Ural Luxury Classic 75 Owners Manual

1 URAL Classic Motorcycles Owner ’ s Manual 2002 Models (All States) BC-75 (Bavarian Classic) LC-75 (Luxury Cruiser) Tourist, Adirondac & Patrol Classic Motorcycles & Sidecars, Inc. P.O. Box 969 Preston, WA 98050 www .ural.com

3 Contents Introduction ............................................................................................................................................................. 7 Warnings, Cautions, Notes ....................................................................................................................................... 9 Chapter 1 Specifications Specifications ......................................................................................................................................................... 11 Torque Specifications ............................................................................................................................................. 14 Conversions .......................................................................................................................................................... 14 Chapter 2 Motorcycle Controls & Instrumentation Motorcycle Controls & Instrumentation .................................................................................................................. 15 Controls ................................................................................................................................................................ 16 Chapter 3 Engine Operation & Maintenance Engine Operation and Maintenance ........................................................................................................................ 19 Pre-Trip Preliminaries ............................................................................................................................................ 19 Starting the Engine ................................................................................................................................................. 19 Operating Precautions ............................................................................................................................................ 21 Running-In the New Motorcycle ............................................................................................................................ 22 Chapter 4 Design & Maintenance Brief Description of Design & Maintenance .......................................................................................................... 23 Engine ................................................................................................................................................................... 23 Lubrication System ................................................................................................................................................ 23 Fuel System ........................................................................................................................................................... 24 Ignition System ...................................................................................................................................................... 25 Chapter 5 Carburetors Carburetors ........................................................................................................................................................... 25 Chapter 6 Power Transmission Power Transmission ............................................................................................................................................... 27 Clutch ................................................................................................................................................................... 27 Gearbox ................................................................................................................................................................ 27 Final Drive ............................................................................................................................................................. 27 Chapter 7 Running Gear Running Gear ......................................................................................................................................................... 29

4 Motorcycle and Sidecar Frames ............................................................................................................................ 29 Spring-Loaded Hydraulic Shock Absorber ............................................................................................................. 29 Adjustment of Sidecar Installation ........................................................................................................................ ..30 Front Fork ............................................................................................................................................................ 31 Steering Head Bearings .......................................................................................................................................... 31 Chapter 8 Wheel & Tires Wheels and Tires ................................................................................................................................................... 33 Tire Data ................................................................................................................................................................34 Running Gear Maintenance .................................................................................................................................... 35 Chapter 9 Controls & Instruments Handle Bar and Controls ....................................................................................................................................... 37 Brakes .................................................................................................................................................................. 37 Brake Adjustment .................................................................................................................................................. 37 Control Cable Adjustment ...................................................................................................................................... 38 Control Cable Maintenance ................................................................................................................................... 39 Speedometer ......................................................................................................................................................... 39 Chapter 10 Electrical Electrical Equipment .............................................................................................................................................. 41 Electrical Symbols ................................................................................................................................................. 42 Electrical Circuits.....................................................................................................................................................42 Electrical Equipment Maintenance .......................................................................................................................... 43 Electronic Ignition .................................................................................................................................................. 43 Ignition Timing ....................................................................................................................................................... 44 Electronic Ignition Components .............................................................................................................................. 45 Electrical Wiring Diagram ....................................................................................................................................... 47 Chapter 11 Maintenance Maintenance of Motorcycle ................................................................................................................................... 49 List of Recommended Lubricants ........................................................................................................................... 49 Lubrication Chart ................................................................................................................................................... 50 Required Lubrication ............................................................................................................................................. 52 Care of Motorcycle Paint ....................................................................................................................................... 52 Preservation and Storage ....................................................................................................................................... 53 Battery .................................................................................................................................................................. 53 List of Individual Tool Set, Spare Parts, Accessories & Documents ......................................................................... 54 Chapter 12 Patrol Motorcycle With Engageable Sidecar Drive Patrol Motorcycle with Engageable Sidecar Drive ................................................................................................. 57 Description ............................................................................................................................................................ 57 Handling Differences from the Single Wheel Drive .................................................................................................. 57 Sidecar Maintenance ............................................................................................................................................. 58

5 Chapter 13 Learning to Ride the URAL Learning to Ride the Ural Motorcycle with Sidecar Accessory ................................................................................ 59 Safe Operating Rules ............................................................................................................................................. 60 Chapter 14 Warranty Warranty ............................................................................................................................................................... 63 Terms Used in this Warranty Section .................................................................................................................. 63 Warranty Responsibilities ..................................................................................................................................... 63 Warranty Disclaimers, Limitations & Exclusions .................................................................................................. 65 Distributors Limited Warranties - New Motorcycle ............................................................................................. 66 Warranty Time Period .......................................................................................................................................... 67 Distributor’s Limited Warranties - Motorcycle Tires ............................................................................................ 67 Distributor’s Limited Warranties Emission Control System .................................................................................. 69 Distributor’s Limited Warranties - Noise Control Systems .................................................................................. 70 Distributor’s Limited Warranties - Replacement Parts ......................................................................................... 71 Distributor’s Limited Warranties - Ural Accessories ............................................................................................ 71 EPA Noise Regulations ......................................................................................................................................... 72 Classic Motorcycles Emission Control System Waranty ...................................................................................... 73 Classic Motorcycles Noise Control System Warranty ........................................................................................ 75 Reporting Safety Defects ...................................................................................................................................... 75 Manufacturers Warranty Coverage ...................................................................................................................... 75 Chapter 15 Service Coupons Service Coupons ................................................................................................................................................... 79 New Address Form ............................................................................................................................................... 89 New Owner Form ................................................................................................................................................. 91 URAL Starting and Running Tips .................................................................................................... Inside Back Cover

7 INTRODUCTION Welcome to the URAL Motorcycling Family! Your new 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 Tourist, BC-75 LC-75 Adirondac, and Patrol. This manual 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 maxi- mum motorcycle performance and for your personal motorcycling safety and pleasure. Please pay particular attention to the section “Learning to Ride the Ural Motorcycle with Sidecar” and the separate manual “Driving the Ural Sidecar Motorcycle.” It is critical that a beginning sidecar driver becomes thoroughly familiar with the special operating characteristics of sidecar outfits before venturing out on the 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 and Ural certified Service Center has the facilities, experience and genuine Ural parts neces- sary to properly render this valuable service. The Ural represents an important piece of German and Russian history since it has been continually manufactured with the same general arrangement and outward appearance for the past 60 years after Russian engineers initially copied the BMW’s of 1939. It truly is an “instant antique” as many of our owners have said. Since the Ural weighs 700 lb. empty with the attached sidecar, has a large frontal area and is powered by an old fashioned 745cc engine, it is not a fast motorcycle. The Ural Tourists’ top speed is 65 mph with a cruising speedsof 55 mph but only after faithful adherence to the break-in period. If you are a vintage enthusiast, collector, local commuter, hunter, fisherman, have children, grandchildren or a dog that likes to ride, or you just like to be noticed on a rig that draws a crowd wherever you park, welcome aboard! The classic boxer twin has a German heritage. So effective, simple and powerful is this design that Porsche, Volkswagen, and even Harley (during the war with the XA model) made this design their choice. The reliability and torque of this elegant motor is due to its original design in 1912 by Max Friz, a brilliant German aircraft-engine builder. He devised a compact and rugged engine that delivered significant torque for its displacement, at low and constant rpms, without the gyro effects of other twins. The military and civilian uses became legendary. The German motorbike builder BMW, began sing the design in their motorcycles in 1922. Because of its opposed cylinder layout the “Boxer” as it was dubbed, turns the crankshaft in line with the motorcycle (or airplane!). This allows for a straight-through shaft connection from the engine, through the

8 gearbox and through a stainless steel driveshaft to a rear wheel final drive gear in the wheel hub. This drivetrain design is exactly like the millions of rear wheel drive automobiles built over the past eighty years! It is a time tested, proven drive system made elegantly simple by the “Boxer” opposed cylinder engine. Today the “Boxer” engine has evolved into the high tech and electronically sophisticated and complicated versions that can be found not only in BMWs but also in Porsches, Hondas and others. These are wondrous engines at wondrous prices! But they still retain the basic “soul” of Max Friz’s first engines. And although it is not as evolved as the most modern “boxers”, the IMZ 750 cc is true to the earlier versions in looks, but also has many modern internal components. These parts, like pistons, rings, valves, valve seats and oil seals are modern and western made. The carburetors are made in Japan. These parts make the engine more reliable and cleaner. However, the “boxer” is still an air cooled power plant. As such it must be carefully monitored during operation to prevent overheating. As the gear making and other machine tools in the Ural plant are “vintage” ones, a careful break-in of the engine is very important. Neglecting to follow the prescribed speeds during break-in or the frequent oil changes will cause this wonderful engine to rebel against its “abusing” owner. However, by treating the “boxer” with respect and raising it well, you will be rewarded! So its true that sometimes simple is better, and old fashioned ideas and designs have strong reasons for the ability to continue for a long time. It is the main reason why over millions of Urals have been sold around the world. Any suggestions or comments are welcome! Write to us or post an e-mail on the Ural Discussion bulle- tin board at www.ural.com. Happy Riding!

9 Important Notice! Statements in this manual preceded by the following words are of special importance: WARNING: MEANS THERE IS THE POSSIBILITY OF PERSONAL INJURY TO YOURSELF OR OTHERS. CAUTION: Means there is the possibility of damage to the vehicle. NOTE: Other information of particular importance has been placed in italic type. CAUTION! During the initial 2,500 km, a fundamental bedding-in of parts for all the mecha- nisms of the motorcycle takes place. During this period do not overload the engine or race the motorcycle in excess of the speeds specified in the section “Running-In of New Motorcycle.” Doing so will void the warranty. Maintenance intervals recommended are based on operational experience under various climatic and road conditions. However, these intervals may be extended or reduced following repeated checks of the lubricant condition and general technical condition of the motorcycle. Carefully study this Owner’s Manual before starting the motorcycle. Specifications and design are subject to change without notice.

Ural Luxury Classic 75 Owners Manual

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