Ural (Урал) - Dnepr (Днепр)
Contents
1. Spread the jaws of a vise so the bearings inner race is resting on the jaws use a hammer to tap the pinion gear shaft through the bearing If you plan on reusing the gear make sure you put something under the vise to catch it so it does not hit the floor and get buggered up 1 There is not enough room to use standard jaw type puller so to remove the inner race of the needle bearing bought a cheapo bearing separator kit fom Harbor Freight for 30 Pittsburgh brand 93980 The kit has a 2 and 3 separator and accessories Lifetime guarantee TE inus me Sag utt _ TTT af Painting Ker I niml ia E 17 7j d ume airas i4 j mm f cnm ad ru m erue riot 2c TLEECENTER 00 hr Eee ver vn ali tn lere Megan Via I used the 2 PAra 4 extensions 6 yoke adapter and the lead screw provided in the kit I used a 1 2 ratchet with an 11 16th s socket to turn the lead screw PE ui HIS 7 m nri ra zu e F NS aE EMT DIET Attach the separator so the blades are under the inner race and in the small gap between the pinion gear and bearing race 2 T UTC2. E Er pr 38 wm P Paue HERE rame DB BE eut wceSERERERE noes 285 Here is the new 4204 bearing to the right of me old Russian bearing Always order you bearings sealed if available In some applications one or both seals may be left in place as an additional oil seal The seals are easily removed with a screwdriver or pick Toss the disassembled splined hub back in the parts box 7 6 Driven Gear Disassembl FES Retrieve the driven gear hub for disassembly f Another view of the worn teeth on the hub This causes a bit of slop with the rear wheel hub T C ire 1 i HN eo A NO aung panain wo ch zr E LL j Front view of the hub showing the ring gear on the outside edge To start disassembly turn the hub over You can see the eight 12mm bolts and 4 half moon lock washers with hold the ring gear to the hub bras gH C IL hi DP i TE F SRL od ay 4 gang ul penay nag Ht i Fike Ps 4 S Se ph p n Use screwdriver to pull the 25 a WEY ak Sang iu i PED m Under this seal you will find X3 6 4 X 7 fractional and onl iaa Lo nob al 3
3. 5 li 3 4 1 CH i m Bi 85 10 remove the 45 X 59 X 7 final drive collar seal B Tore ed 4 rain Using a 131 mm X 17mm wrench double nut the 13 mm and 17 mm final drive studs MENO L t i E EE 5 eii sis torthick nin 4 i to dull dining eee SES LL lacus are uil mis New Savile dr jed far ekle riv designe and remove them You onl ced to do this if you are re placing repairing or stripping a trashed housing If necessary the steel hub insert can be removed by placing the final drive on some wood blocks and use the tommy bar and hammer T Gale i 0 tap it out Again not necessary under normal conditions ki p E ue 1 E TL a B 4 LET j E ri E PROFESSIONAL ix GRADE TOOLS 3 B LEVEL PRICES To remove the rear foot b Er ae a LAE ER UuSe a 13mm wrenc 1 d h to remove the nut and a flat blade Screw driver I push the sp lined rod through the 1 ME Cx Er 4 H H H r gt a 7 C EE E 7 e fo 12 3 rim ua raa TE vo X
4. i an 05 08 m 2 Eu A m ONO ae i 3 3 H E cm ZH E T 1 ES 1 id b hob rr EP y M a j w LL MY re jn ps pn rt ie 2 7 i3 i 7 x 9000 VON i fu F ER J 4 v fis 5 AES meets im HE l 2 8 F 46 USE 2 a E Pri gt i E 2 1 E 2 i P mn 2 Aem IRE n ppt zS bibi a E que BA BL RUM JE i i PA i inis nm i 2 m 1 s 1 B uui ip Ns me Put all the bits amp pieces in containers so they don t get lost use cut down oil bottles as parts bins Slip the rear axle up through the final drive and bump the final drive f d on a table or rap it gently with a hammer to separate the outer case top from the final drive case bottom 1 Remove the giter cover which contains the ring gear driven gear hub which is what the wheel drum splines mount to Set the outer cover assembly aside Be careful as some of the 45 needle bearings stuck in the grease on the driven gear might fall off The final drive case will have or more paper gaskets installed Make note of how many are used The gaskets act as spacers to obtain
5. ENTERS MURAT Lr AVA ANE Mairtin euer Pa LaRoche de L Qo tmi perm tpe E i F rien __ EITANT GTE L T i a LLECIMWER dom Side view of placement snug up the nuts so the separator is tight with no mm be cum e uox ae m deem p oce omo iE M mm m um acum iau e due n some mcm T n TET EF se the Never m mm cr summ Eu v amp kx WE aif apa Tb Lx w uur li LTWETLEZ Ekmek B ru Brod mpaka ee zo qux ah andan Er run mca eros sms Bard add oral Hi wa ovid chradh deri pp od seien Fal Falla 1 rb ode eg and DO ht ei ESL pemi dur 2 4 bm varus tiap taidat n tin ar WS bg ao than es d ped i x un hat Epi T E T E Tz Airok EE LL Ro MA Home EITESPE B Nu nig Ayrim Rma Daaa ees SPST
6. PRO SION A TOOLS E EVELI 7 LA mm ET TET Vds a BE 4 X j 14 F d ES Pi J p 7 F d TM h E e d LS H 2 bb 1 7 5 4 2 1 1 PF Ut UR pom k a rr gt 7 e ilm 2 1 webbie diam E 1 Lu rmm LET ra m E T o E be L 4 4 The forward brake cam is a press fit and must be heated and pulled to remove which can damaged it I just left it in Put the disassembled final drive housing components in the parts box and pull out the final drive outer cover for further disassembly 7 6 Outer Case Disassembl e M E 1 V i To separate the driven gear hub from the outer cover insert an axle from the inside of the outer cover housing is nma Ll tap it several times to 171 EE F Ra E MACKE Bar ariant Separate the components Occasionally the large 140mm bearing will remain the outer housing It can be removed with a long punch h t nod ady ab ue u Neg 4 MAE
7. 111 113 Fia d avail TED mh i TT ai j aquas Fog REELS som Cmm D MU i 2 3 T otk o zm m r i LL TUER 1 uw able through 1986 LET P 21 Li A rag 9 cuum oin i Faq HTT UL m Seal and spacer removed AK org ro X T In its monthly xr ster ihe BUMI MGIB GC ETT resistance i ii bee bil ment sald fn he ups lion droig plan in Cone ipt Wem id gv The White House opposes hik production baitut Soy n ier should the plan because boceuex erie dal Mor ae 2 I for soy DUM bP HET m CK MARKET ROUNDUP _ e 1 t RICAN AMER 90 Che Last 12 21 428g 2450 n E E 3 an bas ix i rid 4 34 7 E 403 I 5S Fiet 23 3525 j 18 89 WI 70 P 15 Do Qdysit r prese E13 30 2 lel 4t ed E senis Lac dn e m Spacer and seal line up like so CC et T FTNA BEEF je a Et re e E kd Pulblic Next use a wood chis
8. Head on view of the driven gear hub Y s x DA CONES 2 e 5 Eo Inside of the outer cover showing the 2wd shift coupling gear ote the worn teeth on the driven hub splines These mesh with the wheel hub splines VLA Fi 5 1574 Lm wu Place the driven gear hub in the parts box and we ll continue tearing down the final drive outer cover Inside view of the outer cover At 11 o clock the locking detent for the 2wd lever is visible The 2wd shift coupling gear is in the center and to the right the vertical shaft of the engagement lever with the sliding fork for the gear is just visible If it hasn t fallen out already remove the tube spacer m DU La from the outer cover m mier il Uu op sd qam ul pmo JOY PIE b H i T E 4 uu m i kii Hn Trea MEE You need a very large screw driver to remove it Mine would not come out It is not necessary to remove it for further disassembly My middle finger is disengaging the 2WD lever This forces the shifting gear outward on the splined hub to prevent it from engaging the driven gear hub Note the fork and shaft on the right side aa a L 2 M 49 Moving the 2WD lever forward lever obscured by cover with my finger pushes the shifting gear forward along the s
9. FILENTI PLA Un eee e jenem aliha m RT boat zh 1 1 ET B i eae 1 a a F i IE TILEOCENTER L1 amp pmere Lr i Dim E bets EMI THF hh jad Eis Pent 1 eel frank See r abe doi TE dee 5 d mi mar T TR TEME ZU x then attach and secure the yoke to the extension bars it om 1 aan LEVIA HU Ld lirit of Paing se Never i i f ji I f jn i i el e um E Lec dh Pd iau oe v of lead screw and it t down until it con acts the face of the pinion shaft Sa n TILE GEN TE i PL Jia ida ag E E LETRA 7 JY Set the assembly down hold the m one hand while using the to slowly tighten press the lead screw in BEAR IIT EL ID am ari p NAI With no effort at all pesa iy qun impen m wit mpgs Tante cm a gno f aw ha IF aue gue thm EF ed eg siepe Disassembly of the final drive is now complete
10. a a p x d EX T P a 2 f Nb a TRI 2 TEN P ad r 4 LR 4 T gt 7 i e 3 ED TCE T Pig AE ET f I use one of those exp nandable magnetic pick ups to reach in and collect the loose ae E just like fishing If you have a lot of km s on your final drive you can probably just reach in a pull the outer needle bearing race free not good If not you will need a pilot bearing puller or use a long bolt with a washer and nut inside the lip of the outer race and yank it out This needle bearing is an odd ball bearing and not available aftermarket You will need to acquire one through our nearest URAL dealer Em a de 2 LE LE 5 n rs m z as Ee E COMER FANON Ani inc a venient Zum E y t yout Prin et i pet amp riri zibeadg DR icm Te Tro EA E rs 4 s 7 52 ith antes FOR Hn 17 ey iom a irl 3 gau sisi TU LT 1 p Turn the final drive housing over and use a long wp blade screwdriver i arum Ja uum mma P 1 p bme se E n AETI LAM upay qe mrppeg bou sun 4
11. the proper clearance between the ring and pinion gears Note the needle bearings laying inside m ME ET The needle bearings ride here on the driven gear hub label them for later identification Le T DESIT 1 Put the outer cover and bearings aside as we will continue to tear down the final drive housing I use cardboard boxes from a case of oil and kitchen garbage can bags to make parts holders You can pad the bottoms with newspaper 7 000 Final Case Disassembl AL x 414112213 E l Dare Continuing with the disassembly of the final drive housing you can see the final drive dip stick on the left the drain plug at 7 o clock and the top paper gasket a This particular final drive used 4 paper gaskets The gaskets are used as shims to set the ring gear pinion gear lash ey i 3 E 0 HA Rob 4 AN EU zu 15 i 2 453 EL jugi tias ENON ir Use the single tooth pin spanner from the URAL tool kit to remove the bearing nut and seal AT Nd eu FE I A Tr peur re hand thread so CW to loosen 77 i tis a left Peat r A au Turn the bearing nut off and remove note the seal is 33 is fr r 94X8 which actional mm s and only available through your U
12. RAL dealer ins di vata 3 You should replace the O ring seal while the bearing nut is off Note the splined shaft on the pinion gear is now exposed a i 2 Li w a TA iir 410 LM i Grasp the pinion gear shaft and pull it free Careful as there are 28 needle bearings riding on the tip of the pinion gear Some may out with the gear ai te LEN LH FE A gentle tug and the pinion gear is free The inside race of the needle bearing is now plainly visible The outer race and needle bearings are still in the final drive housing Tult Li Feq n A Ini 38 2 i ut SERERE LS LEE Cs mut n 21 af raq nine E 1 a HS Te zl 5304 double row roller bearing DN drive shaft U joint when removing it 8 4 ad PRI and eqs t ana RELIEFA This is how the pinion gear runs on the ring gear Place the pinion gear i n the parts box as we will finish taking it apart later amp b T Not a good view but you can see the outer needle bearing race trust me there are 28 needle bearings stuck in the grease down there 0 1 F 7 j i ti
13. Ural Dnepr Russian Motorcycle Part 8 Chapter 7 of Bill Glaser s Unofficial URAL 750cc Motorcycle Service Manual http myural com servicemanual htm Ernie Franke eafranke tampabay rr com 1 2013 Chapter 7 Driveshaft amp Running Gear 7 1 Description amp General Specifications 7 2 Removal amp Installation of Final Drive 7 3 Removing amp Reinstalling the Propeller Shaft 7 4 Removing amp Reinstalling the Rear Swing Arm 7 5 Driveshaft amp Universal Joint Repair 7 6 Final Drive Disassembly with 2wd 7 7 Final Drive Repair with 2WD 7 8 2wd Sidecar Driveshaft Repair Final Drive Disassembly With 2WD Note This DOES NOT cover the Sportsman final drive pre 2000 Tools Needed 13 mm 17 mm wrench axle URAL pin spanner magnetic pick up long shank thin blade screw driver hammer tommy bar 19 mm socket 6 extension or longer 3 4 tip wood chisel 12 mm socket and ratchet wood blocks vise and 2 bearing separator 7 66 Se arating the Outer Case from Dus Final Drive Case pos vitm T FE tre t 1 j FN eh 4 iit d TE 3 1 t 15 t E O Epia pta hilt ut te TE 13 ja n A att n n ihe real 11 ce pi Mim u z x Ez Pil 1352 14 2 1 ik Seo t 1
14. ce in a 12 6 3 and 9 o clock pattern a e yl 4 Quo 112 a N ALS x lc until the bearing falls free X s del formed Ba E 63 D 5 Q E E E By un ws mmi 63 gt un Nc uf uf o un un gt _ C gt 63 z in bearing on ing over you wi Turning the hous i interested inan jo inter stad in Boch Keen 3 Are you interested in Use a pair of mg BT Ge NE D NE o uo SS SS LUE 4 EP ias E 249 At 6 599 f E 2000 als M Ame 60 pull it free ig I l ti 7 wl P Tal cm lt re T o 4 i 4 H z E a i M e LA H 1 m E Ka I S 4 Li r n park he n m eue EA ANGE a Poeke Be nes as EM Bearing and seal removed gt lever shaft seal and only available through your Now you can remove the 2wd URAL dealer Just pop it out with a screwdriver The outer cover is now co
15. el to bend down lock washer ius 1 EL kin E a a Ert nu ut fee Use a tommy bar to see flat nod ad 5 let PE VET n 4 t atchet wrench Use a 12 mm socket and r um nag ws 2d sexe ONO 2 3 D 0 remove the 8 bolts Can t get enough of these shots showing the worn teeth 7 M i 7 Misa ere i 3 4 bearing cost 360 dollars aftermarket so I suggest you buy the 80 Russian if you need to replace it Use a block of wood that is smaller than the inside diameter of the 1000822 bearing 110 mm place the hub on top of the block of wood use a tommy bar and hammer to tap around the inner bearing race a 9 o clock mu d 3 O clock m pm E FL 4 4 Pai z Ii a gt C 1 repr p 2 UA and 6 o clock pattern until the bearing IS free Hint It is sometimes easier to lay the palm of your punch hand on top the splines and rotate the driven hub 90 degrees after each strike with the hammer Place the disassembled driven hub in a parts box and get the pinion drive out for disassembly 7 6 f Pinion Gear Disassembl 1 PRIORITY EE 5 c nri PETI
16. mpletely stripped Place the parts in your parts box 7 6 d Splined Hub Disassembl a as Retrieve the splined hub and remove the 204 bearing E y i x m umm At qim E LL 0pen the jaws of a vise 0 you set the splined hub atop it with enough spread to allow the be OE and then tap it through with the socket and a hammer Front face of bea ring PS z E ar 5 29 NS ue 1 um 7 m Inside face of bearing Note the cut out in the bearing race at 6 o clock This type of bearing is a high capacity bearing the notch is where extra balls are inserted Do not confuse this bearing with a standard 6204 Ask for a 204 high capacity SA y Ma TIT EFE 1s puntas pps BE re m a 2 ae hk A CET X7 58576 548098 fa es a Repke os pg mE z i 3 4 44 ps5 FARE 558558423 2 a E 2 3 Bote ce eho ge eos gt Se Zi Page ets EIS one z P m 5 Ph d zm Bon 3 mg d a d n ge 4 E WEIT 2 N ECT 5 EEE E BEC E Sos Phe e em Pues ESO 1 I SS E TE
17. plined hub Which would then allow it to mesh with center teeth of the driven gear hub above providing power to the sidecar axle wheel via the splined hub To remove the 2WD shifting g gear r pulli the gear up while rotating it towards the fork shaft of the fork that ride in the groove of the gear i Eck ad Dai ELM E Lix Mark each uide T in n L 4 E ui QE meee 4 PE 2 us With the shifting gear removed you can see the yoke lever shaft and 7000111 55 90 11 bearing This is not a common bearing and will be easier and cheaper to get through your URAL dealer EE zs hou Ml T 12701 d then slide the 2WD engagement lever shaft free Place the pieces in your parts box lip holding the splined Next use a long thin flat blade screwdriver to pry up off the C c hub in the outer cover Clip is removed H 1 i Du ier J p ri Sm um Lr J i ution px The splined hub can now fall free so use ca s 4 A mI n Set the splined drive aside zi id m l pw The 87000111 bearing is read for removal I oW E i Place the housing down and use tommy bar and hammer pi O tap around the outer face of the bearing ra
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