ural (Урал) - dnepr (Днепр russian motorcycle part 1

Ural (Ural (УралУрал) ) -- Dnepr (Dnepr (ДнепрДнепр))Russian MotorcycleRussian Motorcycle

Part 1: Overall DrivePart 1: Overall Drive--ChainChain(Also See Part 2: One(Also See Part 2: One--Wheel Drive (1WD), Wheel Drive (1WD),

Part 3: TwoPart 3: Two--Wheel Drive (2WD), Part 4: Gears and Gear Ratios, Wheel Drive (2WD), Part 4: Gears and Gear Ratios, Part 5: Disassembly of Drive Chain, Part 5: Disassembly of Drive Chain,

Part 6: Drive Train Components, Part 7: Drive Train Maintenance Part 6: Drive Train Components, Part 7: Drive Train Maintenance andandPart 8: Chapter 7 of Bill Glaser's "Unofficial" URAL 750cc MotorPart 8: Chapter 7 of Bill Glaser's "Unofficial" URAL 750cc Motorcycle Service Manual)cycle Service Manual)

Ernie FrankeErnie [email protected]@tampabay.rr.com

1 / 20131 / 2013

Parts to Overall DriveParts to Overall Drive--Chain StudyChain Study•Part 1: Introduction: Overall Drive-Chain•Part 2: One-Wheel Drive (1WD)•Part 3: Two-Wheel Drive (2WD)–Part 3A: Locking versus Non-Locking Differentials–Part 3B: Full-Time Two-Wheel Drive (2WD) with Non-Locking Diff–Part 3C: Full-Time Two-Wheel Drive (2WD) with Locking Differential–Part 3D: Full-Time One-Wheel Drive (1WD) with Locking 2WD (non-Diff)

•Part 4: Gears and Gear Ratios•Part 5: Disassembly and Assembly of Drive Chain•Part 6: Drive Train Components–Part 6A: Drive Trains and Drive Shafts–Part 6B: Drive Train Components

•Part 7: Drive Train Maintenance•Part 8: Chapter 7 of Bill Glazer’s "Unofficial" Ural 750cc Motorcycle Service Manual

•Notes for Model and Component Numbers–Model Designations:

•MV (cyrillic MB) = MB = CF (Example: MB-750 = MV-750, CF-650 = MB-650)–Component Designations:

•ВП = VP (Example: ВП48801 = VP48801)•H = N (Example 72H05121 = 72N05121)

We trace the evolution of the Russian motorcycle drive-train from the simple One-Wheel Drive (1WD) to the Two-Wheel Drive (2WD), with

its differential (lockable and non-lockable) and non-differential rear drives.

Cardan and Rear DriveCardan and Rear Drive• Final Drive (FD) –Consists of a Propeller Shaft (Cardan), Flexible Coupling (Flange), Elastic Disc

(Doughnut) and Universal Joint (Cross)–Transmits Torque from Transmission to Rear Drive

• 1WD (One-Wheel Drive)–Rear Drive Has Pair of Bevel Gears with Spiral Teeth without a Sidecar Wheel Drive–Changes Direction of Torque at Right Angles to Rear Power Drive Wheel

• 2WD (Two-Wheel Drive)–Rear Drive Has Pair of Gears with Spiral Teeth, Semi-Detached with Cylindrical Gear to

Drive Sideacar Wheel–Changes Direction of Torque at Right Angles to Power Drive Wheel–Changes Amount of Torque Transmitted by Propeller Shaft (Cardan)–Distribute Torque between Drive Wheel and Sidecar Drive Wheel in a Specific Ratio

(19:11)

Oil Filler PlugOil Filler Plug

Splines Splines (beneath protective cap)(beneath protective cap)

Universal JointUniversal Joint

Propeller ShaftPropeller Shaft

Flexible FlangeFlexible Flange

Rear Drive Rear Drive CasingCasing

Example: Ural 1WD Drive TrainExample: Ural 1WD Drive Train

Oil Drain PlugOil Drain Plug

Components of Overall DriveComponents of Overall Drive--ChainChainElastic Elastic

CouplerCoupler

Drive ShaftDrive Shaft

Flexible Flexible FlangeFlangeRear DriveRear Drive

Universal Universal JointJoint

Rear Brake Activation LeverRear Brake Activation Lever

Bevel GearsBevel Gears

Universal JointUniversal Joint

Doughnut or BiscuitDoughnut or Biscuit

PropshaftPropshaft

• Final Drive (FD)– a.k.a. Drive Chain

• Propeller Shaft (Propshaft)– a.k.a. Cardan, Drive Shaft, PTO (Power Take-Off) Shaft

• Elastic Coupler– a.k.a. Cardan Coupler, Russian Doughnut, Biscuit, Rubber Puck, Flexible Disc

•Bevel Gears– Pinion Gears– Drive Gear (Small Gear)– Driven Gear (Large Circular Gear) a.k.a. Crown Gear

•Universal Joint – a.k.a. Cardan (French for Gimbal) Joint, Hooke Joint, U-Joint, Cross– Simple Flexible Coupling Using a Double-Yoke and Four-Point Center Cross– Used as Coupling in Drive-Shaft of Rear-Wheel Drive Vehicles

The Final Drive (FD) consists of a rear drive, universal joint, drive shaft, flexible flange and an elastic coupler.

German German BMWBMW RR--71 71 ((motoridingmotoriding..ruru))

Cardan Cardan ShaftShaft(Propeller Shaft)(Propeller Shaft)

Flexible FlangeFlexible FlangeUniversal JointUniversal Joint

underneath the Cowlunderneath the CowlElastic CouplerElastic Coupler

(Doughnut)(Doughnut)

Power TakePower Take--Off (PTO)Off (PTO)

The German R-71 was the father to all heavy Russian sidecars, , and was duplicated in the Russian Mand was duplicated in the Russian M--72.72.

Four Types of Final Drives in Russian SidecarsFour Types of Final Drives in Russian Sidecars1. Full-Time, Straight Final Drive (1WD)–One-Wheel Drive (1WD)–Available in Various Ural / Dnepr Models

2. Full-Time, Two-Wheel Drive (2WD) with non-Locking Differential–Dnepr MB-650M (1985-1991)–Dnepr MT-12 (1977-1985)–Dnepr MT-16 (1985-2005)–Dnepr Rear Drive Casings Allow for Adding Locking Differential–First Available in Ural: “Sportsman” IMZ 8.107 (1995-1998)•Only True Differential for Ural•Pre-“Patrol” Model

3. Full-Time, Two-Wheel Drive (2WD) with Locking (Engageable) Differential–Dnepr MB-750 (1964-1973)–Dnepr MB-650 (1968-1984)–Dnepr MB-750M (1973-1977)

4. Full-Time, One-Wheel Drive (1WD) with Engageable Locking 2WD (non-Diff)–Available in Various Ural Models•Production: Patrol (1998-Current), Gear-Up (2001-Current) and Patrol-T (2009-Current)•Limited Editions with Engageable Sidecar Drive Shaft:–Derivatives of Patrol or Gear-Up–Basic (2005), Raven (Vorona) (2006), Pustinja (2007), Wjuga (2008), Sahara (2009) and Taiga (2010)

Ural (Ural (УралУрал) / Dnepr () / Dnepr (ДнепрДнепр)) Drive Train and Rear SuspensionDrive Train and Rear Suspension

750cc OHV650cc OHV650cc OHV650cc OHV650cc OHV650cc OHV650cc OHV650cc OHV650cc OHV750cc SV750cc SV750cc SVEngineEngine

Full-Time 1WD with Engageable 2WD (No Diff)Full-Time 1WD with Engageable 2WD (No Diff)Full-Time 2WD with non-Locking DifferentialFull-Time, Straight Final Drive (1WD)Full-Time, Straight Final Drive (1WD)Full-Time, Straight Final Drive (1WD)Full-Time, Straight Final Drive (1WD)Full-Time, Straight Final Drive (1WD)Full-Time, Straight Final Drive (1WD)Full-Time, Straight Final Drive (1WD)Full-Time, Straight Final Drive (1WD)Full-Time, Straight Final Drive (1WD)

Drive TrainDrive Train

Swing ArmSwing ArmSwing ArmSwing ArmSwing ArmSwing ArmSwing ArmPlungerPlungerPlungerPlungerPlungerRear SuspensionRear Suspension

12-Volt1995-1998“Sportsman” IMZ 8.107

2003-Present1984-2002

1976-19841974-19761971-19731965-19711961-19651958-19611956-19611952-19581941-1950ProductionProduction

6-VoltM-726-VoltM-72K6-VoltM-72M

12-VoltM-67 (IMZ-8.101)12-VoltM-67.36

12-Volt8.103 Series “650”12-Volt“750”Series

6-VoltM-66 (Ural-3)6-VoltM-63 (Ural-2)6-VoltM-62 (Ural-1)6-VoltM-61

VoltageVoltageUral (Ural (УралУрал) Model) Model

650cc OHV650cc OHV650cc OHV650cc OHV650cc OHV650cc OHV650cc OHV650cc OHV750cc SV750cc SV750cc SV750cc SV750cc SV750cc SV750cc SVEngineEngine

Full-Time 2WD with Non-Locking Differential * *Full-Time, Straight Final Drive (1WD)Full-Time, Straight Final Drive (1WD)Full-Time, Straight Final Drive (1WD)Full-Time 2WD with Non-Locking Differential * *Full-Time 2WD with Locking Differential *Full-Time, Straight Final Drive (1WD)Full-Time, Straight Final Drive (1WD)Full-Time 2WD with Locking (Engageable) Diff *Full-Time 2WD with Locking (Engageable) Diff *Full-Time 2WD with Non-Locking Differential * *Full-Time, Straight Final Drive (1WD)Full-Time, Straight Final Drive (1WD)Full-Time, Straight Final Drive (1WD)Full-Time, Straight Final Drive (1WD)

Drive ChainDrive Chain

Swing ArmSwing ArmSwing ArmSwing ArmSwing ArmSwing ArmSwing ArmSwing ArmSwing ArmSwing ArmSwing ArmSwing ArmSwing ArmPlungerPlungerRear SuspensionRear Suspension

12-Volt1985-1991MB-650M

1985-20051984-20051976-19841973-1976

1968-19841971-19761967-19711973-19771964-19731974-19821963-19771959-19631956-19601951-1956ProductionProduction

6-VoltMT-12 (Dnepr-12)

12-VoltMB-6506-VoltK-650/MT-96-VoltK-650/MT-8

12-VoltMT-1012-VoltMT-10.36

12-VoltMT-16 (Dnepr-16)12-VoltMT-11 (Dnepr-11)

6-VoltMB-750M6-VoltMB-750

6-VoltK-7506-VoltK-750M

6-VoltM-72N (H)6-VoltM-72

VoltageVoltageDnepr (Dnepr (Днепр) ModelModel

* Locking Feature Deleted after Two Years of Production, * * Optional Kit Available to Add Locking Differential

Russian TwoRussian Two--Wheel Drive (2WD) TimeWheel Drive (2WD) Time--LineLine

KMZ’s (Dnepr factory) first production 2WD was the MB-750 (1964), with a rear drive modeled on the WW-II BMW R75.

The first production Ural 2WD post-war was the short-lived Sportsman in the mid-1990's, to be followed by the non-diff Patrol and Gear-Up.

1940 19701950 196019551945 1965 1975

SaharaSahara

1975 20051985 199519901980 2000 2010

TaigaTaiga

WjugaWjuga

PustinjaPustinja

RavenRavenBasicBasic

Ural Ural ““PatrolPatrol””(non(non--Diff 2WD)Diff 2WD)

Ural Limited Editions

Ural Limited Editions

(non(non--Diff 2

WD)

Diff 2WD)

Ural Ural ““GearGear--UpUp””(non(non--Diff 2WD)Diff 2WD)

Ural Ural ““PatrolPatrol--TT””(non(non--Diff 2WD)Diff 2WD)

DneprDneprMBMB--650M650M

Ural Ural ““SportsmanSportsman””(True Differential)(True Differential)

DneprDneprMBMB--750750



Mother of All Mother of All Russian Sidecars: MRussian Sidecars: M--7272

MM--72 Minor Redesigned 72 Minor Redesigned and Issued as Mand Issued as M--72N72N

SwingSwing--Arm Frame IntroducedArm Frame Introducedwith Kwith K--750750

Locking Differential Added on MBLocking Differential Added on MB--750, 750, MBMB--650 and MB650 and MB--750M, Later Dropped750M, Later DroppedMBMB--750 Introduced 750 Introduced

with Differential Drivewith Differential Drive

MM--73 (Modified M73 (Modified M--72) with an 72) with an EngagableEngagable Sidecar Drive and Brake, Sidecar Drive and Brake,

but No Production)but No Production)



Locking Differential Locking Differential Upgrade Kit AvailableUpgrade Kit Available DneprDnepr

MTMT--16DneprDneprMTMT--12 1612

Standard OneStandard One--Wheel Drive (1WD) Russian SidecarsWheel Drive (1WD) Russian Sidecars

1949 Ural M1949 Ural M--7272

Focusing on the area to the right of the rear drive (non-U.K.), 1WD motorcycles don’t have a transverse driven shaft to power the sidecar wheel.

1967 Ural M1967 Ural M--6363

1965 Dnepr K1965 Dnepr K--750750

1959 Ural M1959 Ural M--6161

1959 Dnepr K1959 Dnepr K--750750

1982 Dnepr MT1982 Dnepr MT--10.3610.36


Dnepr MTDnepr MT--1111Dnepr MTDnepr MT--1111

Dnepr MTDnepr MT--1111

Dnepr MTDnepr MT--99

1995 Dnepr MT1995 Dnepr MT--1111Dnepr MTDnepr MT--10.3610.36

Dnepr’s M-72, K-750, MT-10, MT-10.36, MT-11 and Ural’s M-72, M-61, M-62, M-63, M-66, M-67, M-67.36 were all one-wheel drive (1WD).


1956 M1956 M--72M with Sidecar 72M with Sidecar Temporarily RemovedTemporarily Removed

1991 MT1991 MT--1111

2011 Ural Retro2011 Ural Retro

Focusing on the area to the right of the rear drive, 1WD motorcycles don1WD motorcycles don’’t have a driven shaft to power the sidecar wheel.t have a driven shaft to power the sidecar wheel.

UralUral--TT

Taiga Limited EditionTaiga Limited Edition PatrolPatrol--TT

PatrolPatrol

2WD 2WD Engageable Engageable Lever (nonLever (non--Diff)Diff)

Modern Urals offer an engageable, non-differential, only for off-road driving.

Modern Urals with Standard OneModern Urals with Standard One--Wheel Drive (1WD) Wheel Drive (1WD) and and EngageableEngageable, Locked Two, Locked Two--Wheel Drive (2WD, nonWheel Drive (2WD, non--Diff)Diff)

Ural PatrolUral Patrol--T with FullT with Full--Time 1WD and Time 1WD and EngageableEngageable 2WD2WD

Engageable Engageable 22--Wheel DriveWheel Drive

(non(non--Diff)Diff)

Ural Ural ““Limited EditionLimited Edition”” Sidecars with Standard Sidecars with Standard FullFull--Time 1WD andTime 1WD and EngageableEngageable 2WD (non2WD (non--Diff)Diff)

WjugaWjuga (2008)(2008)

PustinjaPustinja (2007)(2007)BasicBasic (2005)(2005)

Taiga (2010)Taiga (2010)

Sahara (2009)Sahara (2009)

VoronaVorona ““RavenRaven”” (2006)(2006)

Modern Urals offer an engageable, non-differential, only for off-road driving, as an option for the Patrol and Gear-Up versions.

• Sidecar Wheel Creates a Resistance to Movement on Its Own Track–Tends to Turn Bike to the Right

• Effective Way to Improve Control Is to Transfer Torque to Sidecar Wheel•Applied to Dnepr’s MB-750 / MB-650 in Limited Production–Basis for Dnepr-12 (MT-12) and Dnepr-16 (MT-16) with Increased Production

2WD Transmission Scheme: 2WD Transmission Scheme: 1.1. EngineEngine2.2. ClutchClutch3.3. TransmissionTransmission4.4. Final DriveFinal Drive5.5. Sidecar Wheel Gear ReducerSidecar Wheel Gear Reducer6.6. DifferentialDifferential7.7. Drive WheelDrive Wheel

• Selected Skewness Differential Ratio: 19:11 (Number of Gear Teeth)–63% of Torque Supplied to Main Gear & 37% to Sidecar Wheel Reducer–No Need to Set Camber and Toe Angles, as the Sidecar Is Not “Pulling“• Plane of Wheels Parallel to Each Other and Perpendicular to Road

Surface•Reduces Rolling Resistance (Compared to Conventional Sidecar Rig)

Up to 25%• Increased Tire Mileage and Reduced Fuel Consumption

•Differential Operation–In Rear Drive Are Two Gear Shafts (Master and Slave) with a Pair of

Cylindrical Gears–Slotted Hub-Driven Gear Protrudes from Gear Cover and Interfaces with

Internal Splined Wheel Hub–Shock Absorber Connected to Welded Ear on Side of Differential–Transverse Propeller Shaft Passes under Sidecar Tub to Sidecar

Reduction Gear–Reduction Gear Constructed with a Pendulum Wheel Suspension• Fixed to Sidecar Frame in Same Manner as Dnepr MT-10.36

TwoTwo--Wheel Drive (2WD) with DifferentialWheel Drive (2WD) with Differential (roker.kiev.ua)

Unlike automotive differentials, consisting of bevel gears to distribute torque to the wheels symmetrically, the mechanism of Dnepr’s MB-750 and MT-12

include a cylindrical gear transmission to the wheels, providing an uneven effort, where the sidecar wheel receives about 30 to 40% of the load and the bike wheel

receives about 60 to 70%.

Dnepr’s MT-12 has a full-time 2WD (true differential), and no locking activation lever.

MTMT--12 with Full12 with Full--Time 2WD Time 2WD (Transverse Shaft to Sidecar Wheel)(Transverse Shaft to Sidecar Wheel)

nonnon--Locking DifferentialLocking Differential(Hence No Activation Lever)(Hence No Activation Lever)

1981 MT1981 MT--1212

Dnepr MTDnepr MT--12 (2WD) with Full12 (2WD) with Full--Time DifferentialTime Differential

Dnepr MTDnepr MT--16 (2WD) with Full16 (2WD) with Full--Time DifferentialTime Differential ((databikesdatabikes.com).com)

1994 MT1994 MT--16161986 MT1986 MT--1616

1986 MT1986 MT--16161994 MT1994 MT--1616

Area for Later Addition Area for Later Addition of Locking Kitof Locking Kit

Dnepr’s MT-16 has a full-time 2WD (true differential), and no locking activation lever.

MTMT--16 Full16 Full--Time (nonTime (non--Locked) 2WD Differential Locked) 2WD Differential (www.(www.advrideradvrider.com)

Propshaft Propshaft from Gearbox

from Gearbox

Rear Brake PadsRear Brake Pads

Driv

e Sh

aft t

o

Driv

e Sh

aft t

o Si

deca

r Whe

el

Side

car W

heel

Place for RetroPlace for Retro--Fitting Fitting of Locking Differentialof Locking Differential

Elastic CouplerElastic Coupler

.com)

If the MT-16 had a locking differential added, such as in the MB-750, it would have a shaft with an actuation arm at the location shown by the red arrow.

Ural Ural ““Sportsman,Sportsman,”” with Fullwith Full--Time 2WDTime 2WD

1995 Ural 1995 Ural ““SportsmanSportsman””

As Ural’s first and only full-time 2WD sidecar, the “Sportsman” does not need a lever on the rear drive. The Sportsman was produced from 1995 to 1998,

morphing into today’s “Patrol,” which had an engageable 2WD (non-differential).

1975 MB1975 MB--750M 750M with Fullwith Full--Time 2WD Time 2WD ((sovietsteedssovietsteeds.com).com)

For the first few years the MBFor the first few years the MB--750M 750M had a Locking Differential, which had a Locking Differential, which was later dropped as shown here.was later dropped as shown here.

All 2WD Dneprs are full-time with true differentials, and some Dneprs have locking diff’s on top of that. All 2WD Urals, except for the Sportsman,

cannot be used on hard surfaces when 2WD is manually engaged, because there is no real differential.

Russian Powered Sidecar (2WD) DevelopmentRussian Powered Sidecar (2WD) Development• In 1943/4, M-73 (modified M-72) with Engageable Sidecar Drive and Sidecar Brake

Developed–Never Put into Mass Production Due to Ready Availability of Jeeps

• In 1958/9, Swing-Arm Frame Introduced into Next-Generation K-750–K-750 Essentially Same Bike as M-72 with a Swing-Arm Frame Replacing Plunger Frame,

to Cope with Rugged Russian Terrain• In 1964, MB-750 (Military Version of K-750) Introduced with Differential Drive to Sidecar

Wheel–Two-Wheel Drive (2WD) Brother of K-750–KMZ’s First Production 2WD–MB-750 (MW-750) (1964-1973) Had Full-Time 2WD with Planetary Differential–Swing-Arm Framed, Sidevalve (SV) 750 cc Engine–Differential Drive Modeled on the WW-II Zundapp System–Lockable Differential Seems to Have Only Been Used for a Few Years, Then Dropped–Rear Drive Castings Remained the Same, Allowing for Retro-Fit

• In 1995, First Production Ural 2WD, Post-War Bike Was the Sportsman (1995-1998)–Full-Time 2WD with Planetary Differential–Replaced by the Patrol with Engageable 2WD (non-differential) Drive

Just as the one-wheel drive (1WD) sidecar can be traced back to the German R71, the split torque two-wheel drive (2WD) differential

can be traced back to the BMW R75.

Changes in Final Drive ChainChanges in Final Drive Chain• Introduction of “Mother” of Russian Heavy Sidecar Motorcycles: M-72–Born 1941–Exact Copy of the 1938 BMW R-71 (except for larger gas tank and weaker metallurgy)–One-Wheel Drive (1WD) Standard

•Dnepr Differential Drive Sidecars: –MB-750 (1964-1973) / MB-750M (1973-1977): 2WD Brother of K-750•MB-750 / MB-750M: Military Version of MT-12 with Full-Time 2WD and Engageable

Locking Differential Added• Lockable Differential Seems to Have Only Been Used for a Few Years, Then Dropped

–MB-650 (1968-1984) / MB-650M (1985-1991): Full-Time 2WD with 650cc Engine–MB-650-M1 (1985-2007): Military Version of MT-16–MT-12 and MT-16 Full-Time 2WD, Supplying Power to Pusher (73%) and Sidecar (37%)• Differential Lock Not Present (No Locking Lever)•MT-12 (1974-1982): Civilian Model with Full-Time 2WD and No Locking Differential•MT-16 (1985-2005): MT-11 with Full-Time 2WD and No Locking Differential

•Ural Differential Drive: “Sportsman”–First Production Ural with 2WD (1995-1998)–True Differential–Pre-Patrol Model

•Ural Changed to Engageable Two-Wheel, Non-Differential Drive (2WD) Sidecars:–Engage Sidecar Drive Shaft Using Lever Near Rear Drive–Available in Various Models:• Production: Patrol (1998-Current), Retro, Gear-Up (2001-Current),

Patrol-T (2009-Current)• Limited Editions with Engageable Sidecar Drive Shaft: Basic (2005), Raven (2006),

Pustinja (2007), Wjuga (2008), Sahara (2009) and Taiga (2010)

We have seen One-Wheel Drive (1WD), full-time Two-Wheel Drive (2WD), 2WD with locking differential and finally engageable 2WD, where the driver could manually put the sidecar wheel into place when the going got nasty.

Ural OneUral One--Wheel Drive (1WD): Wheel Drive (1WD): Lacking Any Sidecar (Transverse) Propeller ShaftLacking Any Sidecar (Transverse) Propeller Shaft

One quickly notices that the 1WD rear drive does not have a transverse drive shaft to power the sidecar wheel.

Final Drive: Propeller Shaft and Rear Drive

Propeller Shaft

Propeller Shaft

Rear DriveRear DriveUniversal JointUniversal Joint

Flexible JointFlexible Joint

Power from GearboxPower from Gearbox

Rear Wheel AxleRear Wheel Axle

1 1 -- Driven Gear Fastening Bolt Driven Gear Fastening Bolt 13 13 -- Oil Drain Duct Oil Drain Duct 25 25 -- Flexible Disk Band Flexible Disk Band 2 2 -- Driven Gear Rim Driven Gear Rim 14 14 -- Needle Bearing Needle Bearing 26 26 -- Flexible Disk (Doughnut)Flexible Disk (Doughnut)3 3 -- Gasket Gasket 15 15 -- DoubleDouble--Row Ball Bearing Row Ball Bearing 27 27 -- Flexible Joint Driven Disk (Flange)Flexible Joint Driven Disk (Flange)4 4 -- Crankcase Bushing Crankcase Bushing 16 16 -- Adjusting Washer (Shim) Adjusting Washer (Shim) 28 28 -- Packing RingPacking Ring5 5 -- Needle Bearing Roller Needle Bearing Roller 17 17 -- Universal Joint Fork Seal Universal Joint Fork Seal 29 29 -- Needle BearingNeedle Bearing6 6 -- Casing Seal Casing Seal 18 18 -- Protective Washer Protective Washer 30 30 -- Wedge BoltWedge Bolt7 7 -- Seal Cover Seal Cover 19 19 -- Universal Joint Universal Joint SplinedSplined Fork Fork 31 31 -- Bearing NutBearing Nut8 8 -- Rear Wheel Axle Rear Wheel Axle 20 20 -- Lock Ring (Lock Ring (CirclipCirclip) ) 32 32 -- GasketGasket9 9 -- Seal Spring Seal Spring 21 21 -- Universal Joint Cross Universal Joint Cross 33 33 -- Driving GearDriving Gear10 10 -- Distance Bushing Distance Bushing 22 22 -- Grease Cup Grease Cup 34 34 -- Casing CoverCasing Cover11 11 -- Casing Casing 23 23 -- Propeller Shaft Propeller Shaft 35 35 -- Adjusting Washer (Shim)Adjusting Washer (Shim)12 12 -- Driven Gear Hub Driven Gear Hub 24 24 -- Lock RingLock Ring 36 36 -- Ball BearingBall Bearing

Final Drive: Propeller Shaft and Final Drive (cont.)•Power Delivered from Gearbox to Rear Wheel by Drive Shaft (propeller shaft) and Rear Drive with Bevel Gears•Drive shaft Coupled to Gearbox via Flexible Rubber Collar (doughnut) and Universal joint–Flexible Joint (27) Is a Coupling Fitted with Plates and Pins–Splined Propeller Shaft (23) Fits into Coupling Disk (27)–Flexible Disk (26) Transitions to Transmission Gear Box–Flexible Coupling Helps Dampen Torque Impulses–universal joint Allows suspension travel of the rear wheel

•Rear Drive is a Cast housing containing a helical bevel gear set–Bevel Gear Set•Contains Small Pinion Gear (Driver) and Ring Gear (Driven)•Turns the Rear Wheel Axle at a Lower Speed than the Propeller Shaft•Gear Backlash Adjusted via Washers or Shims (16) Installed between Side Portion of Casing Cover and Inner Race of Ball Bearing (15)–0.004 to 0.012” / 0.1 to 0.3 mm Backlash Necessary between Gear Faces

•Rear Casing Serves as Backing Plate for Brake Shoes, Oil Reservoir and Support for Right-Hand End of Rear Wheel Axle–Oil Fill Hole Provided in Cover (34)–Casing (11) Has Oil Drain Hole at Bottom with a Plug–Cover (34) Attached to Casing Has a Slot and Two Studs Used to Fasten the Whole Drive to the Swinging Fork Arm of the Rear Suspension

The final drive transfers power from the transmission output, via flexible coupling, propeller shaft and flexible coupling, to the rear drive, where it is

transferred to the rear wheel (pusher) and for 2WD, the sidecar wheel.

Recent Quality Improvements in Ural Final Drive ChainRecent Quality Improvements in Ural Final Drive Chain• 2003: New 750cc Ural Engine Replaced the 650 cc Engine–Higher Output Ratio Gearing on 3rd & 4th Gears Allowing a Higher Cruising Speed of 65

mph for Standard 4.62 Final Drive (FD) Ratio–New Drive Shaft with Course Splines to Reduce Chance of Stripping Out Drive Coupling

• 2006 Improvements–Knob Style Dipstick Removable by Hand–Nylock Nuts Used to Secure Final Drive to Swing Arm–Engaged Austrian Design Office HC Concepts to Improve Ural Power Train•Redesigned Many Internal Gears, Bearings and Seals in Final Drive•Results Seen in the 2007 Ural

–Use of final drive lock nuts–Labeled final drive engagement lever

• 2007 Improvements–Redesigned Drive Shaft with Longer and Stronger Splines–Improved 2WD Engagement Rod with Uni-Balls

• 2008 Improvements–Herzog Drive Bevel Gears Stronger and Heat-Treated for Prolonged Life, Tighter

Tolerances, and Cooler Running Temperatures (earliest availability summer 2008)• 2009 Improvements–Standard Greaseable U-Joints for 2WD Shaft

• 2010 Improvements–New U-Joint Polymers 40% Stronger

• 2011 Improvements–Improved High-Strength Final Drive Ring Gear Bolts

• 2012 Improvements–Castle Nut Replaced with Standard Self-Locking Nut on Flex Coupler–New Polymer Material Replaced Rubber for Flexible U-joint, 40% Stronger –Tourist, Patrol, Gear-Up, Patrol T: Sidecar Drive Shafts Powder-Coated on 2WD Models–Gear-Up: Sidecar Drive Distance Bushing Changed to Reduce Drive Bearing Failures

1968 Dnepr MB1968 Dnepr MB--750 with Manual Locking Differential (2WD) 750 with Manual Locking Differential (2WD) ((databikesdatabikes.com).com)

DneprDnepr’’s MBs MB--750 has a true differential 2WD, with a manual activation lever.750 has a true differential 2WD, with a manual activation lever. A shift linkage on the final drive hub indicates that it is a selectable locking differential.

Manual Locking Manual Locking Activation LeverActivation Lever

Control RodControl Rod

Transverse Shaft to Transverse Shaft to Sidecar Wheel Gear ReducerSidecar Wheel Gear Reducer

Handling Differences between the Ural SingleHandling Differences between the Ural Single--Wheel or OneWheel or One--Wheel Drive (1WD) and the TwoWheel Drive (1WD) and the Two--Wheel Drive (2WD) Wheel Drive (2WD) ((myuralmyural.com).com)Note: This does not include characteristics for the 1995-1998 Ural “Sportsman” model, or Dnepr’s MT-12, MT-16, MB-750,

MB-750M, MB-650, MB-650M, all of which have a full-time differential drive.

• Use of Ural 2WD (non-Differential) Is Strictly for Off-Road, Gravel, Snow, Ice or Wet Slippery Surfaces–When 2WD Engaged, both Rear and Sidecar Wheel Locked Together and Turn at the Same Rate• No Differential

–Left Turns Are Easier than Right Turns, as It Is Easier for the Sidecar to Turn Around the Motorcycle than Other Way Around–Using Power, the Motorcycle Can Be Slid Rapidly in a Left 180° Turn on Loose/Soft Ground–Right Turns Require a 10 ft to 15 ft Turning Radius, Depending on Surface Type–2WD Meant for Extricating or Negotiating Through or Out of Low-Traction Environments

• Avoid “Flying the Chair" While in 2WD–Sidecar Wheel Contacting the Ground While Engaged in 2WD Can Damage the Axle Splines or Final

Drive Engagement Gears–Pulling in the Clutch Disengages Power to the Drive Train, Which Will Lessen Any Chance of Damage

When the Wheel Again Makes Contact with the Ground• Normal “Pulling" and “Drifting" Tendencies Are Reversed While in 2WD–Normally in 1WD, Application of Throttle Causes Rig to “Pull" to Right Due to Drag of Sidecar Wheel–Letting Off Throttle Causes the Rig to “Drift" to the Left Due to Free-Wheeling of Sidecar Wheel–When 2WD Engaged, Power Is Split between Rear and Sidecar Wheels; Approximately 63% of Power

Goes to Rear Wheel and 37% to Sidecar Wheel–Apply Throttle When There Is No Longer Drag, but Acceleration from the Sidecar Wheel Which Will

"pull" (push) You to the Left–When You Let Off the Throttle, You Now Have More Drag Since the Sidecar Wheel Is Tied to the

Transmission/Engine; and You Will "drift" to the Right–Just As You Can Use the Normal "pulling" and "drifting" Tendencies to Assist You thru Normal 1WD

Turns, the Same Can Be Done While in 2WD–Remember the Tendencies Are Reversed and Somewhat Amplified While in 2WD

The dream sidecar is a bike with 2WD with a differential like the MT-16, but with the ability to lock-in straight drive for off-road situations.

Dnepr 2WD Sidecar Transverse Drive ShaftDnepr 2WD Sidecar Transverse Drive Shaft

Sidecar Sidecar Gear ReducerGear Reducer

Transverse Transverse PropshaftPropshaft

Transverse Transverse PropshaftPropshaft

With the tub removed, the sidecar drive shaft and gear reducer is clearly seen.

Rear Suspension on MRear Suspension on M--72, M72, M--61 and M61 and M--62 (1WD)62 (1WD)•Plunger Rear Suspension Was the Original Rear Suspension Design: M-72–Plunger Was Used on M-72, Ural M-61 and M-62 –M-61 and M-62 Plunger Frames Different from the M-72 Frames–Rear Suspension Connected to Rear Drive

•Next Generation Was the K-750–In 1958 Kiev Motorcycle Plant (KMZ) Replaced Plunger Framed M72-N with the Swingarm-Framed K-750–Essentially the Same Bike with a Swing-Arm Frame Instead of Plunger Frame–Swing-Arm Is an Improvement in Rear Suspension with Shocks–The K-750 was a Soviet improvement on plunger framed R-71/M-72 Design to Better Cope with Roads and Terrain Found throughout the USSR–Rear Swing-Arm on Inside of Frame unlike Later Ural Swing-Arm Located on the Outside of Frame

MM--72 Plunger Suspension as 72 Plunger Suspension as Part of Rear Drive CoverPart of Rear Drive Cover

Final Drive with Oil Filler in the Cover Final Drive with Oil Filler in the Cover Was Introduced Along with the Was Introduced Along with the Splined Splined DriveDrive--Shaft on the MShaft on the M--6161

Early MEarly M--72 Plunger Rear Suspension System72 Plunger Rear Suspension System

1954-1960PlungerM-72K (IMZ)1956-1960PlungerM-72M (IMZ)1956-1959PlungerM-72H (KMZ)1959-1963Swing ArmK-750 (KMZ)

1941-1956PlungerM-72 (IMZ, KMZ)

1963-1977Swing ArmK-750M (KMZ)

1965-1968Swing ArmUral M-63 (IMZ)1961-1964PlungerUral M-62 (IMZ)1960-1961PlungerUral M-61 (IMZ)

ProductionSuspension TypeMotorcycle (Factory)

MM--72 Rear Suspension72 Rear Suspension

M-72 pioneered the plunger (coiled spring) suspension, which was replaced in the K-750. Ural’s M-61 and M-62 also used the plunger suspension system.

MM--72 Plunger Rear Suspension 72 Plunger Rear Suspension ((bcozzbcozz.multiply.com).multiply.com)

MM--62 Final Drive and Rear Plunger Suspension 62 Final Drive and Rear Plunger Suspension (www.(www.uralural--m62.com)m62.com)

MM--62 62 (1WD)(1WD)

M-72 pioneered the plunger suspension system, but was replaced in the K-750. Ural’s M-61 and M-62 also used the plunger suspension system.

1WD versus 2WD Suspension of Rear Drive1WD versus 2WD Suspension of Rear Drive

2WD: C2WD: C--Shaped Fork Shaped Fork of Rear Drive Swingof Rear Drive Swing--ArmArm

•Swing-Arms Differ on the Drive Side–1WD Swing-Arm Has a Simple Plate Which Bolts to Four Studs around the AxleHole of the Rear Drive Casing–2WD Swing-Arm Has a C-Shaped Fork Which Attaches to the Circumference Bolts on the Rear Drive Casing

Gearboxes are also distinguished by the appearance and method of fastening to an arm rear suspension.

Ural MUral M--62, M62, M--63, M63, M--66, M66, M--67 Swing67 Swing--Arm FrameArm Frame

1.Silent Block Pendulum Fork2.Spacer3.Plug4.Bolt lower tip5.Swingarm Rear Suspension Fork6, 7. Threaded Bushing Assembly8. Pendulum Fork Bolt9. Washer10, 11, 12, 13. Reinforcing Plate14. Rubber Bushing15. Frame16. Spring Shock Absorber

4 Holes for Mounting Swing-Arm Directly to

1WD Rear Drive Casing

Because Ural’s M-62 / M-63 / M-66 / M-67 do not offer 2WD, the swing-arm is not C-shaped on the open end.

Ural MUral M--66 (1WD) Rear and Sidecar Wheel Suspension66 (1WD) Rear and Sidecar Wheel Suspension1. Sidecar Wheel Axle2. Guard Plate3. Pendulum Wheel Axle Lever4. Sidecar Wheel Shock Absorber13. Motorcycle Frame21. Rear Suspension Swing-Arm Fork24. Sidecar Frame25. Clamping Holder (cross-section)26. Silent Block27. Pin

Sidecar Wheel SwingSidecar Wheel Swing--ArmArm

Rear Drive SwingRear Drive Swing--ArmArm

Ural MUral M--63 (1WD) Rear Swing63 (1WD) Rear Swing--Arm SuspensionArm Suspension

Rear SwingRear Swing--Arm Arm SuspensionSuspension

The M-63 was the first Ural to use a rear swing-arm suspension. Notice that unlike the KMZ/Dnepr bikes, the swing-arm is on the outside of the frame.

Modern Ural 1WD versus 2WD SuspensionModern Ural 1WD versus 2WD Suspension8. IMZ8. IMZ--8.1078.107--09081 Rear Suspension Swing09081 Rear Suspension Swing--Arm for 2WDArm for 2WD

(IMZ(IMZ--8.107 is Ural Sportsman (19958.107 is Ural Sportsman (1995--1998) or 650cc Patrol (19991998) or 650cc Patrol (1999--2002)2002)

9. IMZ9. IMZ--8.1038.103--09081 Rear Suspension Swing09081 Rear Suspension Swing--Arm 1WDArm 1WD(IMZ(IMZ--8.103 is a 650cc Ural)8.103 is a 650cc Ural)

33. 33. ““Silent BlockSilent Block”” BushingBushing

The swing-arm is different between the 1WD and 2WD modern Urals. The 2WD version uses a C-shaped support which allows

the transverse shaft to drive the sidecar wheel.

The Differential (Standard vs. Locked)The Differential (Standard vs. Locked)• Sometimes Called the “Pumpkin", Where the Rear Axle Intersects with Drive Shaft•Consists of a Set of Gears that Convert Rotating Motion of Driveshaft for 1WD, and Split

Power to each of the Driving Axle Shafts (Pusher and Sidecar Wheels) for 2WD•A True Differential Transmits Power to the Wheels, While Allowing Them to Rotate at

Different Speeds, Thus the Term "differential"–Need for Wheels to Rotate at Different Speeds When Turning Corners• Inner Wheel Travels a Shorter Distance than the Outer Wheel in the Turn

–If One Wheel Slips (for Instance One Wheel Comes into Contact with Mud, Snow, or Ice, or If the Wheel Is Somehow Removed from Contact with the Road after Encountering an Obstacle or Area of Soft Ground) More Torque Is Sent to the Wheel That Slips• If That Slipping Wheel Completely Looses Traction, All Power Will Be Sent to That

Slipping Wheel and You Have No Forward Momentum, at Which Point It Will Be Stuck–When Off-Road, This Is Where the 2WD Differential Fails to Remain Effective•When Off-Road There Are Many Situations Where a Wheel Will Spin Free

•A Locking Differential Solves This Problem by Delivering 100% of Available Torque to the Wheel with the Most Traction–Locking Differential or Locker Provides Increased Traction Compared to a Standard or

"open" Differential by Disallowing Wheel Speed Differentiation between the Two Wheels–Locking Differential Essentially "locks" Both Wheels Together–Thus Difficult to Negotiate a Turn On-Road–Forces Both Wheels to Turn in Unison, Regardless of the Traction (or lack thereof)

Available to Either Wheel Individually

Dnepr 1WD / 2WD Rear Drives and Sidecar Gear ReducerDnepr 1WD / 2WD Rear Drives and Sidecar Gear Reducer ((oppozitoppozit..ruru))

Rear Drive (1WD)Rear Drive (1WD)Rear Drive Mounting (2WD)Rear Drive Mounting (2WD)

RearDriveRearDrive (1WD)(1WD)

2WD 2WD Dneprs Dneprs use a gear reduction box to match the transverse rotation speed use a gear reduction box to match the transverse rotation speed to that of the sidecar wheel.to that of the sidecar wheel.

Rear Drive (2WD)Rear Drive (2WD)Sidecar Gear Reducer (2WD)Sidecar Gear Reducer (2WD)

MM--73: Prototype to M73: Prototype to M--72 72 ((bcozzbcozz.multiply.com).multiply.com)

• First Soviet 2WD Was the IZH-1 (1929), but Never Achieved Large Production•M-73 (1950s) was Prototype of M-72 incorporating Sidecar Wheel Drive–First production 2WD was Either the M-73 or TMZ-53 of 1942-43 Time frame•M-73 Featured Improved Off-Road Performance with Sidecar Wheel Drive–The M-73 was built from late 1942 to 1944 in Small Numbers–Had a Dog Clutch to Sidecar Drive, Otherwise a Normal M-72

• TMZ Was a 1000 cc Sidevalve, Modeled on the BMW R75–Rigid rear and lockable differential drive with reverse.

•Both KMZ and IMZ built prototype 2WD plunger frame bikes in the 1950's–KMZ’s (Dnepr’s) First Production 2WD was the MB-750 (1963)• Swingarm-Framed Sidevalve•Differential Drive Loosely Patterned on the WW-II Zundapp System• Locking Differential Added on the MB-750M (1973-77)

–Production IMZ (Ural) 2WD Was the Sportsman in the late 1990's• Full-Time Differential Drive•Replaced by Patrol with an Engagable, non-Differential Drive for Off-Road

CloseClose--Up of the Three Gear Levers; Up of the Three Gear Levers; Neutral Finder/GearNeutral Finder/Gear--Change Lever, Change Lever,

Hi/Lo Ratio Lever and Sidecar Drive Lock LeverHi/Lo Ratio Lever and Sidecar Drive Lock Lever

ural (Урал) - dnepr (Днепр russian motorcycle part 1

Documents