retail purchaser of the URAL motorcycle from an authorized 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 Europe who is authorized by Ural
Motorcycles to sell motorcycles (see www.ural.cc for a complete list of authorized dealers).
• Prior to delivery to the purchaser, the dealer who is authorized by Ural Motorcycles to sell motorcycles
must perform the complete set-up and pre-delivery procedures.

Warranty Time Period for Current Model Year

• Duration of Ural Motorcycles Limited Warranty is 24 months, starting with the date the motorcycle is
sold to the first retail purchaser.
• There is no mileage limitation.
• Any unexpired portion of this limited warranty will be transferred to subsequent owners, upon the
resale of the motorcycle during the limited warranty period.

Warranty Coverage
• To obtain warranty service, return your motorcycle at your expense within the limited warranty period
to your authorized Ural dealer. Your authorized Ural dealer should be able to provide warranty service
during normal business hours, depending upon the workload of the authorized dealer’s service
department and the availability of necessary parts.
• Ural Motorcycles will repair or replace, at its options, any part (including parts of the emission control
systems) that are found to be defective in material or workmanship under normal use for the applicable
time period.
• In cases when warranty repair takes longer than 14 days, the warranty time period (see Warranty Time
Period) is extended for the period of time required to complete the repairs, during which the motorcycle
could not been ridden.
• Ural Motorcycles will reimburse non-URAL repair shops performing warranty repairs only if all the
warranty processing and approval procedures are completely fulfilled and/or carried out according to
Ural Motorcycles guidelines (see Warranty Claim Filing Procedures).
WARRANTY DISCLAIMERS LIMITATIONS & EXCLUSIONS
Ural Motorcycles Disclaims Any Responsibility For:
• Loss of time due to warrantable issues and/or repairs.
• Loss of use of motorcycle dues to warrantable repairs.
• Transportation expenses including, but not limited to, towing and/or rentals.
• Any other incidental or consequential damages and/or expenses.

THERE IS NO OTHER EXPRESSED WARRANTY (OTHER THAN THE SEPARATE EMISSIONS

LIMITED WARRANTIES) ON THE MOTORCYCLE.
Any implied warranty of merchantability or fitness for particular purpose is limited to the duration of the express
warranty, or to the duration set forth in your state’s warranty statutes, whichever is shorter.

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
• 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 items including, but not limited to:
 Spark plugs
 Filters
 Lubricants
 Compliance fittings (throttle body mounting flanges)
 Tires
 Gaskets
 Fuel line
 Fuses
 Bulbs
 Battery
4. Paint and/or decal fading, peeling, blistering, chipping or rusting.
5. Surface rust or corrosion on the chassis and/or drivetrain.
The Following Activities Will VOID Warranty Coverage:
• Any operation or use outside of that described in Owner’s Manual
• Racing
• Competition
• Rental and/or other commercial use
• Alteration of the odometer reading
• Towing

Dealer’s Warranty Responsibilities:

• Thoroughly check and road test new units before delivery.
• Complete and send Warranty Registration and Card of Delivery to Ural Motorcycles 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.
• Attend service schools and annual dealer meetings as provided by Ural Motorcycles.
• Submit warranty claims to Ural Motorcycles within 10 business days of the repair date.
• Send failed parts and/or parts assemblies for an inspection to Ural Motorcycles within 3 (three) business
days upon Ural Motorcycle’s request at Ural Motorcycles shipping expense.
• Provide digital pictures of failed and/or defective parts and assemblies with all claims.

Owner’s Warranty Responsibilities:

• As the owner of Ural motorcycle, you are responsible for the performance of the required maintenance
listed in your owner’s manual. URAL recommends that you retain all receipts covering maintenance on
your motorcycle, but URAL 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 URAL 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 URAL may deny you warranty coverage if your
motorcycle or a part has failed due to abuse, neglect, improper maintenance or unapproved
modifications.
9. Emission Control Information
Page
Crankcase Emission Diagram 9-2
California Emission Control Diagram 9-3
CRANKCASE EMISSION DIAGRAM

CLOSED CRANKCASE:
No crankcase emissions will be discharged directly into the ambient atmosphere
throughout the useful life by any vehicle.

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:

NOTE
IT IS AGAINST LAW TO TAMPER WITH OR REMOVE
EMISSION RELATED COMPONENTS.
EVAPORATIVE EMISSION CONTROL:
All models 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:

NOTE
IT IS AGAINST LAW TO TAMPER WITH OR REMOVE
EMISSION RELATED COMPONENTS.
10. Schematics

Wiring Diagram

For current wiring schematics please visit our website at www.imz-ural.com