Ural motorcycle box repair video

Disassembly

For disassembly it is necessary to remove: — the clutch release rod with the release bearing parts; — starting lever; — a disk with two fingers of an elastic coupling of the cardan transmission from the secondary shaft; — right crankcase cover with manual speed control lever; - fork guide shaft; - shift forks; — unscrew the screws of the front cover; - after this, alternately hitting the primary and secondary shafts with a copper hammer; — remove the front cover with shafts and gears.

If necessary, disassemble the mechanisms: - disengaging the clutch; — foot switch; — manual switching; — gear shift forks; - launcher; - a cover with shafts and gears of constant mesh.

When disassembling the clutch release assembly, you should pay attention to whether there are any traces of crushing or twisting of the square end of the rod, whether the felt seal of the rod is damaged, whether the cylindrical end of the rod rotates freely and without jamming in the tip, whether the thrust bearing balls are falling out of the separator, whether the rubber ring (clutch slider seal).

Pay attention when disassembling the foot switch. For wear, crushing and breaking off the working edges of the pawls and the teeth of the selector sector. For jamming of the spring when compressed in the countersinks of the pawls. To loosen the return spring thrust screws, and also check whether the lever or the axis of the foot shift lever is bent and whether its finger is worn out, and whether the seals are in good condition.

When disassembling the manual speed control. It is necessary to make sure that there are no cracks in the place where the sector is welded to the roller and that there are no scuffs on the working surfaces, and also check whether the shift sector oil seal is in good condition and whether the shift lock ball is not stuck.

It is not recommended to disassemble the cover with rollers and constant-mesh gears unless clearly necessary, but you should only make sure that the gear teeth are in good condition, that the movable couplings are reliably engaged with the constant-mesh gears, that the movable couplings are easy to move and that the gearbox bearings are in good condition.

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Removal and repair of Ural motorcycle gearbox

To remove the gearbox without unscrewing the motor, you need to do the following:

Remove the rear wheel from the motorcycle.
Remove the cardan drive.
Remove 1 bolt and 3 nuts securing the gearbox to the engine.
Then the gearbox can be pulled out of the motorcycle frame and you can begin to inspect it.

Repairing a Ural motorcycle gearbox involves replacing worn gears, followed by adjusting the gear shift mechanism. You should also pay attention to the seals - their wear will cause oil leakage, as a result of which the Ural motorcycle gearbox will operate in conditions of insufficient lubrication.

Fault Inspection

When inspecting the parts, you should check the ease of movement of the forks along the rod. Condition of fork stays and ring grooves in movable couplings. The amount of axial movement of the forks in the groove of the engagement couplings.

The following malfunctions may occur in the trigger mechanism: - wear, crushing or chipping of the pawl; — jamming of the pawl pusher; — breakage of the pawl spring; — bending the ends of the return spring of the starting pedal; — damage to the working end of the buffer pin; — cracks in the starting lever; - wear of the oil seal.

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Owner reviews

A powerful unit with decent performance characteristics, in the right hands can live forever, or as long as there are spare parts. Considering how many opposition pieces were riveted in the USSR, there is every chance of passing it on to one’s grandchildren as an inheritance. Anyone who says that this is a bad spender simply does not know how to handle it. Igor, Smolensk.

I started my two-wheeled life with a stroller, like many, and rode until I earned money for an old Honda Steed. When I sold the stroller and switched to a Japanese one, I drove it once and realized that when I go to hell, part of the torment will be credited to me there))) Ivan, Tver.

In stock condition, it’s trash, killed by a disregard for it. With the right approach, the motorcycle is reliable and durable, it will go anywhere, there are enough horses and torque, it can be repaired with a hammer and a screwdriver, and it will eat any gasoline. If you put survivability at the forefront, then Uralei has no competitors except old Harleys, but here the price of the issue is completely different. Anton, Murom.

Gearbox assembly

Reassembling the gearbox follows the reverse order of disassembly. First, the trigger shaft assembly with gear is installed into the hole in the rear wall of the crankcase. Then place the crankcase with the front hole up; after that, placing a paper gasket, insert the primary and secondary shafts assembled with a cover and bearings into it and press them into the rear wall of the crankcase with light blows of a hammer. Then the trigger shaft is put in place.

When installing the front bearing sleeve of the trigger shaft, it must be turned counterclockwise so that the spring is sufficiently wrapped and the starting pedal is sharply thrown back to its original position until it stops against the spring-loaded buffer rod.

After this, the parts of the gear shift forks, manual and foot shift, thrust bearing and rod are installed. After assembling the box, it is necessary to adjust the operation of the foot switch.

masses of units

Post by Nitro » Mon Apr 21, 2008 7:05 pm

There is no data on radiators. Accordingly, most of the data is not available, but you can estimate

Power unit 2101 117 kg Lubrication system 2101 3.75 l Cooling system 2101 9.9 l

Power unit 2108 82 kg Lubrication system 2108 3.5 l Cooling system 2108 7.8 l

Power unit 331.7 128 kg Lubrication system 331.7 4.8 l Radiator 2141 5.5 kg Cooling system 2141 9 l

Power unit 1111 66.5 kg Lubrication system 1111 2.5 l Cooling system 1111 4.8 l

KP 2101 26 kg Carter KP 2101 1.35 l

KP 2108 34 kg Carter KP 2108 3.3 l

KP 2141 40 kg Carter KP 2141 3.4 l

KP 1111 24.5 kg Carter KP 1111 1.8 l

Rear hub 2108 assembled 2.5 kg Brake disc 2108 4 kg Knuckle 2108 4.5 kg Caliper 2108 3 kg

Rear hub 2141 assembled? kg Brake disc 2141 4.2 kg Knuckle 2141 5 kg Caliper 2141 ? kg

Front suspension 2101 assembled? kg Front suspension 2108 assembled 55 kg Front suspension 2121 assembled? kg Front suspension assembly 2141 72.5 kg Front suspension assembly 2410 ? kg OKA stand assembly 14.2 kg

CV joint 2141 standard 6 kg

Gas tank 2101 39.0 l = 28.7 kg Gas tank 2104 45.0 l = 33.1 kg Gas tank 2108 43.0 l = 31.6 kg

Wheel 2108 beskam 13.4 kg Wheel 2410 21 kg

Post by zilbergilzen » Mon Apr 21, 2008 9:57 pm

Post by wat » Tue Apr 22, 2008 1:43 am

Posted by Nitro » Tue Apr 22, 2008 9:12 am

Post by zilbergilzen » Tue Apr 22, 2008 6:40 pm

Weight of units (in kg): Engine assembly - 114; gearbox with clutch housing - 32; transfer case - 27.6, rear axle - 60.5, front axle with front wheel drive - 32; complete body without upholstery - 284; wheel with tire - 21.

Post by ForSash » Tue Nov 18, 2008 10:14 am

Maybe it will help someone (don’t take it as advertising, please - this is serious work that has been going on for more than one year)

Historically, we supply components for various pneumatic manufacturers. First of all - for “Litvina”, as well as for “Trekol”. So, this is not the first year we have been collecting information on the weight of spare parts. They themselves hung about 20 thousand pieces of iron in warehouses. About 30 thousand more were found from other sources.

We don’t yet keep it in the public domain in the form of a complete reference book, but you can look at the characteristics of individual parts. In particular, here on the website https://www.avtoall.ru, in our product cards, the weight is marked for the spare part, if it is known to us. (don't take it as an advertisement)

Post by ilmar » Tue Nov 18, 2008 1:27 pm

Posted by ACD » Tue Nov 18, 2008 1:54 pm

Post by ilmar » Tue Nov 18, 2008 2:36 pm

Post by ForSash » Tue Nov 18, 2008 3:28 pm

I am interested in this weight as an average statistical parameter. For example, if an SPZ bearing weighs 150 grams, then the same SKF bearing will weigh the same, because I will simply copy the weight from one to the other. Therefore, I cannot say that each figure given is 100 percent verified. For example, a reference book on weights of spare parts from the ZIL plant was given to me as a terrible military secret, and only after 135 requests. And you can’t keep track of the number of typos that manufacturers come across, even though we try and hang the hardware in warehouses ourselves. Again, there is the question of the weight of the packaging container, the density of liquids, and completeness. Well, in general, there are a lot of subtleties in this seemingly simple matter.

Therefore, it somehow doesn’t even occur to me to post such data in the form of a DIRECTORY. This is sewn into the internal database, rather as a GUIDELINE by which you can estimate whether the weight of the cargo will fit into a 3-ton container or whether you need to order a 5-ton container. Well, something like this, in general.

Source

Types of engines

The feature thanks to which the Irbit motorcycle has a constant circle of fans in Russia (abroad they prefer the sidecar version, since almost no one else produces such motorcycles) is the boxer engine. Currently, the bulk of motorcycles are produced for export, since in Russia they are reluctant to buy domestic motorcycles costing 500,000-600,000 rubles. But on sale you can always find Urals made from the last century, which are very popular among lovers of rarities. Obviously, after purchasing the engine of such a motorcycle, it needs to be rebuilt and updated.

Even the first M-72s were equipped with boxer engines - the pride of the Irbit Motor Plant. The rows of cylinders of such a motor are located at an angle of 180 degrees relative to each other, that is, actually in the same plane. During operation, the pistons move simultaneously and in opposite directions. It turns out that all pistons (2 or 4) arrive at the top “dead” point synchronously. Thanks to this design, the boxer engine is more stable, since it has a low center of gravity compared to a V-twin arrangement. The synchronized movement of the pistons neutralizes mutual vibration. Depending on the year of manufacture, engines could have a volume of 500, 650 and 750 cm³.

Examples of prices for the engine, its installation and replacement

It is not always necessary to completely replace the motor; it is often necessary to carry out maintenance, replace rings or various elements of the motor. A major overhaul includes disassembling the unit, checking for the presence of diaphragms, boring cylinders, replacing carburetors, moving, changing consumables and reassembling. In general, such work costs from 10,000 rubles . Workshops and companies provide a guarantee on the quality of their work, usually for 1 year. Private craftsmen can charge less for some part of the work - from 1,500 rubles , it all depends on a personal agreement.

A complete engine replacement is necessary if it no longer produces full power and valve adjustments and ignition system repairs have no effect. The motorcycle cannot accelerate more than 80 km/h even on a flat surface. Compression in the cylinder is measured and if the compression meter shows less than 450 kPa, then it is useless to change the carburetor.

A new engine is needed if, when the Ural is moving, there is a lot of smoke from the breather tube, knocking noises are heard, there is damage to the crankcase and other parts that cause increased oil consumption (which cannot be eliminated by replacing the seals or rings). In this case, the cost of repairs may exceed 100,000 rubles (including the cost of replaced mechanisms).

Total information

Motorcycle type: with sidecar. Wheelbase, mm — 1430. Ground clearance, mm — 130. Track, mm — 1100

Dimensions, mm: — length — 2420; — width — 1650.

Height (by ignition key) - 1000

Motorcycle weight, kg: — dry — 335; - worker - 380.

Fuel consumption on the highway, l/100 km - 7. Fuel reserve on the highway, km - 310. Highest speed, km/h - 85.

Capacity (oil), l: - engine crankcase - 2.0; — gearbox housing — 0.8; — reverse gear housing — 0.150; — air purifier — 0.2.

Fuel tank capacity, l - 22.