Russian Motorcycle (Ural) Part XXXI-5: Full-Time 1WD with Engageable 2WD (non-diff)
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1 Russian Motorcycle (Ural) Part XXXI-5: Full-Time 1WD with Engageable 2WD (non-diff) (Also See Part XXXI: Drive Chain Evolution, Part XXXI-1: One-Wheel Drive (1WD), Part XXXI-2: Two-Wheel Drive (2WD), Part XXXI-3: Full-Time 2WD with non-locking Diff Part XXXI-4: Full-time 2WD with Locking Diff, Part XXXI-6: Gears and Gear Ratios, Part XXXI-7: Drive Train Components, and Part XXXI-8: Disassembly of Drive Chain) Ernie Franke 10 / 2018
2 Four Types of Final Drives in Russian Sidecars 1. 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 ( ) Dnepr MT-12 ( ) Dnepr MT-16 ( ) Dnepr Rear Drive Casings Allow for Adding Locking Differential First Available in Ural: Sportsman IMZ ( ) Only True Differential for Ural Pre- Patrol Model 3. Full-Time, Two-Wheel Drive (2WD) with Locking (Engageable) Differential Dnepr MB-750 ( ) Dnepr MB-650 ( ) Dnepr MB-750M ( Locking feature deleted after two years) 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) 2
3 Ural (Урал) / Dnepr (Днепр) 1WD with Engageable Non-Diff 2WD Ural (Урал) Model Production Engine Voltage Drive Train Rear Suspension M cc SV 6-Volt Full-Time, Straight Final Drive (1WD) Plunger M-72K cc SV 6-Volt Full-Time, Straight Final Drive (1WD) Plunger M-72M cc SV 6-Volt Full-Time, Straight Final Drive (1WD) Plunger M cc OHV 6-Volt Full-Time, Straight Final Drive (1WD) Plunger M-62 (Ural-1) cc OHV 6-Volt Full-Time, Straight Final Drive (1WD) Plunger M-63 (Ural-2) cc OHV 6-Volt Full-Time, Straight Final Drive (1WD) Swing Arm M-66 (Ural-3) cc OHV 6-Volt Full-Time, Straight Final Drive (1WD) Swing Arm M-67 (IMZ-8.101) cc OHV 12-Volt Full-Time, Straight Final Drive (1WD) Swing Arm M cc OHV 12-Volt Full-Time, Straight Final Drive (1WD) Swing Arm Sportsman IMZ cc OHV 12-Volt Full-Time 2WD with non-locking Differential Swing Arm Series cc OHV 12-Volt Full-Time 1WD with Engageable 2WD (No Diff) Swing Arm 750 Series 2003-Present 750cc OHV 12-Volt Full-Time 1WD with Engageable 2WD (No Diff) Swing Arm Dnepr (Днепр) Model Production Engine Voltage Drive Chain Rear Suspension M cc SV 6-Volt Full-Time, Straight Final Drive (1WD) Plunger M-72N (H) cc SV 6-Volt Full-Time, Straight Final Drive (1WD) Plunger K cc SV 6-Volt Full-Time, Straight Final Drive (1WD) Swing Arm K-750M cc SV 6-Volt Full-Time, Straight Final Drive (1WD) Swing Arm MT-12 (Dnepr-12) cc SV 6-Volt Full-Time 2WD with Non-Locking Differential * * Swing Arm MB cc SV 6-Volt Full-Time 2WD with Locking (Engageable) Diff * Swing Arm MB-750M cc SV 6-Volt Full-Time 2WD with Locking (Engageable) Diff * Swing Arm K-650/MT cc OHV 6-Volt Full-Time, Straight Final Drive (1WD) Swing Arm K-650/MT cc OHV 6-Volt Full-Time, Straight Final Drive (1WD) Swing Arm MB cc OHV 12-Volt Full-Time 2WD with Locking Differential * Swing Arm MB-650M cc OHV 12-Volt Full-Time 2WD with Non-Locking Differential * * Swing Arm MT cc OHV 12-Volt Full-Time, Straight Final Drive (1WD) Swing Arm MT cc OHV 12-Volt Full-Time, Straight Final Drive (1WD) Swing Arm MT-11 (Dnepr-11) cc OHV 12-Volt Full-Time, Straight Final Drive (1WD) Swing Arm MT-16 (Dnepr-16) cc OHV 12-Volt Full-Time 2WD with Non-Locking Differential * * Swing Arm * Locking Feature Deleted after Two Years of Production, * * Optional Kit Available to Add Locking Differential 3
4 Ural Two-Wheel Drive (2WD) Non-Diff Time-Line Wjuga Taiga Sahara Ural Patrol (non-diff 2WD) Basic Raven Pustinja Ural Patrol-T (non-diff 2WD) Ural Sportsman (True Differential) Ural Gear-Up (non-diff 2WD) cc Engine 750cc Engine The first production Ural 2WD was the short-lived Sportsman in the mid-1990's, followed by the non-diff Patrol and Gear-Up available today. 4
5 Ural Patrol, Engageable, Non-Diff 2WD (1998-to-Current Production) Non-Diff 2WD Activation Lever Transverse Sidecar Drive Shaft Later Model of Tie Rod-to-Lever Joint (Heim Joint) Brake Activation Lever Engageable 2-Wheel Drive (2WD) The Patrol pioneered Ural s entry into engageable two-wheel drive (2WD, non-diff) in 1998 for off-road performance. 5
6 Ural Gear-Up, Engageable, Non-Diff 2WD (2001-to-Current Production) Engageable 2-Wheel Drive (2WD) Ural s Gear-Up followed in 2001, as a rugged, macho Patrol. 6
7 Modern Urals with One-Wheel Drive (1WD) and Engageable Two-Wheel Drive (2WD, non-diff) Patrol 2WD Engageable Lever Gear-Up Taiga Limited Edition Patrol-T Modern Urals employ one-wheel drive (1WD) for on-road driving. 7
8 Ural Limited Edition Sidecars with Full-Time 1WD and Engageable 2WD Basic (2005) Vorona Raven (2006) Pustinja (2007) Wjuga (2008) Sahara (2009) Taiga (2010) Modern Urals employ an engageable, non-differential, only for off-road driving. 8
9 Ural Engageable, Non-Diff, Two-Wheel Drive (2WD) Lever for Engageable, Non-Diff 2WD 2WD Engaged 2005 Ural Gear-Up 1WD Latest Model of Tie Rod-to-Lever Joint (Heim Joint) Transverse Drive to Sidecar Wheel 2012 Ural Patrol 9
10 2010 Ural Patrol-T C-Shaped Swing-Arm Attachment to Rear Drive Casing 2WD Rear Drive Casing Latest Model of Tie Rod-to-Lever Joint (Heim Joint) Patrol-T's drive shaft, seen above, is engaged by sliding a lever. 10
11 Patrol / Gear-Up with Engageable, Non-Diff Sidecar Drive Notice: Lever Arm Is Located AboveAxis. Patrol Reverse Gear Lever 2WD Control Tie-Rod 2WD (non-diff) Engagement Control Gear-Up 2WD Engaged Reverse Gear Lever 1WD Sidecar Drive Disengaged Sidecar Drive Engaged Notice: Lever Arm Is Located Below Axis. When engaged by the operator for off-road use, the sidecar wheel is driven by a transverse drive shaft connected with the rear drive via a universal joint. 11
12 Ural Gear-Up Final Drive for Engageable 2WD (Non-Diff) Rear Drive Oil Fill (80/90) Older Type of Tie Rod-to-Lever Joint (Rod-and-Cotter Pin) Universal Joint 2WD Engaged Manually-Engageable Lever for 2WD 1WD to Sidecar Wheel Drive Shaft Fork Transverse Drive Shaft Ural Patrol and Ural Gear-Up have two driving modes; 1WD for normal on-road driving and 2WD (non-differential) for off-road over short impassable sections, where the sidecar wheel is directly geared with the main (pusher) wheel. 12
13 Final Drive Assembly for All Engageable 2WD Urals (Ural of New England) Rear Brake Activation Lever Oil Drain Hole Universal Joint from Gear Box Rear Brake 2WD Activation Lever Output to Sidecar Wheel Rear Brake Activation Lever Universal Joint from Gear Box Oil Drain Hole Rear Brake Activation Lever Rear Brake The Ural rear drive has an engageable (non-differential) direct drive to power the sidecar wheel (2WD). 13
14 5. U-Joint Assembly Final Drive Assembly, Engageable 2WD 64. Drive Shaft Cross 30. Drive Shaft Assembly 27. Flexible Coupling (Doughnut or Biscuit) 52. Shims 23. Pinion Drive Gear 25. Bearing Nut 26. Seal assembly 3. Bearing Nut Assembly 63. Limiter 62. Spring 61. Sidecar 2WD Shift Lever 2. Engageable Drive 33. Dipstick 8. Driven Gear (Crown Gear) 7. Final Drive Gear Case 9. Driven Gear Hub 57. Tie Rod (Newer Linkage with Heim Joints Shown) 35. Oil Drain Plug 39. Shims 40. Roller Bearing (45 each) 18. Shift Sleeve 2WD Engageable Drive (non-diff) 42. 2WD Activation Lever 43. 2WD Control Shaft 17. Final Drive Cover Assembly 16. Driveshaft Fork 69. Bevel Gear Set 10. 2WD (non-diff) Fork 13. Splined Hub 14. Double-Row Bearing 1. Final Drive Assembly 14
15 Ural Engageable 2WD (cont.) # Part # Description Notes Qty 1 IMZ Rear Drive Assy. Installed before July IMZ Rear Drive Assy. Installed since July 05. Up-Graded final drive (Rubena seals, longer splines on drive shaft) 1 2 IMZ Engageable 2WD 1 3 IMZ Bearing Nut Assy. Installed since July IMZ Bearing Nut Assy. Installed before July 05. Different seal diameter of bore 1 4 IMZ Driveshaft Assy. Does not include flex coupling #27 - must order separately 1 4 IMZ Driveshaft Assy. Installed since July Does not include flex coupling # IMZ Driveshaft Assy. Installed from Does not include flex coupling # ИМЗ U-Joint Assy. 1 6 IMZ Dipstick and Breather 1 7 IMZ Rear Drive Gear Case Installed before July 05. Different outer diameter of seal 1 7 IMZ Rear Drive Gear Case Installed since July Crown Driven Gear See #69. Recommend & ordered in a set, factory-bedded for noiseless operation 1 9 IMZ Driven Gear Hub Installed before July 05. Different outer diameter of seal 1 9 IMZ Driven Gear Hub Installed since July IMZ Fork Bearing GOST May use new bearing below 1 11 SKF 16011/c3 Bearing New bearing is allowed 1 12 IMZ Seal Russian - May use new seal below 1 12 NAK TF Seal New seal from Direct replacement 1 13 IMZ Splined Hub Installed before July 05. Different outer diameter 1 13 IMZ Splined Hub Installed since July Double-Row Ball Bearing May use new bearing below 1 14 SKF 3204 A-2rs1/c3 Double-Row Ball Bearing New bearing is allowed Rubber Seal Assy. Installed before July 05. Different outer diameter of seal 1 15 IMZ Rubber Seal Assy. Installed since July NAK TC Rubber Seal Assy. New seal from Replace for all from July IMZ Driveshaft Fork Assy. Installed before July 05. Different outer diameter of seal 1 16 IMZ Driveshaft Fork Assy. Installed since July IMZ Rear Drive Cover Assy IMZ Shift Sleeve Rubber Seal Assy. Installed before July 05. Different outer diameter of seal 1 19 IMZ Rubber Seal Assy. Installed since July NAK TC Rubber Seal Assy. New seal from Replace for all from July Bearing GOST Bearing 1 15
16 Ural Engageable 2WD (cont.) # Part # Description Notes Qty Double-Row Ball Bearing Rear Drive, Driving Gear See #69. It is recommended & ordered in a set, factory-bedded for noiseless operation 1 24 SKF 3304A/s3 Double-Row Ball Bearing 1 25 IMZ Bearing Nut Installed before July 05. Different thread dimension for seal 1 25 IMZ Bearing Nut Installed since July IMZ Seal Assy Installed before July 05. Different outer & inner diameters 1 26 IMZ Seal Assy Installed since July NAK TC Seal Assy New seal use from July of Flexible U-Joint Coupling 1 28 IMZ Flexible U-Joint Plate Installed before July 05. Different length of splines 1 28 IMZ Flexible U-Joint Plate Installed since July IMZ Drive Shaft Fork Assy Installed before July 05. Different diameter for seal 1 29 IMZ Drive Shaft Fork Assy Installed since July IMZ Drive Shaft Installed before July 05. Different length of splines 1 30 IMZ Drive Shaft Assembly 31 IMZ Gear Case Seal Before July of NAK TC NBR Gear Case Seal New seal use from July of IMZ Breather Plug 1 33 IMZ Dipstick Assy IMZ Ring Special Washer IMZ Drain Plug P27 Stud М10х1-6gх IMZ Gear Case Cover Gasket 1 39 IMZ Shim 1.1mm 1 39 IMZ Shim 0.95 mm 1 39 IMZ Shim 0.95 mm 1 39 IMZ Shim 0.8 mm 1 39 IMZ Shim 0.65 mm x15.8A5 Roller 3х15.8А Lock Ring 1 42 IMZ Lever 1 43 IMZ Shaft 1 44 IMZ RH cover seal Russian - May use new below 1 44 NAK TC RH cover seal New seal from Direct replacement 1 16
17 Ural Engageable 2WD (cont.) # Part # Description Notes Qty P2 Cotter Pin 3.2х IMZ Key 2 47 IMZ Ring А IMZ Distance Bushing 1 49 IMZ Distance Bushing 1 50 IMZ O-Ring O-Ring Shim mm Adjusting Washer. Used for final drive assembling subject to clearance Shim mm Adjusting Washer Stopper P27 Stud М10х1-6gх IMZ Gear Case Bushing 1 56 IMZ Distance Bushing 1 57 IMZ Tie Rod P27C Washer P2 Washer 8L P27C Blind Nut М8, Zn 1 61 IMZ Sidecar Drive Shift {ever Quadrant Shaft Spring 1 63 IMZ Shaft Aasy with Limiter 1 64 IMZ Driveshaft Cross See #5. Only Sold in Assy Driveshaft Sealing Ring See #5. Only Sold in Assy U-joint Sealing Ring Band See #5. Only Sold in Assy Needle Bearing See #5. Only Sold in Assy U-Joint Lock Ring B IMZ Bevel Gear Set 1 70 IMZ Protective Cover P Bolt M8X
18 Ural 2WD Sidecar Drive Assembly (750/650cc) # Part # Description 1 IMZ Rear Drive, Engageable 2WD 2 IMZ Sidecar Drive, Swing-Arm 3 IMZ Cardan Shaft, Drive Shaft 4 IMZ Shaft with Drive Shaft Fork Assembly Sidecar Shaft Assembly, 2WD Vendor ID: SKU: PT060 List Price: $ ( The Ural sidecar drive assembly does not have a speed reducer, whereas 2WD Dneprs do. 18
19 Final and Sidecar Drive Assemblies, Engageable 2WD 3. Shaft with Drive Shaft Fork 1. Shaft with Joint Assembly 2. Shaft with Drive Shaft Fork Assembly Flexible Flange (Mates with Elastic Coupler) 10. & 12. Ball Bearings 7. Sidecar Drive Shaft Assembly 8. Sidecar Shaft 11. Bushing 14. Hub 4. U-Joint Assembly 5. Protective Cover 9. Protective Washer # Part # Description Notes Qty 1 IMZ Shaft with Joint Assy. 1 2 IMZ Shaft with Driveshaft Fork Assy. 1 3 IMZ Shaft with Driveshaft Fork Not sold separately - See Item #1 sold only as assy. 2 4 IMZ Universal Joint Assy. 2 5 IMZ Protective Cover Clamp 2 7 IMZ Sidecar Driveshaft Assy. Not sold separately - See Item #1 sold only as assy. 1 8 IMZ Sidecar Shaft Not sold separately - See Item #1 sold only as assy. 1 9 IMZ Protective Washer Ball Bearing May use new bearing below 1 10 SKF rs1/c3 Ball Bearing New bearing from IMZ Bushing Ball Bearing Russian - May use new bearing below 1 12 SKF rs1/c3 Ball Bearing New bearing from IMZ Distance Ring 1 14 IMZ Hub 1 15 IMZ Brake Drum Cover 1 16 IMZ Driveshaft Cross Not sold separately See Item # IMZ Sealing Ring Not sold separately See Item # IMZ Sealing Ring Band Not sold separately See Item # IMZ Needle Bearing Not sold separately See Item # Lock Ring Drive Shaft Cross (Universal Joint (Cross-Piece) 15. Sidecar Brake Drum Cover 19
20 Ural 650 cc (IMZ /37) Rear and Sidecar Drive Assemblies # Engine Part # Decription 1 750/650 cc IMZ Engageable Rear Drive 2 750/650 cc IMZ Sidecar Drive, Swing-Arm Part 3 750/650 cc IMZ Cardan Shaft, Driveshaft Part 4 750/650 cc IMZ Shaft with Driveshaft Fork Assembly IMZ Rear Drive Assembly IMZ Sidecar Drive Assembly 20
21 Rear Drive Cardan - Ural 650 Part # Description Wedge Bolt Anti shock disk, high quality b Rubber for shock absorb disc, high quality b Rings for antishock disc Fork Cardan cross + clips Conical bolt + nut Fork b Elastic Disc b Rings for Elastic Disc Drive Shaft Cross (Universal Joint (Cross-Piece) 21
22 Ural 650 cc (IMZ /37) Transverse Drive Shaft Universal Joint (Cross-Piece) Item Part # Description 1 IMZ Seal Holder 2 IMZ Universal Joint Cross Seal 3 IMZ Cross Bearing 4 IMZ Retaining Ring 5 IMZ Sidecar Wheel Shaft 6 IMZ Safety washer Bearing 8 IMZ Wheel Lever 9 IMZ Distance Bushing Bearing 11 IMZ Washer 12 IMZ Bushing 13 IMZ Tie Rod, Sidecar Brake Assy P2 Washer P Bolt M8 16 IMZ Shaft with Universal Joint Fork 18 IMZ Propeller Shaft Assy. 19 IMZ Propeller Shaft Cross 20 IMZ Distance Ring 22
23 Ural 650cc (IMZ , -40, , ) 23
24 Ural 650 cc (IMZ /37) Rear Drive Disengageable 1 IMZ Cover with Bearings Assy. 2 IMZ Bearing Nut Assy. 3 IMZ Casing Seal with Spring Assy Stopper 5 IMZ Bushing 6 IMZ Rear Drive Casing 9 IMZ Drain plug P29 Washer P29 Nut M8x14-6H 12 IMZ Ring 13 IMZ Shim, 1,1 mm thick 14 IMZ Shim, 0,95 mm thick 15 IMZ Shim, 0,8 mm thick 16 IMZ Shim, 0,65 mm thick Needle Bearing 17 IMZ Housing 18 3x15,8А5 Roller 3x15,8A P29 Bolt M8-6 x22 20 IMZ Lever 21 IMZ Fork 22 IMZ Shaft Drive Gear, Pinion Two-Row Ball Bearing 25 IMZ Final Case Bushing Crown Driven Gear 27 IMZ Ring 28 IMZ Driven Gear Hub Bearing 30 IMZ Shift Coupling 31 IMZ Ring A Bearing 33 IMZ Splined Hub 34 IMZ Distance Bushing 35 IMZ Distance Bushing Bearing IMZ Seal Assy Distance Bushing, LH 39 IMZ Housing Cover 40 IMZ Fork Ring 41 IMZ Pin 42 IMZ Driveshaft Fork Assy Rubber Packing Assy Adjusting Shim, 0,08 0,07 mm Adjusting Shim, 0,18 0,16 mm Adjusting Shim, 0,4 0,36 mm 47 IMZ Distance Bushing Bearing Nut Gasket 49 IMZ Bearing Nut 50 IMZ Driveshaft Seal Assy 51 IMZ-8, Sliding Lock 24
25 Rear Drive (1WD) Ural Joint f cover for differential b Gland, rear drive / O-ring, differential Glands 49,3 x 33 x 8, pair b b Crownwheel set. Sidecar ratio Thread M8x1, Hub Shim for crown wheel 46x58x1,3 mm Washer for crown wheel bolts Shim 21x30x0,4 mm Shim 21x30x1,0 mm Shim 21x30x0,55 mm Shim 21x30x0,7 mm Shim 37x46x0,20 mm Shim 37x46x0,27 mm x Shim 37x46x0,5 mm Bushing A / / L Oil drain plug + washer Needle bearing Double row bearing, medium quality, produced in EU 3 x 15,8 Needles set of 45 pcs 207 SKF Ball bearing 72x35x17 C3 western quality SKF, Bigger axial play than ordinary bearing, essential for use in russian engines 207 Ball bearing 72x35x / Stud M8 x 33 for differential Bolt for crown wheel M8x1,25x Bolt for crown wheel M8 x 1,0 x 14 25
26 Ural Engageable 2WD Lever Linkage Tie Rod on Rear Drive 2WD Control Tie Rod 2WD Control Tie Rod 2007 Gear-Up Linkage Held onto Lever by Washer and Cotter Pin 2WD Control Tie Rod Later, Linkage Held onto Lever by Heim Joints 2WD Control Tie Rod 2007 Gear-Up Once the Ural is in 2WD, both wheels are locked together (non-diff). 26
27 Ural 2WD Linkage Rod Bent 2WD Shift Linkage Rod? Wimpy Linkage Bends When Shifting into 2-Wheel Drive (2WD) Solution: Upgrade Shift Rod to New Style Standard in 2006 and Later Models Heavier Rod with Heim Joints on Each Ends Heim Joint (N. America) or Rose Joint (U.K. and elsewhere) Rod-End Bearing: Mechanical Articulating Joint Part Description Part # WD Shift Lever (61) IMZ IMZ IMZ IMZ WD Tie Rod (57) IMZ IMZ IMZ IMZ WD Rear Lever (42) IMZ IMZ IMZ IMZ Old Linkage Lever New (2007) Lever with Heim Joints 27
28 Ural Gear-Up Engageable 2WD Suspension 2WD Engaged Universal Joint Transverse Drive Shaft 1WD Manually-Engageable Lever for 2WD to Sidecar Wheel Drive Shaft Fork Note that the Transverse Shaft Drives the Sidecar Wheel Directly, and Not thru a Gear Reduction which Is Present in Full-Time 2WD Motorcycles, such as the MT-11 and MT-16. Sidecar Wheel Pivot Point The universal joint allows the rear drive to move up-and-down relative to the gear box and the frame. 28
29 Rear Drive Suspension: 1WD versus 2WD 2WD Swing-Arm (3 and 3A) C-shaped Bracket 1WD Swing-Arm (4 and 6) # 1WD Part # Description 3 IMZ WD Swing-Arm 3A IMZ WD Swing-Arm Assembly 4 IMZ or IMZ IMZ or IMZ WD Swing-Arm 1WD Swing-Arm Assembly The 2WD swing-arm connects to the rear drive with a C-shaped bracket. 29
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