If I wanted easy, I wouldn't have bought a Ural

Are ya having a problem with your rig? We'll try to help. Share your tech tips and experiences here. Dr. Billy Glaser, author of the "Unofficial 750 Ural Service Manual" site myural.com, is moderating this section.
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Here is the place for you to ask questions about or share your experiences about servicing or repairing your Ural or Dnepr. Please post topics concering modifications or accesories in the "Modifications and Acessories" section. Please post oil related questions in the "Oil Threads" section.
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JamesG
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If I wanted easy, I wouldn't have bought a Ural

Post by JamesG » Sat May 28, 2011 5:07 pm

Some of you may have seen my introductory post where my new to me 2002 Bavarian Classic blew up its timing gear on the trip home from buying it from "Murph" here.
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The typical bad generator gear induced gear train failure.

This is where I will log my rebuild and solicit help and advise from the peanut gallery. I hope you all enjoy the show and wish me luck in this. I'd bought a Ural fully aware that it would require "tinkering", was even looking forward to it, but I'd hope to not have to jump straight into it right off the bat. Oh well...

So I've got the rig in the shop and started tearing it down.

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Already a hanger queen...

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Still need to get the clutch off and crank out.

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Its a pile of Ural...

Got the motor mostly torn down and so far pretty good. The cam shaft seemed to have survived the trauma, its still true. Boy those Russians can design it tough. Some of the bearing surfaces show minor scoring, more like streaking, but no gouges.

The alternator is toast.

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The front case is cracked all the way around and when it was running, oil was getting past the seal and into the body. I think I will bow to the wisdom of the collective and spring for the denso unit.

The plan for the rebuild is to completely tear down and get it as clean as a whistle, then rebuild it with new bearings, seals, and timing gear train. Also going to open the transmission and final drive to make sure there are no other surprises waiting. The gear box because it was shifting very roughly, gears would clatter on every shift. So I want to see if there is any damage to the gear sets or the shift forks and adjust it.

Speaking of forks, when I was jacking up the bike, I noticed that the forks were very odd. I could compress or extend them a couple of inches and they would stay there as if they had a lot of "stiction" in them. I will probably take them apart when cleaning up the the frame and rotating wheels around.

Question.

On a 750 with 4100 kms on it, is it worth while to re-ring and re-hone the cylinders? Re-hone the bores and let the rings re-bed? Or just throw it back together and let it sort it out itself? There is minor grooving and no noticeable cross-hatching left. Ordinarily I would know the difference, but Urals are *special* like that.

Thanks guys,
-James

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JustTroItIn
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Re: If I wanted easy, I wouldn't have bought a Ural

Post by JustTroItIn » Sat May 28, 2011 6:37 pm

Looks like you are on the right track. My forks on the Dnepr are pretty much the same way, even after rebuild. They do work, they just never fully unload unless I jack the front wheel off the ground.

I would go ahead and throw new Hastings rings in there since you have it apart. They are superior to the Russian jobs.
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Re: If I wanted easy, I wouldn't have bought a Ural

Post by a1930ford » Sat May 28, 2011 7:10 pm

:lurker:
Last edited by a1930ford on Mon Oct 01, 2012 7:31 pm, edited 2 times in total.
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Re: If I wanted easy, I wouldn't have bought a Ural

Post by JamesG » Sat May 28, 2011 7:23 pm

a1930ford wrote:Its a bit late, but my first suggestion to anyone tearing into a Ural is to invest in some large plastic baggies and label everything.
You mean like this:

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:wink:

Good idea on the VIN number and applying dialectric to connectors. That hadn't occurred to me.

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Re: If I wanted easy, I wouldn't have bought a Ural

Post by hrpchr » Sat May 28, 2011 8:08 pm

An older, um, very mature, mechanic who kept all several of his ex-wives in alimony and still had the largest roll around tool chest I have ever seen did it by, among other things, building and restoring VW dune buggies. He once gave me the guru eye and said, “Daylight puts the voodoo in piston rings.” I took that to mean every time you tear down an air-cooled motor to the point you can see the rings then replace the rings. Seemed like sound advice – passing it along.

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a1930ford
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Re: If I wanted easy, I wouldn't have bought a Ural

Post by a1930ford » Sat May 28, 2011 10:07 pm

:lurker:
Last edited by a1930ford on Mon Oct 01, 2012 7:32 pm, edited 1 time in total.
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Re: If I wanted easy, I wouldn't have bought a Ural

Post by matman1972 » Sat May 28, 2011 11:52 pm

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hey, that's what my 650 looked like in December. have fun!

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Except, i had a different problem...
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Re: If I wanted easy, I wouldn't have bought a Ural

Post by gremlin96 » Sun May 29, 2011 9:40 am

a can of wd40 works wonders when you have the parts out for a bit. spray every part with a light coating and they will say rust free for a bit.
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Re: If I wanted easy, I wouldn't have bought a Ural

Post by a1930ford » Sun May 29, 2011 2:31 pm

:lurker:
Last edited by a1930ford on Mon Oct 01, 2012 7:32 pm, edited 1 time in total.
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Re: If I wanted easy, I wouldn't have bought a Ural

Post by matman1972 » Sun May 29, 2011 2:44 pm

gremlin96 wrote:a can of wd40 works wonders when you have the parts out for a bit. spray every part with a light coating and they will say rust free for a bit.
they all look like new now. Soaked in kroil for a couple days and everything came out great. I do like the vinegar for the fuel tank before rekote.
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Re: If I wanted easy, I wouldn't have bought a Ural

Post by JamesG » Tue May 31, 2011 4:40 pm

You guys get your own threads. :P

Got the clutch apart (only stripped one screw). More "surprises".

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I don't think the flywheel is supposed to be full of powdered clutch material clods...

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Unhappy looking clutch pack.

Lets see:

Outer plate is 4mm.
First driven plate is 4.5mm
Intermediate plate is a beefy 5.4mm
Second driven plate is also 4.5mm
And the last thrust plate is 4mm.

I guess I will be needing new friction plates too... on a 2002 with 4100kms on it.
:roll:

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Re: If I wanted easy, I wouldn't have bought a Ural

Post by matman1972 » Tue May 31, 2011 5:04 pm

JamesG wrote:You guys get your own threads. :P

Got the clutch apart (only stripped one screw). More "surprises".

I don't think the flywheel is supposed to be full of powdered clutch material clods...

Unhappy looking clutch pack.

Lets see:

Outer plate is 4mm.
First driven plate is 4.5mm
Intermediate plate is a beefy 5.4mm
Second driven plate is also 4.5mm
And the last thrust plate is 4mm.

I guess I will be needing new friction plates too... on a 2002 with 4100kms on it.
:roll:
But it is more fun to hijack yours, less work! :lol:

Yeah, that is quite a bit of clutch material you're collecting there. Must be all them burnouts done by the PO. :wink:
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Re: If I wanted easy, I wouldn't have bought a Ural

Post by cdscoot » Tue May 31, 2011 7:01 pm

On the other hand that nut sure is shiny!
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Re: If I wanted easy, I wouldn't have bought a Ural

Post by sputnik » Tue May 31, 2011 7:36 pm

he knew he was selling, and took it out and beat the everlovin........ :lol:

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Re: If I wanted easy, I wouldn't have bought a Ural

Post by JamesG » Wed Jun 01, 2011 3:31 pm

F'in flywheel... :(

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